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<p>This study investigates the factors affecting weld failure in the retention belts of the Hazelett machine dam blocks. This retaining strap is made from CK67 alloy steel, which has high mechanical strength and resistance to deformation. These components fail prematurely due to the metallurgical properties of this alloy and harsh working conditions. Based on the analysis, retaining belts fail due to the fatigue caused by cyclic loading. Due to the belt’s geometry, fatigue testing could not be performed, so increased weld strength was used as a criterion to investigate and enhance the fatigue life. Metallographic tests, chemical composition analysis, fractographic examinations, and mechanical tests were performed to examine failure mechanisms. The results reveal that incomplete weld penetration, improper joint surface preparation, impurities, and uncontrollable residual stresses significantly reduce joint strength and fatigue life. Additionally, tensile characteristics of welded samples enhanced to be about 28.05% by chamfering the joint at a 45° angle, 21.17% by preheating of weld structure at 200&#xa0;°C, 34.43% after removing the weld reinforcement, 9.13% by cleaning the surface from moisture and grease, and 7.22% by improving the connection geometry to a butt joint with a 45° bevel. Eliminating after welding can decrease the tensile stresses on weld metal and prolong its life by retarding fatigue failures. </p>

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Welding Failure Analysis of CK67 Steel Belts in the Continuous Casting Process: A Real Case Study in Hazelett Technology

  • 期刊论文

  • 发表日期：

    2025年7月17日

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  • Mahdi Jafari Mohammad Abadi,
  • Gholam Reza Khayati,
  • Saman Nemat,
  • Hamid Haj Mohammadi,
  • Ali Reza Hashemi

摘要

This study investigates the factors affecting weld failure in the retention belts of the Hazelett machine dam blocks. This retaining strap is made from CK67 alloy steel, which has high mechanical strength and resistance to deformation. These components fail prematurely due to the metallurgical properties of this alloy and harsh working conditions. Based on the analysis, retaining belts fail due to the fatigue caused by cyclic loading. Due to the belt’s geometry, fatigue testing could not be performed, so increased weld strength was used as a criterion to investigate and enhance the fatigue life. Metallographic tests, chemical composition analysis, fractographic examinations, and mechanical tests were performed to examine failure mechanisms. The results reveal that incomplete weld penetration, improper joint surface preparation, impurities, and uncontrollable residual stresses significantly reduce joint strength and fatigue life. Additionally, tensile characteristics of welded samples enhanced to be about 28.05% by chamfering the joint at a 45° angle, 21.17% by preheating of weld structure at 200 °C, 34.43% after removing the weld reinforcement, 9.13% by cleaning the surface from moisture and grease, and 7.22% by improving the connection geometry to a butt joint with a 45° bevel. Eliminating after welding can decrease the tensile stresses on weld metal and prolong its life by retarding fatigue failures.