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Characteristics
2
Ferrous Metals & Non-Ferrous Metals
3
Classification
Iron Aluminum
Others Others
4
Extraction of Iron
5
Extraction of Iron
6
Blast Furnace Temperatures
7
iron (III) oxide + carbon monoxide iron + carbon dioxide
REDUCTION
This oxide helps to remove some of the acidic impurities from the ore
calcium oxide + silica calcium silicate
The impurities are removed react with calcium oxide to make a liquid slag that
floats on top of the molten iron. The slag is collected after the denser iron has
been run out of a tap hole near the bottom of the furnace.
The production of iron in a Blast Furnace is a continuous process. The furnace
is heated constantly and is re-charged with raw materials from the top while it
is being tapped from the bottom. Iron making in the furnace usually continues
for about ten years before the furnace linings have to be renewed.
The energy costs of the operation are kept to a minimum by collecting and
cleaning the hot gas that leaves the furnace. This gas contains a lot of carbon
monoxide. It can be re-used as a fuel for other steelmaking processes or to
heat up the air blast to the furnace.
Refining iron
The metal that leaves the Blast Furnace contains between 4% and 5% of
carbon. This much carbon makes a very hard but brittle metal which is not
much use. The next step in the production of steel is to reduce the levels of
carbon and other impurity elements in the hot metal.
Routes to steel
Two methods of making steel are dominant in modern
steel industries all over the world.
Route 1 Basic Oxygen Steelmaking (BOS)
The hot metal from the Blast Furnace contains up to 4.5% of carbon.
Steelmaking reduces the carbon content to a level that matches the
customer’s requirements. This is often less than 0.1%. Basic Oxygen
Steelmaking (BOS) makes steel from Blast Furnace iron and small
amounts of scrap metal.
The diagram shows oxygen being blown into the furnace or BOS vessel
through a water cooled oxygen lance. This oxidises carbon and the other
unwanted elements in the hot metal. Carbon is oxidised to carbon
monoxide gas, which passes from the converter to a cleaning plant. After
cleaning, it can be re-used as a fuel gas. The rest of the elements in the
metal are converted to acidic oxides. They combine with the lime and
other fluxes that are added during the blow. This produces a slag that
floats on the surface of the metal.
The steel is tapped from the furnace when it is at the correct temperature
and composition. The furnace is tilted and the molten metal is run out via
the taphole into a ladle. Once the steel has been removed, the furnace is
turned upside down and the slag that is left inside runs into another ladle.
The solidified slag can be used in the production of cement and as an
aggregate in road building.
The Basic Oxygen Process furnace
FLUXES & COOLANT
FUMES TO CLEANING PLANT
TAP HOLE
STEEL SHEEL
REFACTORY LINING
The Basic Oxygen Process furnace (STEPS)
20 minutes
Route 2 Electric Arc Furnace Steelmaking (EAF)
Electric Arc Furnace (EAF). This is an electrically heated furnace
that makes steel from scrap metal only.
scrap steel
Most of the metal that is made in the BOS furnace is sold as bulk steel. More
specialist steels are made in the Electric Arc Furnace, although this furnace is
also capable of producing large volumes of other types of steel.
Alloy Steels
•Stainless steel
•High speed steel
22
Low Carbon Steel
23
Medium Carbon Steel
Contains 0.35% - 0.5% of carbon
24
High Carbon Steel
25
Cast Iron
Contains 2%-4% of carbon
26
Stainless Steel
Steel alloyed with
chromium (18%), nickel (8%), magnesium (8%)
Hard and tough
Corrosion resistance
Comes in different grades
Sinks, cooking utensils, surgical instruments
27
Stainless Steels
Main types:
Ferritic chromium:
very formable, relatively weak;
used in architectural trim, kitchen range hoods, jewelry,
decorations, utensils Grades 409, 430, and other 400
Austenitic nickel-chromium:
non-magnetic, machinable, weldable, relatively weak;
used in architectural products, curtain walls, storefronts,
doors & windows, railings; chemical processing, food
utensils, kitchen applications.
series. Grades 301, 302, 303, 304, 316, and other 300
series.
28
Stainless Steels
Martensitic chromium:
High strength, hardness, resistance to abrasion; used in
turbine parts, bearings, knives, cutlery and generally
Magnetic. Grades 17-4, 410, 416, 420, 440 and other
400 series
29
High Speed Steel
Medium Carbon steel alloyed with
Tungsten, chromium, vanadium
Very hard
Resistant to frictional heat even at high temperature
Can only be ground
30
Types of Steel
Various steel alloys are commonly identified with the SAE-AISI numbers,
Classification of Tool Steels
Description or Notable
Designation
Properties
W Water hardening
S Shock resisting
O Oil hardening
A Air hardening
D Die steel, air hardening, high chromium
Hot work, chromium, tungsten, and/or
H
molybdenum
T Tungsten alloy, high speed steel
M Molybdenum alloy, high speed steel
L Low alloy, special purpose
F Carbon-tungsten, special purpose
P Mild steels, low carbon and other types
Classification of Steel
Examples:
2350
2550
4140
1060
Common Carbon and Alloy Steels:
AISI - SAE Classification System
Spring steels
high Re, σR, modulus of elasticity E
C = 0,5...0,7%
Mn-steels (1...2% Mn)
Si-steels (2...3% Si)
Cr-V-steels
TT: Hardening + mid. temp. (300...400°C) g Trostite structure
Ball bearing steels
High hardness (≥ 62 HRC)
C ≈ 1%; Cr = 0,6...1,5% – 105 Cr6
Ball races (63...64 HRC), balls (61...62 HRC)
Structural steels (6)
Medium alloy steels (1)
D95, mm T50, °C
I gr – non-alloy steels (carbon
10...15 20
steels)
II gr – Si-Mn/Cr-steels (~1%) 20 -30...-50
III gr – Mn-Cr-steels 25 -60
IV gr – Ni-Mo-steels 40 -80
V gr – Ni-refractory. (W, Mo, V jt.) 100 -100
Properties:
Hardness: surface – alloy steels 950...1150 HV,
non-alloy steels (carbon steels) 400...500 HV
Core 250...300 HB
High fatigue strength ( by comp. stresses induced nitrides)
THCM Material Grade
Equivalent Material (Acceptable by HITACHI experts)
S.No In JAPAN In INDIA Remarks (If any)
1 S20C C-20 Bar only, except support for carbody, swing pins
2 S25C 25C8, IS-9175 Pin Stopper
3 45C8, IS-5517 For hardening & tempering (Quenching)
S45C
4 45C8, IS-3930 For Flame hardening & Induction Hardening
5 S35C 35C8, IS-5517 Pin,Bush,Idler(Forge)
6 S38C Pin, Bush, Idler(Forge)
40C8, IS-5517
7 S40C Washer
8 S50C 50C8, IS-5517 Pin
9 S53C 55C8, IS-5517 Pin
10 SCM-415 EN354 Gear
11 SCM-420 AISI / SAE 4320/SAE 8620/EN 353 Gear
12 SCM-435 Gear
40Cr4Mo3, IS-5517/En 19/SAE 4147
13 SCM-440 Gear
14 SCR-440 40Cr4 type C, IS-5517 Gear
15 SS 41 / SS ST42S, IS-226 t < 3b
16 ST42 ST42W, IS-2062 3b <= t
17 SM50 ST52-3, DIN 7100-80 Plate
18 ST52 TISTEN52, TISCO Plate
19 SM58 WELTEN 80 Plate
20 FCD 40 SG400/10, IS-1865 Casting
for X2018381 (link) only
21 FCD 45 P&H 2 and SG 450/10 for X201484 (coller), X2015299 (big), X1005309
(yoke) and other similar parts
22 FCD 48 and FCD 50 SG 500/7 Casting
23 STKM 11A Gr 17 ERW HTS, IS-3601 thrust plate , pin
24 STKM 13A Gr 25 ERW HTS, IS-3601 thrust plate , pin
25 STKM 16A Gr 32 ERW HTS, IS-3601 thrust plate , pin
26 SGP IS-2139 Thrust Plate
27 SK 5M T 80, IS-1570 ; EN42J Thrust Plate
28 SPCC IS 513, CR 1 Thrust Plate
29 SPCE Deep drawing type Thrust Plate
30 Welten 60RE TI / Welten 80 temporary
TRO1 0.08-0.12 0.5-0.6 0.3-0.6 0.035Max. 0.035Max. 0.25Max. 0.40Max. 0.15Max. 0.05Max.
TRO3 0.27-0.32 1.2-1.5 0.3-0.6 0.035Max. 0.035Max. 0.25Max. 0.40Max. 0.15Max. 0.05Max.
PH11 0.35-0.42 1.1-1.5 0.3-0.6 0.035Max. 0.035Max. 0.25Max. 0.40Max. 0.15-0.30 0.05Max.
PH6 0.35-0.45 0.6-0.9 0.3-0.6 0.035Max. 0.035max. 0.8-1.10 0.40Max. 0.15-0.30 0.05Max.
GGG50(FCD50) 3.5-3.7 0.1-0.8 1.8-2.8 0.010Max. 0.10Max. 0.08Max. Mg 0.035-0.07 --------- ------
GG25(FC250) 3.0-3.3 0.6-0.8 1.8-2.5 0.13Max. 0.30Max. ----- Cu 0.4-0.55 ------- -------
5 SM 490B 0.18 0.35 1.5 0.035 0.04 - - - 0.44 325 490-610 17 - 150-180 AS ROLLED IS 2062 E350C/HT 490 - IMPORTED
27 J @ - HT 490/ IS 2062 E350C/
6 HT 50 0.20 0.55 1.5 0.05 0.05 - - - 0.38 294 490 19 150-180 NORMALISED - HITEN JFE
27 °C SAILMA 350, SM 50A, ST 52
Cr=0.7 47 J @ -
7 HT 590 0.16 0.35 1.2 0.015 0.03 1.00 0.5 0.57 450 590-710 20 170-200 Q&T IS 2062 E450BR/Weldox 500 HITEN JFE
V=0.08 10 °C
WELTON 47 J @ -5 WELTON 590/IS 2062
8 0.16 0.55 1.6 0.03 0.03 - - - - 450 588 20 160-205 TMT 50
590 °C E450BR
SAILMA 450, SM 58, IS 2062
9 HT 60 0.16 0.55 1.6 0.03 0.03 - - - - 450 588 20 170-200 Q&T - IMPORTED
E450BR, WELDOX 500
HT60, WELDOX
IS 2062 Nb+V+Ti 47 J @ -
10 0.2 - 1.5 0.04 0.04 - - - 450 570 19 170-210 AS ROLLED 500,WELTON 60RE/ IS 2062 6-32 SAIL/JSPL
E450 =0.3 20 °C
E450BR/A
Nb=0.05 THERMOMEC
WELDOX 40 J @ - Optim 500 ML RUKKI SSAB &
11 0.17 0.55 1.7 0.02 0.02 - - , V=0.12, 0.42 500 570-720 16 162-205 HANICALLY 36-60
500 20 °C WELDOX 500- SSAB Rukki
Ti=0.02 TREATED
Cr=0.7 47 J @ - WELTON 780/IS 2062 E650
12 HT 690 0.16 0.35 1.2 0.015 0.03 1 0.5 0.54 570 690-820 17 200-220 Q&T HITEN JFE
V=0.08 20 °C BR/A
THERMOMEC
V=0.2, 40 J @ -
13 DOMEX 600 0.12 0.1 1.9 0.01 0.03 - - 600 650-820 16 185-235 HANICALLY IS 2062 E550 BR/A - RUKKI
Ti=0.15 20 °C
TREATED
V= 0.2 THERMOMEC
14 HS 800 0.1 0.3 1.8 0.005 0.03 - - Al=0.02 - 600 800 14 - 170-230 HANICALLY IS 2062 E650 BR/A - TATA STEEL
min TREATED
Cr=0.8, WELDOX 700/JFE WELTON
47 J @ -
15 HT 80 0.16 0.35 1.2 0.03 0.03 1.5 0.6 V=0.1, 0.57 690 784-931 16 224-266 Q&T 780/IS 2062 E650 - HITEN JFE
20 °C
B=0.006 BR/A/SUMITEN 780-NIPPON
Nb+V+Ti
WELDOX 30 J @ - IS 2062 E650 BR/A, OPTIM
16 0.2 0.6 1.6 0.01 0.02 2 0.7 =0.2 0.64 690 770-940 14 224-266 Q&T 10-130 IMPORTED
700 40 °C 700MC-RUKKI
Cr=0.7
HARDOX CR=1, 45 J @ - QUENCHED Nippon-AR 400/JFE
17 0.18 0.7 1.6 0.01 0.03 0.25 0.25 0.48 1000 1240 16 370-430 5-20 IMPORTED
400 B=0.004 40 °C (Q&T) EH400/Hardox 400-SSAB
7.2 ) In addition, two or more discontinuities smaller than described in 7.1 shall be unacceptable unless separated by
minimum distance equal to the greatest diameter of the larger discontinuity or unless they may be collectively
encompassed by the circle described in 7.1.
Fig. 1
Cases of laminations:
1. ) For spot or single lamination 7.1 is applicable.
b. After welding, if weld defect is found during UT (angle probe) of the joint, then gouge the weld.
c. Again Check the length of the lamination with UT(normal probe). If it is acceptable as per standard then reweld the joint.
d. After rewelding the lamination should be checked again for ascertaining that the lamination is within acceptable limit.
e. If at any stage(steel yard,cutting,fitting,welding etc.) the discontinuity(lamination,slag inclusion etc.) is found beyond
the acceptable limit then the plate stands rejected.
India Industries
R. K. Enterprises
Pins, Shafts & gears, Fixtures 1 Sample @ Heat
Rounds India Forging Yes Chemica (C.E) & Hardness
etc No/Lot Size
India Industrial Enterprise
Shyam Steel R. K. Enterprises
Sterlite Metals 1. Chemical Composition
Construction, tacking & 2. Hardness
Angles & Channels Jindal Steel, Essar, JSW, SAIL, Maruti Metal Yes 1 Sample @ Heat No Details analysis is done
Fixturing 3. Microstructure
Local Manufacturers PSPL In-house for New Development
4. Inclusion rating
India Industrial components
PSPL
Tata Steel
TSPDL
SAIL SAIL
JSPL JSPL
JSPL, SAIL, Tata Steel Shree Krishna As per TDC
(1. Tensile Properties
JFE Garg Engineers
Steel Plates Heavy Structural fabrication Yes 1 Sample @20 Lot Size 2. Impact test (if required)
JIANYING XING CHENG Marubeni Itochu
3. Microstructure
Volestalpine(Imp) A. N. Source 4. Chemical Composition)
NLMK NLMK
NSSCM (Imp) OHMI(Imp)
JFE (Imp) Metal one (Imp)
ESSAR (Imp) Champak Steel
NOT OK OK
Process Details:
Cavity/Impression marks are found on plate surface--> Free from any surface defects
at complete plate Stage
NOT OK OK
No Bend -->OK
NOT OK OK
Process Details:
Heavy Grinding marks are found on plate surface--> at Free from Grinding marks on plate
complete plate Stage
NOT OK OK
Process Details:
Heavy Pit marks are found on plate surface--> at No Pit marks are found on plate
complete plate Stage
| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 59
OPL-5
Description : Notch/Rolling Marks are found on surface of the plates (8-100 mm thick). OPL has been
prepared for the training of the operator so that the defects can easily caught at plate stage & defects free
plates are supplied to HMS.
NOT OK OK
Process Details:
Notch/Rolling marks are found on plate surface--> at Free from Notch marks on plate
complete plate Stage
Process Details:
Silver Defects found on plate surface--> at complete Free from Silver on surface
plate Stage
NOT OK OK
Process Details:
Scab Defects found on plate surface--> at complete Free from Scab on surface
plate Stage
NOT OK OK
Process Details:
Stress Crack Defects found on plate surface--> at Free from Stress Crack on surface
complete plate Stage
NOT OK OK
Process Details:
Seam Defects found on plate surface--> at complete Free from Seam on surface
plate Stage
NOT OK OK
Process Details:
Crack found on plate surface--> at complete plate Stage Free from Crack on surface