jswmi - Tumblr blog

[jswmi]

Testing methods of steel material

As a steel processing center, having products like stainless steel, galvanized steel, electrical steel, we have to keep the steel quality at the best. The steel has to go through many tests to prove its quality. It has to go through Chemical analysis, mechanical testing of metal, Metallurgy testing of Metal. The steel goes through all these tests and then selected for the final processing. Here are few tests explained by JSWMI, a steel processing center that helps decide the quality of steel.

·       Bend Testing:

In this test the ductility, sturdiness, brittleness and soundness of steel. In this test the steel is bend to its maximum capacity and the then the result is recorded and studied for further information.

·       Impact test:

Impact test is run on steel to determine the impact resistance and toughness of the steel. This test also is done in different temperatures so test steel’s durability and performance in different temperatures.

·       Hardness test:

Hardness test is run on steel to determine the stability of steel. This usually to test if the steel is suitable for the given application.

·       Tensile test:

This test is done on steel to verify and understand steel’s tensile strength, yield strength, event. Ductility and reduction of area. This test is important for steel that will be used in hard use applications.

·       Fatigue test:

In this test the steel is put through various stresses and strains. This test applies pressures and pulls on to the steel, the strains and stress is applied till a crack or facture is seen in the material. This test is done to check how much cyclic loading condition the steel can withstand.

 ·       Corrosion resistance test:

As the name suggest this test tests the steel for its corrosion resistance. A salt solution is sprayed on the surface, this shows how the steel will react when exposed to corrosion.

·       Wear test:

Wear test is done for two different things; first to predict how the steel would perform in wear and second to investigate the wear mechanism.

 These tests are run on steel before turning it to stainless steel, galvanized steel, electrical steel. At JSWMI, a steel processing center, we make sure to use the best quality of steel and deliver the best to you.

[jswmi]

CRCA: Advantages & Disadvantages

CRCA steel means Cold Rolled Close Annealed steel. The steel is hot rolled and pickled and then passed through the cold roll to reduce the thickness of the steel. Here is how CRCA steel is made and applications of CRCA steel.

The steel is rolled below its recrystallization Temperature to make it get a variety of properties like being easily formability, a smooth and clean surface. CRCA steel is necessary to manufacture sheets below 1.6mm of thickness, the Hot rolled and pickled steel have impurities and irregularities. Here are few advantages and disadvantages of CRCA.

Advantages:

§  Precise and Accurate Dimensional Tolerances

§  Robust surface finish

§  Improved mechanical & physical properties

§  Improved draw-ability

 Disadvantages:

§  Less Corrosion Resistant

§  Sensitive to the Moisture content

 CRCA is used for projects where precision is required, it is used for making home applications or metal furniture. It is also commonly used in building steel sheds or garages. CRCA is better because it is harder and its finishes are much better than Hot rolled steel. The precision is better because the steel is not exposed to heat. CRCA application are wide ranged.

CRCA sheets are also classified according to the percentage of Carbon content and how easily can it be drawn. The more carbon content is less , the more easily it can be drawn into shape. Below are the 4 types of CRCA steels used in the industry:

·       Ordinary (Carbon Content- 15%)

·       Drawing (Carbon Content -12%)

·       Deep Drawing (Carbon Content - 10%)

·       Extra Deep Drawing (Carbon Content - .08%)

 CRCA is better because in Hot rolled steel the metal properties are altered, the metal goes through a lot of different stages making it hard to work with. At JSWMI steel processing center. CRCA is available in a wide range of thickness, width up to 1870mm and high tensile strengths for various applications in coil / slit, sheet and trap form.

[jswmi]

Colour coated steel and its Uses

Coloured steel is made in two different varieties PPGL and PPGI. PPGL stands for Pre-painted galvalume steel and PPGI stands for Pre Painted galvanised Iron steel. Here is how the steel is painted and what its uses are.

Stainless steel is painted in many different ways, vacuum chamber paint, powder paint and PVD coating. Coloured steel has multiple uses and the uses are all for the exterior use. The coating of the steel has to strong enough to handle all the environmental changes.

Architecture: The coloured steel is used for exterior of the building, this requires the steel to be presentable and weather resistant.

Hardware: Interior and plumbing nowadays require the steel to be water resistant and rust free.

Design: The colour and finish of coloured steel makes it a great steel for art installation and floor or wall installation.

Elevators: Coloured steel are a great choice for lifts/elevators because they add to the beauty and they last long.

Daily use: Electrical appliances, gym equipment, refrigerators and even in the food industry coloured steel is used for the exteriors.

Coloured steel has many different advantages, the colour adds to the beauty of any place it is installed. The pre painted steel does not peel, crack or fade.  Coloured steel is light in weight but lasts long as compared to the steel that is coloured later. Pre painted steel also super resistant to corrosion. Pre painted Steel is also very durable. Coloured steel can also be recycled and hence proves to be a better choice in every scenario.

Coloured steel helps you achieve what you want in less steps. Making a product in simple steel and then painting it can be a bit of a hassle, it can also cost extra money. Pre painted steel saves both time and money.

We at JSWMI we provide Colour coated steel. It is available in wide range of colour combination and emboss patterns, cut into slit or sheet as required by home appliance industry customers. We are steel processing center and we also give other services and product.

[jswmi]

Process of steel slitting

Steel slitting is a technique used to cut metal coil into narrower pieces. Steel slitting is done when tight tolerance is required, the process can be used for both steel sheets and coil roll.

Steel slitting process can be restricted to cutting extremely thin material (0.001 to 0.125in), it can be used in both ferrous and nonferrous metals. Steel slitting is basically done by sending steel sheets or coil rolls through two blades.

The positioning of knives can be varied according to the requirements, at JSWMI we have a spare slitter for offline setup making further process fast and precise. Steel slitting process basically consists of three parts uncoiler, slitter and recoiler. The coiled material is first run through the uncoiler making it straight then is sent through sharp circular blades. There are two blades placed one below and one above the steel, these blades have to be placed as to apply substantial compressive forces, these forces should exceed the tensile strength of the steel to slice through it. These blades are placed precisely according to client’s requirement.

Steel slitting can have many benefits like tight tolerance, keeping product consistency and it reduces the metal scraps. It is also convenient to order pre-cut steel for the work because it saves the metal wastage from trim cutting. Pre-cut slit steel also ensures precision making the products.

At JSW we have two plants where slitting takes place, one at Pune other at Palwal.

Pune: 0.6-6.5mm* 1870mm width (TS up to 1180mm)

Palwal: 0.25-3.2mm* 1870mm width (TS up to 980mm)

We have a large capacity at both of the plants, 180,000 MT/year and

120,000 MT/ year at Pune and Palwal respectively.

We at JSW are your one stop destination for steel slitting. We are a fully functional steel processing centre. We also offer other services such as cut to length and packing.  

[jswmi]

Process of steel manufacturing

Steel is one of the most preferred materials for construction, manufacturing of tools, cars and for various other applications. It is an alloy of iron and some other element such as chromium.

 Steel has been manufactured since ages, but the large scale commercialization of the process began only in the 19th century. The 1850s and 1860s saw the advent of different revolutionary techniques, turned the steel-making process into a mainstream industry. The ensuing technological advancements in the injection technology as well as in the process control, has made mass production of steel easier, and an integral part of the global economy.

 Manufacturing

 Ancient steel manufacturing process was carried out in bloomeries and crucibles. The Industrial Revolution brought about the development of large scale methods of producing steel.

 Steelmaking involves removal of impurities such as nitrogen, silicon, phosphorus, sulphur and carbon from the sourced iron, as well as alloying other elements such as manganese, nickel, chromium, etc., to produce different grades of steel.

 Modern steel industries use recycled materials as well as traditional raw materials such as iron ore, coal and limestone. Almost all the steel manufactured today uses 2 processes-basic oxygen steelmaking (BOS) and electric arc furnaces (EAF).

 There are 6 basic steps in the Steel-making processes, which are as follows-

 1.         Iron-making

 This is the first step in the manufacturing of pure steel. In this step, the raw materials like iron ore, coal and lime are melted in a blast furnace. This results in the formation of molten iron, also known as hot metal, which still contains 4-4.5% of carbon and other impurities, which makes it brittle. These have to be subsequently removed.

 2.         Primary Steel Making

 The remaining impurities are removed by either BOS or EAF methods.

In the BOS method, recycled or scrapped steel is added to the molten iron in a convertor. Oxygen is blown through the metal at high temperatures and this reduces the carbon content to about 0-1.5%.

 In the EAF method, scrap steel is fed through high-power electric arcs to melt the metal and convert it into high quality steel.

 The steel that is obtained at the end of this step, by either of the methods, is called raw steel.

 3.         Secondary Steel Making

 This step involves treating the raw steel in different ways to get different grades of steel. This may include addition or removal of certain elements, and/or altering the temperature and the production environment.

 The final grade of steel that is desired determines the further techniques that need to be applied. These may include-

 •    Stirring

•    Altering the temperature

•    Ladle injection

•    Removal of gasses

•    CAS-OB

 4.         Continuous Casting

 In this step, the molten steel is cast into cooled moulds, causing the steel to harden. Using guided rollers, the steel is drawn out of the moulds while it is still hot and then allowed to cool and fully solidify. Next, it is cut to the desired lengths, depending on the applications-beams, slabs, billets, etc.

 5.         Primary Forging

 In primary forming, the cut steel is formed into different shapes, generally by hot rolling, which eliminates the casting defects and gives a desirable shape and surface quality. Seamless tubing, long products, flat products and various other speciality products can be obtained by this process.

 6.         Secondary Forming

 The final step is the secondary forming process, which gives the steel its finished shape and properties. Various techniques can be applied at this stage, which involve-

 •    Heat treatment (tempering)

•    Joining (welding)

•    Shaping (cold rolling)

•    Coating (galvanising)

•    Machining (drilling)

•    Surface treatment (carburising)

  JSW Steel of India and Marubeni-Itochu Steel of Japan have collaborated to create JSW MI. The vast expertise of these two steel giants strives to provide the highest quality products and services to our customers. We aim at maintaining the highest level of quality, integrity, efficiency and responsibility in all the tasks and activities that we undertake.

[jswmi]

Electrical steel and it’s applications

Electrical steel is an alloy made to produce specific magnetic properties. When the regular steel is magnetized it absorbs energy, this steel is especially designed to reduce this power loss. Electrical steel is preferred in many situations over regular steel. There are two types of electrical steel:

Grain orientated electrical steel:

Steel when alloyed with iron and silicon is called grain orientated electrical steel(GOES). This steel is developed to have low core loss and high permeability. This is grain orientated material is made overall magnetic flux is increased by 30% in the direction the material is rolled. This also reduces magnetic saturation.

GOES is mostly used in high efficiency transformers, generators and motors.

 Non-orientated fully processed electrical steel:

This electrical steel has uniform magnetic flux in all directions. It has lower silicon percentage in the alloy, this provides the steel with magnetic permeability and thermal conductivity. It has better performance because of it’s properties of high frequency and low losses.

This type of electric steel is used in magnetic circuits in motors, transformers, electric system housing. This steel has difficulty in punch ability as it is fully processed. Extra organic coating is added to use as lubricant in punch process.

 Non-orientated semi processed electric steel:

Non-orientated semi processed electric steel have a major difference that it has no silicon alloy. This steel is annealed at low temperature after final cold rolling. Although while using the user has to stress-relief anneal to the steel varying on the application. The organic coatings done to the fully processed electrical steel is not required as punch ability in semi processed steel is much higher.

This steel is used in small rotors, stators and small power transformers.

Electric steel has advanced magnetic properties and are very commonly used in the following systems.

1)    Rotating machines:

Electrical vehicle driving motors, Hermetic motors, Alternating current (AC) motors , Intermittent service motors 

  Static machines:

Power and distribution transformers, Reactors and magnetic amplifiers, Welding transformers, Audio transformers, Current transformers, Magnetic switches and relays, Electrical ballast.

 Here are few advantages of electric steel:

It’s cost is very low compared to others. It also reduces the cost of many other processes like lamination. It also give low power loss per cycle, low core loss and high permeability compared to regular steel.

Motors and motor parts prefer electric steel because of it’s magnetic properties. Electric steel reduces torque and energy consumption. Electric steel is safe and reliable that is a very preferred choice.

 Electric steel is available in wide range of grades. Coils or sheets are made available according to the applications of electric steel. At JSWMI we are one of the best steel processing center and produce electric steel.  

[jswmi]

Advantages of Stainless Steel

Indian culture is very familiar with stainless steel cutlery.  Our parents prefer serving on stainless steel plates rather than opting for plastic or glass cutlery.  In our day to day life, we're surrounded by these materials. Not only for hygiene and resilience, but stainless steel have many other advantages.

 What is Stainless Steel?

Stainless Steel is a part of the family of iron. It is an iron based alloy that contains a minimum of approximately 11% chromium and varying amounts of Carbon, Silicon and Manganese

 Types of Stainless Steel:

·       Austentic

·       Ferritic

·       Duplex

·       Martensitic

  Advantages of Stainless Steel:

 Corrosion Resistance: Chromium is the element used for stainless steel alloy. Chromium brings in stainless steel, a corrosion resistant quality. Lower grades can resist water and atmospheric changes in temperature,  grades of steel with a which have a better quality alloy can resist corrosion to most acid, alkaline solutions, and environments with a lot of chlorine as well.

 Fire and Heat Resistance:  High chromium and nickel alloyed grades resist scaling and resist high strength at high temperatures. Hence, Stainless Steel is used widely in heat exchangers, super heaters, boilers, feed water heaters, valves and main stream lines as well as aircraft and aerospace.

 Advantage of Strength to Weight: Stainless Steel has a better hardening and strengthening compared to other materials. It also saves considerable costs while manufacturing.

 Ease of Fabrication: Stainless Steel can be cut, bent, formed, assembled, and fabricated compared to other materials.  They can also be rolled out into thin sheets of steel in a steel processing centre.

 Impact resistant: Stainless steel has a high amount of toughness, ranging from elevated temperatures to freezing ones.  Stainless steel is particularly suitable for cryogenic temperatures.

 Long Term Value:  Stainless steel has a long term value because the maintenance of stainless steel is very very low. Stainless Steel is the least expensive of all the materials. Therefore, stainless steel saves a lot of cost. Hence, high life expectancy and low cost makes it the most viable option.

 100% Recyclable: Stainless steel is completely recyclable, so much so that more than 50% of new steel comes from recycled scrap steel.

 Hygiene: Stainless Steel has a very easy cleaning ability. Therefore, Stainless steel becomes the first choice for hospital instruments, kitchens and even food processing plants.

[jswmi]

What is hot rolled pickled and oiled steel?

What is hot rolled steel?

This method is a mill process in which the steel is rolled to a high temperature, more than 1700 degree Fahrenheit. This temperature is higher than the recrystallization temperature.  When the steel is heated higher than recrystallization temperature, it can be shaped and formed in whatever size and shape required.

Hot rolled steel is much cheaper as compared to cold rolled steel. However, when the steel cools off, it will shrink slightly, which gives less control on the size and shape. After cooling off, the steel forms a scale like structure, as remnants of being exposed to much cooler temperatures.

Hot Rolled Pickled and Oiled Steel

To remove the scaling from the steel surface, the steel is oiled and pickled. The hot rolled pickled and oiled steel is acquired when it is dipped and pickled in acid to remove the scale, and later it is oiled to keep it from rusting.

In a steel processing center,  prior to picking the steel, surface particles such as air, dust, paint or any other residues or substances are removed using alkaline or other cleaning agents.

The pickling process is obtained when the rolled steel is dipped into water and other inorganic solutions.  The steel is also dipped into tanks of hydrochloric acid, causing a complex reaction that removes scaling entirely.

This steel now has a smooth surface, and good flatness, which is ideal for a lot of applications.

The main purpose of pickling and oiling the hot rolled steel is to retain the properties of steel, especially against the rust.

  Benefits of pickling and oiling steel

·        When the metal goes through the pickling process, contaminants and other unwanted elements are removed.

·        An acidic solution used to treat the metal, in order to make the surface of steel free of any roughness or impurities.

·        Pickling helps to lessen the effects of any pre treatment process

·        Hot rolled and oiled steel is used especially for cutting, punching or piercing.

 Applications of Hot Rolled Steel

 ·        Constructions.

·        Pipes and tubes.

·        Truck frames.

·        Doors and shelving.

·        Railroad tracks.

·        Railroad car parts.