GALVANIZATION

Galvanization refers to any of several electrochemical processes named after the Italian scientist Luigi Galvani. It refers to an electro deposition process used to add a thin layer of another metal to an item made of steel, in order to prevent rusting. More recently, though the term has been broadened in common usage to include applying a protective metallic coating to an underlying piece of metal, using a process known as hotdip galvanization. Approximately, one third of the steel shipped by the company/industry is coated on its surface by a metallic, inorganic or organic coating. In this group the most widely used coatings are zinc, zinc alloys or aluminum. In hot dip galvanizing lines, which also have usual entry and exit groups, the strip moves first at constant speed say 150 m/sec through a cleaning section and a long, horizontal, non-oxidizing pre heating furnace. The hot strip, still protected by the inert furnace atmosphere in along steel channel, enters the zinc bath at temperature of about 480 degree Celsius, supplying heat to the zinc bath which is at about 440 degree Celsius. The liquid zinc is contained in a refractory-lined, induction-heated vessel called the zinc pot. When it contacts the strip surface, the liquid zinc alloys with the iron and forms a strong

metallurgical bonding. However, the iron zinc alloy is brittle, so that the coating if too thick, will crack during formation and keeping the alloy layer less than 15 % of the total coating thickness. Excess liquid zinc is wiped off each side of the strip by two gas knives, which have long, slot like orifices through which high gas is blown. Coating thickness is controlled by adjusting gas pressure and location of knives.

Electrolyte galvanizing lines have similar entry and exit sections, but they deposit zinc in as many as 20 electrolytic cells. Zinc cat ions present in the electrolyte are converted by the current into regular zinc atoms, which deposit on the work piece. The bath is supplied with zinc cat ions. The electrolyte is an acidic sulphide of zinc sulphide or zinc chloride with other bath additives to improve the quality of the coating and the current efficiency. Coating thickness is easier to control because of good relationship between electric current and deposited zinc. The control parameters of such a line are mainly the current density between cathodes and work piece, the line voltage, the chemical composition of the electrolyte, and base speed. Electrolytic lines normally produce lower coatings weights than do not dip lines, and they can also easily supply

differential coatings on one sided coatings for specific applications. Many lines can deposit, zinc alloy coatings, such as zincnickel or zinc-iron, and some lines are capable of producing multilayered coatings, the goal being to optimize a combination of specific requirements such as corrosion resistance, durability. The processing speed of electrolytic galvanizing lines can often reach 180 meters per minute. Electrolytic timings lines for the production of tin plate are in principle, of similar design, except that all rolls are smaller, the line speed is faster and differential electrolyte and anodes are used. Electrolytic coatings lines also coating lines also coat work piece with chromium and other metal and alloys. Most of these lines have a shear line installed at the end to produce work piece upon request. Many long products are also surface coated. Wires are often hot dip galvanized in continuous multi-strand lines. In addition, electrolytic coating of wire with all type of metal is often done by hanging coils from currying chooks.

LE-4 FURNACE
SPECIFICATION TOTAL LENGTH-22 M PRE-HEATING LENGTH-6.25 M VESTIBULE-15.75 M TOTAL WIDTH 1.4M

TEMPERATURE SPECIFICATION {DEGREE CENTIGRADE} ZONE 1-1030 to 1050 {SLIGHT AIR RICH} ZONE 2-1010 to 1030 {SLIGHT AIR RICH} ZONE 3-970 to 990 {SLIHT GAS RICH} ZONE 4-P70 to 990 {SLIGHT GAS RICH}

There are four types of furnace: 1. LE-FOUR FURNACE 2. D.S.W (DIRECT STEEL WORK) FURNACE 3. F-4 4. F-3

Finishing Products: It may be classified into 3 types: 5. MS-1 6. MS-2 7. MS-3

LE-4 FURNACE
Le-4 furnace is a furnace very popular for wire heat treatment process in this furnace wires are treated in steps. The product coming out of furnace is of very high quality and high strength. PAY OFF: It consists of five kinds of material 24 inch bag in 22/28 inch former DIM 1000 Rollers Separator

ROLLERS: These are used to roll the wire to increase their straightness and surface finish. There are many set of rollers for the wires. There are two types of rollers 1ST TENSION ROLLER: This is the first set of rollers for wire to pass. They bridge out tension in wire and straighten it.

HEAT TREATMENT PROCESS

Firstly, the wire is or the rod is made to go inside the furnace. This is the first step to make a wire. The furnace has different zones. One of the zones has a temperature of about 1000 degree C to heat up the rod. And then the other zones have a temperature of 500 degree C to suddenly cool up. This is called head (Pb) bath. After it gets out of the furnace it is made to go pass through the sand.

Thereafter, it is made to clean up by passing through the water tank, this is made because to clean up the sand. After that it is made to pass through acid, basically HCl, and then again it is cleaned by water. It is water with phosphate because in wire will, when it is passed through a die it will not create heat. So to decrease heat, it is us ell this is called heat treatment process to increase ductility.

PICKLING
Originally, continuous wire pickling systems were open bath of acid with mechanical devices (sinkers) used to submerge the wires, later developments included heating of the acid and addition of covers with fume extractors. A subsequent improvement was the flood weir system in which the acid is pumped from a reservoir tank to the processing tray before overflowing back to the reservoir, thus eliminating the need for sinkers and laminar. With the advent of water seals in July 2, 1984 wire pickling systems became known as fumeless.

One of the more recent developments in continuous wire pickling systems is for the hydraulic jump type of wire pickling apparatus. This design has permitted an increase in the wire speeds but has the disadvantages of a relatively short turbulent region in the wire speeds but has the disadvantages of a relatively short turbulent region confined to only one acid section. During pickling operation the acid (eq. HCL) becomes chemically depleted thus necessitating the dumping of part of the tank so that fresh acid can be added. Since the hydraulic jump system has only one acid section, a large volume of fluid must be drained each time fresh acid is required to create hydraulic jump. Another disadvantage is that large and expensive acid pump is required to create a hydraulic jump.

USHA MARTIN LIMITED

A PROJECT REPORT ON PICKLING, PATENTING AND GALVANIZATION PROCESS

SR.MANAGER HRD: ARVIND KUMAR GUIDED BY: K.N.MAHTO SUBMITTED BY: 1.MRINAL KAR (GYAN VIHAR UNIVERSITY, JAIPUR)
LETTER NO: - HRD/SUM/TRG/O61/12-13. 2. KUMAR SAURAV (SRI CHANDRASEKHAREDRA SARASWATI VISWA MAHAVIDYALAY) LETTER NO: - HRD/SUM/TRG/321/12-13.

PICKLING HOUSE HCl

[Low strength 2-12]

HCl
[High strength 12-20]

RINSE WATER

PHOSPHATE
(26-32) (Temp. 70 +_ 5 C)

WATER RINSE

BORAX
(100-115) gm/lit.(Temp 90 c)

WIRE DRAWING

PREFACE
We take an opportunity to present this standard treatise entitled as STUDY OF PATENTING, PICKELING AND GALVANISING PROCESS at Usha Martin Ltd. RANCHI. The objective of this for me is to learn the various manufacturing processes of wire in industry, to understand the team work during the working hours. This project covers the background history of Usha Martin Ltd., evolution of company, crossing the various hurdles with serving the nation. In this project, I have covered the products of Usha Martin Ltd with its application in various fields. This project is all about obtaining of raw material for wire and rope making to dispatch to various customers via various manufacturing processes; viz-patenting, pickling, galvanizing, inspection after galvanizing and winding. I have taken the help of various standard books. I also went through some of the internet sites to get the right idea of presenting this project.

ACKNOWLEDGEMENT
We owe a sincere thanks to many people who helped and supported me during this project. My heartiest thanks to Mr. Arvind Kumar, Manager HRD, Usha Martin, for providing me an opportunity to make this project and for his sincere support. We would also like to thank my institution and my faculty members without whom this project would have been a distant reality. I also extend my heartfelt thanks to my family and well wishers.

1. Mrinal Kar 2. Kumar Saurav

PATENTING
The special heat treatment given to a medium carbon, high carbon and alloy steel wire rod is called patenting. The process consists heating the material well above the austenitzing temperature to ensure formation of homogenous austenite. After soaking for sufficient time at this temperature, the steel is quenched in a bath maintained at constant temperature. For given steel, the quenching bath temperature is kept in the vicinity of the nose of TTT curve. This results in transformation of austenite to fine pearlite. Once the transformation is complete the steel is cooled either in air or by spraying water. In some cases, a small amount of upper bainite has been observed. Lead bath or salt baths are commonly used for quenching the steel. The process is mainly used for wires, ropes and springs. The higher the soaking is always above the austenitizing temperature, the greater is the stress developed, making the steel susceptible to distortion and quench cracks. This is particularly dangerous for high carbon steels. On the contrary, use of too low temperature is again not desirable as it imparts poor mechanical properties, especially ductility, as measured by percentage elongation and percentage reduction in area. Patenting heat treatment results in a homogenous and fine

pearlitic structure; such a structure is capable of heavier drafting during wire drawing than is possible with common heat treatment process. Since low carbon steels can be drawn heavily in an annealed condition, patenting heat treatment is not employed or such steel.

MANUFACTURING PROCESS OF ROPE

REFERENCES
1. www.google.com 2. www.wikipedia.org 3. www.ushamartin.com

MANUFACTURING PROCESS OF WIRE STRAND

CONTENT
1. GROUP PROFILE 2. LE-4 FURNACE 3. HEAT TREATMENT 4. PICKLING 5. PATENTING 6. GALVENIZATION 7. CONCLUSION 8. REFRENCES

LE-4 FURNACE: FLOW CHART

PAY OFF PAY OFF FURNACE FURNACE LEAD BATH LEAD BATH SAND BATH SAND BATH WATER BATH WATER BATH ACID BATH ACID 1 ACID 2
Auto spoke

WATER BATH

PHOSPHATE BATH
BORAX BATH

FLUX BATH DRYER FOR L.C.G. ZINC BATH CHARCOAL WIPING LIME BATH

WATER BATH BORAX BATH DRYER FOR PWLC

TAKE UP

CONCLUSION
UML is the 2nd largest wire and rope manufacturer in the
world and has the largest variety in South East Asia. It is multi product, diversified engineering conglomerate with 10 production units in India, 1 in Thailand, 1 in UK and 1 in Dubai. It is saving valuable foreign exchange by exporting its product to 42 countries like USA, Africa and Middle East, conforming to the strictest product quality standards. It is a constant supplier of wire and aired rope. With the modern concepts like TPM, value engineering, customer satisfaction and human resource development, it is trying to reach unparalleled heights. UML provides revenue to the government and also provides employment to lots of people. UML is serving through a leading daily Prabhat Khabar, Krishi Gram Vikas Kendra, Usha Martin Technical Institute.