A Foaming Bath Method for Direct Heat
Wire Rod Manufacture*
By Katsuhiko YAMADA,** Yoshihiro HASHIMOTO,*** Kunio OJIMA* *
and Takashi ASAKURA**
Synopsis
Thebehavior of thehotrolledwirerodsduringcoolingin waterwas
preciselyinvestigated
bya laboratory
testandit has beenmadeclearthat
coolingbysubcool-boilingina gaswatermixedfluidcanbea newcooling
methodand thisfluidcanbe takenas a newcoolantwhichhasexcellent
characteristics
for patenting.
The newdirectheattreatmentsystemhavingtheverywiderangeof
cooling
speeds, in whichthisnewcoolingmethodandnewcoolant wasap-
pliedas theprincipaltechnology,
wasdeveloped.
Thetreatedwirerodshavenotonlythegoodmechanical properties
but
alsothehighuniformity withina coil.
Key words: heat treatment;wire rod; coolingmethod;patenting;
mechanical
property.
I.Introduction
The advantages of controlled cooling for hot rolled
wire rods are widely known as follows :
(1) It eliminates the heat treatment before cold
drawing.
(2) In some cases it provides the better quality
than that given by off-line heat treatment.
(3) It reduces the indirect manufacturing costs
by preventing the defects caused by coil handling and
rust, shortening the leading time from rod to final
wire products, and reducing the amount of wire rod
stock.
(4) It improves pollution problems caused by
heat and surface treatment.
Stelmor process (the forced air cooling), and ED
(Easily Drawable)1~ process (the cooling by boiling
water) are both quite popular as the partial substitute
of lead patenting for the past more than 10 years.
Recently, the new processes such as EDC (Easily
Drawable Conveyor),2'3> D0,4) DLP5~ and other new
controlled cooling processess~ have been developed
and commercialized and they have extended the varia-
tion of cooling and improved the quality of treated
products. Though each of them has superior charac-
teristics, the cooling function is not multiple but single.
It means that they are not always advantageous as
the controlled cooling system which must accept the
production of small lots with many grades and the
reduction of investment cost as one of the trend of
steel manufacturing technology from now on.
The following two targets were aimed by Sumitomo
Electric Industries, Ltd. at the planning stage of new
controlled cooling process.
(1) Any cooling speed in the range of 2 N
100°C/s must be able to be chosen so that the
* Based on the papers presented to the 110th ISIJ Meeting, October 1985, S1135 to S 1137, at Nii Bata
script received on April 28, 1986; accepted in the final form on September 12, 1986. © ISIJ 1987
** Special Steel Wire Division, Sumitomo Electric Industries, Ltd., Koya Kita, Itami 664.
*** Itami Research Laboratories, Sumitomo Electric Industries, Ltd., Koya Kita, Itami 664.
(42) Technical Report
Treatment System for
process covers all kinds of heat treatments from
annealing to quenching.
(2) The mechanical properties of the treated coil
must have the uniformity which is equivalent to that
of off-line treated one.
As the concrete means, the air cooling conveyor
having the heat isolation tunnel was adopted for the
cooling speed below 10°C/s, and the process of
continuously dipping into cold or warm water was
adopted for above 50°C/s. One of the most difficult
heat treatments is patenting whose cooling speed is
10' 30°C/s and the subcool-boiling method has not
been applied for this purpose in spite of its possibility.
The reason is that the film boiling transits to nucleate
boiling at the early stage of cooling and then cooling
speed is extremely accelerated and finally the trans-
formation finishes not through the formation of pear-
lite but through martensite. Few technical reports
have been found which refer what metallurgical fac-
tors affect this transition from film boiling to nucleate
boiling.7)
Therefore, the boiling phenomenon was carefully
investigated and the cooling behavior was analyzed.
It was made clear that the growth of FeO whisker on
the surface greatly affected the transition from film
boiling to nucleate boiling. Finally, the new coolant
of gas-water mixed fluid by which the growth of FeO
whisker can be suppressed and the cooling speeds can
easily be controlled was found out and the new cooling
system based on this new coolant was developed.
On the other hand, wire rod is generally heat
treated in the form of overlapping nonconcentric
spirals. Therefore, it is difficult to avoid the lack of
uniformity of cooling within a coil. As the counter-
measure for this problem, a few analyses were carried
out and the results were reflected to the design of the
equipment.
II. Cooling Behavior of Wire Rod in the Gas-
Water Mixed Fluid
The trial to utilize the subcool-boiling phenomenon
was carried out to get high tensile strength (TS)
and good drawability which were equivalent to those
by lead patenting. It has already been made clear
through the preliminary investigation that the coolant
temperature, the flow rate of coolant and the surface
condition of wire rod greatly influence the cooling
speed and also that the characteristics of the coolant
extremely depend on the gas bubbles injected in warm
University in N iigata. Manu-
 Transactinos Is", Vol. 27, 1987 (43)

water.

1. Specimensand Experimental Method

The material used was JIS SWRH 82B whose
chemical compositions were 0.80 % C, 0.25 % Si,
0.68 % Mn, 0.015 % P, 0.011 % S and 0.017 % Al
(wt%). As the specimen, wire of 11.0 mm in diam-
eter whose surface was mechanically shaved from
the wire of 11.3 mm in diameter after cold drawing
from 12.3 mm dia. wire rod was prepared in order to
avoid the influence of surface conditions.
UµJ 11V YY 1µ1,l,. V'~L..! 111111111 •111

Figure 1 shows the equipment used in this experi-

Fig, 1. Schematic drawing of quenching unit.
ment. The bubbles were uniformly provided by
injecting certain volume of air from the bottom of
the tank and the temperature of the coolant was
controlled by electric heater and the specimen stage
was repeatedly movable in the horizontal and the
vertical directions. The specimen was heated up to
950 °C in the furnace followed by keeping for 15 min
in N2 gas atmosphere, and then dipped into the
cooling tank after keeping it for a predetermined
period of time in air.
The temperature of specimen was measured by Fig. 2. Cooling curves at the center of wire rod in warm

CA thermocouple inserted into the axial center of it. water.

The experiment factors that influence the cooling

were selected as follows:
1) time of preoxidation by air before immersion in
coolant
2) temperature of coolant
3) kinds of injection gas
4) volume of injection gas
5) relative flow velocity between specimen and
coolant
6) overlapping conditions of specimens.

2. CoolingCurve of the Specimen

Figure 2 shows one of the examples of cooling
curve measured at the axial center of the specimen
cooled in warm water. In this figure, the variables
are time of preoxidation by air to and temperature of
coolant T. The to corresponds to the time spent
till dipping after rolling in actual operation. As to
temperature of coolant T two cases are selected,
namely saturated boiling which occurs similarly in
the ED process and subcool-boiling whose cooling
ability is about double in comparison with ED
process. The figure suggests that to delicately influ-
ences the cooling curve and that the occurrence of
pearlite transformation is observed when tp is long
and T is high.
Figure 3 is the cooling curve when to is fixed at
about 4 s and variables are the temperature of
coolant and the condition of with/without air bub-
bling. It was recognized that the film boiling was
stable enough to perimit pearlite transformation in
the air-water mixed fluid even if the coolant tempera-
ture was as low as 80°C. Furthermore, it was found
that the cooling speed during the film boiling stage
clearly relates to the coolant temperature. These
two facts suggest that the air-water mixed fluid has
the great ability to be a new coolant for patenting.
Figure 4 shows the effects of three factors men-
Fig, 3. Effect of coolant temperature on cooling curve.
tioned above on temperature T~ at which the transi-
tion from film boiling to nucleate boiling takes place.
In the case of cooling in warm water, T~ revealed
some peculiar changes. In other words, when to
was about 4 s T. rose with drop in water tempera-
ture, while when to was below 0.5 s T, remained
at about 500°C level and was independent of water
temperature. On the other hand, in the case of
cooling in the air-water mixed fluid TTY always stood
at about 500°C with stability. It may be concluded
from these facts that the air-water mixed fluid is
a good coolant on its stability and reappearance.
3. Tensile Strength of Treated Wire Rod and Treating
Conditions
1. Preoxidation Time, Coolant Temperature and Kind
of Coolant
Figure 5 shows the influence of t0, T and kind of
(44) Transactions ISIJ, Vol. 27, 1987

Fig. 6. Effect of gas flow rate on tensile strength.

equivalent to that attained by lead patenting.

2, Gas Flow Rate
Secondly, the experiment was carried out varying
the injection rate of air from zero to 2.7 m3/min.m2
under the constant condition in which t0=4 s and
T=80°C and the other experiment was carried out
Fig. 4. Influence of coolant temperature Tand air bubbling by injecting N2 gas instead of air. Figure 6 shows
on critical temperature T,.. the influence of gas flow rate v on TS. In the case
of air injection, the figure shows that when v is below
0.3 m3/min. m2, martensite transformation (marked
as the abnormal low TS spot) takes place due to the
nucleate boiling which is usual in warm water. It
also indicates that TS increases with increase in v
and film boiling becomes stable enough to suppress
the occurrence of an abnormal spot. However, in
the case of N2 gas injection, the nucleate boiling takes
place at the early stage of cooling resulting in abnor-
mal low TS. This is the very significant phenomenon
in the case where the gas-water mixed fluid is applied
as a coolant.
3. Relative Flow Velocity between Wire Rods and Coolant
Hot rolled wire rods are heat treated in the form
of overlapping non-concentric spirals during trans-
portation in the coolant vessel. In this case, the
effect of the relative flow velocity necessarily generated
between wire rods and coolant probably cannot be
ignored.
In this point of view, the experiment was carried
out to reveal the cooling behavior of specimens giving
the flow velocity by reciprocated motion of which
direction was normal or parallel to the wire rod axis.
Fig. 5. Effect of temperature of coolant on tensile strength As the coolant temperature, three levels were
of wire rod. selected, i.e., 100, 85 and 80°C. Figure 7 shows the
relation between TS and relative flow velocity and
coolant on TS. It is suggested as the general trend the following behavior has been made clear.
as follows : (1) Tensile strength increases linearly with in-
(1) Tensile strength increases linearly with de- crease in relative flow velocity.
crease in coolant temperature. (2) The flow velocity of which direction is per-
(2) In the case of subcool-boiling when the cool- pendicular to the rod axis gives higher rate of increase
ant temperature is below 90°C, the abnormal low in TS than that parallel to the rod axis.
TS values caused by martensite transformation due (3) The coolant temperature is the lower, the
to the nucleate boiling are apt to appear. rate of increase in TS is the higher.
In the case where to was about 4 s, TS of wire The cause of these phenomena can be explained
rods produced by cooling in gas-water mixed fluid that the flow velocity varys the thickness of steam
at 80°C was 10 kgf/mm2 above that produced by film generated on the rod surface and the coolant
cooling in boiling water. The wire rod was obtained temperature distribution close to the wire rod surface.
with TS as high as about 125 kgff mm2, which was Large variety of flow velocity necessarily take place

Fig. 7. Effect of relative flow speed between
on tensile strength of rod.
in the actual operation and the informations obtained
through this experiment are reflected to a designing
point to secure the uniformity of mechanical properties
within a coil.
4. Overlap of Rod Rings
At the actual operation of direct heat treatment,
wire rods are not treated in the shape of streight
bars but of rings. Therefore, rings are necessarily
overlapped to some extent. Concerning to the varia-
tion in TS caused by overlap, it is reported that the
cooling by dipping in boiling water (ED process)
gives smaller influence than the cooling by forced air
(Ste].mor process). The relation between TS and
overlapping conditions in a gas-water mixed fluid
is given in Fig. 8. This figure shows that the differ-
ence in TS extends to 5 kgf/mm2 according to the
overlapping conditions. Therefore, in order to pro-
duce the wire rod with better uniformity in mechan-
ical properties, it is necessary to take effective counter-
measures to overcome this overlap problem.
4. Factors Concerningto the Behavior of Boiling
It was already mentioned in the previous section
that the transition from film boiling to nucleate
boiling greatly affects the characteristics of heat
treatment. It was also made clear that in the case
of cooling by subcool-boiling, the cooling behavior
and the TS obtained were definitely influenced by the
time of preoxidation and the existence of air bubbles
in the warm water. These are all deeply significant
facts and the further analysis was carried out.
1. Surface of Heat-treated Wire Rod
First, two specimens cooled by dipping in warm
water and the gaswater mixed fluid were prepared
under the condition in which the time of preoxidation
was about 4 s. Evaporated Au was coated onto
the rod surface and close observation was carried out
using SEM (Scanning Electron Microscope). It was
found that whiskers were formed on the specimen
cooled in warm water and they appeared to be Fe-
Oxide. On the other hand, no whisker was found
Transactions ISI1, Vol. 27, 1987 (45)
rod and coolant
Fig. 8. Effect of various overlapping conditions of wire rods
on tensile strength.
on the specimen cooled in the gas-water mixed fluid.
This fact suggests that whiskers are closely related to
cooling behavior.8~
2. Time of Preoxidation and Reheating Temperature
Figure 9 shows the surface condition observed by
SEM as a function of to. Under the condition in
which t0=0.2 s, whiskers are not formed whether
bubbles are injected into the coolant or not. Under
the condition in which to=1 ~4 s, the whisker forma-
tion was observed on the specimen cooled in warm
water, though it was suppressed when cooled in the
gas-water mixed fluid.
Next, in order to clarify the condition which drives
whisker formation, many specimens cooled in warm
water varying to and reheating temperature T,. were
prepared and then they were investigated by SEM
whether whisker is formed or not. Figure 10 shows
the bounds where whisker is formed and it is tolerably
limited.
3. Kind of Gas
Since the whisker was not formed under the condi-
tion in which plenty of air was injected in warm
water, the key to cooling behavior seemed to be the
oxidation ability of bubbles. As the kinds of injec-
tion gas, 02, N2 and Ar were picked up and the same
experiment was carried out. The result came up
to our expectations, namely when injection gas 02,
whisker was not observed and when N2 and Ar,
whisker was formed.
5. Application of New Coolant of Gas-Water Mixed
Fluid for ControlledCooling
Gas-water mixed fluid is the quite different coolant
from the simple warm water and has excellent charac-
teristis useful for heat treating the steel.
(1) It provides the stable film boiling suppressing
the nucleate boiling at the cooling stage of 7O0'-
500°C, which is the very important range of tempera-
ture for heat treatment.
 Transactions ISIJ, Vol. 27, 1987
(46)

Fig . 9. Scale morphology of rod surface and preoxidation time to (a) in warm water

and (b) in air-water mixed coolant.

III. Design and Operation of Multi-f unction

Fig . 10. Influences of preoxidation time
temperature on scale morphology.
(2) The cooling ability depends on the coolant
temperature and it is greater than that of forced air
cooling.
(3) The cooling ability can be enhanced by the
relative flow velocity between wire rod and coolant.
Furthermore, for practical application, we have
made clear quantitatively the way how to deal the
factors such as (1) rolling temperature (2) time of
preoxidation, (3) coolant temperature, (4) kind,
quantity and way of gas injection, (5) relative flow
velocity, (6) overlap of rod rings, and so on.
Direct Heat Treatment Equipment
Many systems have already been developed as the
direct heat treatment for hot rolled wire rod. Sumi-
tomo Electric Industries, Ltd. have newly developed
and installed the multi-function direct heat treatment
equipment of which principal technology is the new
coolant and the new cooling method. The equipment
covers a very wide range of cooling speeds of 2
100°C/s, which means each wire rod is enabled to
be subjected to the necessary heat treatment just after
being rolled.
The design policy, the structure and the operation
to an d preoxidation
of the equipment are described below.
1. Design of the System
1. Design Policy
Three principal points were decided at the begin-
ning of design as follows :
(1) The new process must cover several kinds of
heat treatment from annealing to quenching, and for
this purpose the cooling speeds have to be variable
from 2 to 100°C/s. Table 1 shows the contents of
treatments planned.
(2) The heat treatment must give rods enough
uniformity within a coil equivalent to that by off-
line (indirect) heat treatment. For instance, the
standard deviation of TS of the patented rod must
 Transactions ISIJ, Vol. 27, 1987 (47)

be below 1.5 kgff mm2.
(3) Several kinds of heat treatment must be
quickly converted from one to another in order not
to decrease the productivity.
2. Designing
(1) Structure
As shown in Fig. 11, a laying head, a roller con-
veyor for preoxidation and a dry/wet convertible
conveyor were successively arranged.
For cooling below 10°C/s, the popular air cooling
method consisting of roller conveyors was adopted.
This roller type has the advantage of uniformity in
heat treatment within a coil. For cooling above
10°C/s, two continuous dipping and pulling up
methods were adopted using warm water and gas--
water mixed fluid as coolants. Buffer tanks were
prepared for each coolant. The new coolant was
made by skillfully injecting the oxidating gas into
warm water so that the bubbles were plenty, uniform
and fine.
(2) Control of the Cooling Speeds
At the dry line, cooling speed was controlled by
ring pitch, isolation covers and air blowers. At the
wet line, it was done by coolant circulating system
and hot/cold water mixing system using a micro-
computer which enables to control coolant tempera-
ture precisely and easily.
(3) Improvement in the Uniformity of Cooling
Generally speaking, in order to obtain the higher
TS the more sensitive cooling conditions is necessary
and results in the worse uniformity within a coil.
When wire rod treavels through the coolant in the
shape of nonconcentric spirals, wire rod encounters
two kinds of lack of uniformity. One is that the
rings are piled up at conveyor edge sides and the other
is that the relative flow takes place between rod rings
and coolant and these are both important problems
especially for the patenting treatment by the new
coolant. For the former problem, the conveyor was
designed to be able to (1) give the enough ring pitch,
and (2) move the contact points among rings by
cascade conveying method at different speeds.
For the later problem, the coolant circulation
system by which the coolant is caused to flow in the
same direction as that of movement of rods in the
vessel was installed to exclude the effect of relative
flow velocity.
2. Actual Operation
The operational conditions of wet line are as
follows:
1. Control of the Coolant Temperature
The importance and the way of temperature control
for the new coolant is already mentioned above.
Figure 12 shows the appearance of coolant tempera-
ture control in actual operation. The coolant tem-
perature at the inlet of processing tank was kept
constant regardless of the rolling intervals, on the
other hand the coolant temperature of the outlet
changed according to the wire rod existence. The
reason why the changes are not square comes from
the fact that the movement of the wire rod and the

Table 1. Kinds of heat treatment.

Fig. 12. Change in temperature of coolant during opera-

tion of new process by gas-water mixed coolant.

Fig. 11. Sc hematic view of new process.

( 48 ) Transactions ISIJ, Vol. 27, 1987

coolant is not perfectly synchronous. erties of SWRS 82B steel rod, 13 mm in diameter
2. Flow Velocity of Coolant and it supports the feature that the new cooling
Figure 13 shows the distribution of flow velocity process is equivalent to lead patenting in the prop-
within a cross section perpendicular to a direction of erties of rod.
rod movement in the processing tank. Though the Figure 17 shows the mechanical properties of PC
flow velocity was not uniform through vertical direc- wire, 5.0 mm in diameter, which is cold drawn from
tion, it was comparatively uniform at near the pass a wire rod of 13 mm in diameter and it reveals that
height. This distribution was measured when the the wire has enough TS and ductility to satisfy the
conveyor was not carrying wire rod and the velocity specification of the final product.
measured at upper portion in actual operation was Equation (1) is the result of regression analysis on
lower than that shown in Fig. 12. This informs us TS of wire rod, 13 mm in diameter, cooled by this
that the distribution of flow velocity in actual opera- new method.
tion may be considerably uniform.
3. Troubles with Traveling TS= 31-0.7X TTw+93X[%C]+23X[%Mn]
At the early stage of start-up operation, many kinds +52 X [%Cr]+0.051 X T1+o.006+ T,.......... (1)
of traveling problem took place within a half year.
Almost all problems had been solved and now the
operation conditions are stable enough.

IV. Quality of Wire Rod Directly Heat Treated

The new process provides several kinds of a neces-
sary heat treatment for carbon steel, low alloy steel
and stainless steel wire rods whose diameters are in
the range of 5.0.'14.3 mm.

1. EDC Rod -
The feature of this EDC treatment is that the
appropriate TS level and higher uniformity can be
given to high carbon steel wire rod.9~ Hot rolled
wire rod is continuously put into the hot water kept
at boiling point and pulled up at about 400 °C. Fig. 14. Mec hanical properties of ED and EDC rod.
Though EDC has the most simple function of the new
process, this new one includes some additional
improvements compared with the other existing EDC
processes.
Figure 14 shows the mechanical properties of the
wire rod treated by EDC process in comparison with
that by old ED process and it reveals the higher
uniformity and ductility. Figure 15 shows the
variation in TS within a coil and a ring.

2. High Tensile Patented Rod

High tensile patented rod was manufactured by
the new cooling process with the new coolant ex-
plained in the previous section and the mechanical
properties were equivalent to those by lead patenting
process.
Figure 16 shows an example of mechanical prop-
Fig. 15. Variation in TS for EDC rod.

Fig. 13. Flow speed distribution of coolant in cross section

of processing tank. Fig. 16. Mechanical properties of patented rod.

 Transactions ISIJ, Vol. 27, 1987 (49)

Table 2. Estimation concerning intensity of influence

of factors on tensile strength.

Fig. 17. Mechanical properties of PC wire.

where, TS : Tensile strength (kgf/mm2)

l w: Temperature of inlet coolant (°C)
T f : Temperature of rod at finishing roll
(°C)
TT,: Temperature of rod at laying head
(°C).
Concerning to the variables picked up in Eq. (1),
they are quality controlled in the actual operation
within such narrow ranges as shown in Table 2. The
variation in TS can be estimated by applying control
Fig. 18. Mechanical properties of AP rod.
range R to Eq. (1). Table 2 informs that the intensity
of influence on TS is ranked in the following ascending
order: finishing temperature, impurity element Cr%
and C%.

3. Air CooledRod
The high carbon steel wire rod mainly used for
tire cord is properly and uniformly cooled through
air cooling line in order to obtain especially high
drawability. This line is also applied for low alloy
steel and Fig. 18 shows the mechanical properties of
Si-Cr steel wire rod (equivalent to SAE 9254) for
valve springs and reveals its appropriate strength and
ductility to satisfy the cutting ability and cold
Fig . 19. Mechanical properties of DA rod.
drawability.

4. Direct AnnealedRod stainless steel is easily attained.

Though this process does not involve annealing in
the strict meaning but simple slow cooling treatment,
sufficient heat treatment can be made in most cases.
For the slower cooling, wire rods are piled thickly in
the form of nonconcentric spirals and travels slowly
through the tunnel covered by isolation plates.
Figure 19 shows the mechanical properties of wire
rod for CO2 welding wire and it reveals that the rod
is softened enough to satisfy the considerably higher
drawability.
In the case of manufacturing the high tensile
quenched and tempered wire, hydrogen included in
wire rods delicately affects the ageing phenomena just
after tempering and the delayed failure during using.
This problem is solved by this treatment.
5. Direct QuenchedRod
Direct quenched rod is able to be manufactured by
the appropriate combination of the chemical com-
position of steel and the cooling ability. For this
purpose gas-water mixed fluid or water is used as
a coolant and the solution treatment for austenitic
Table 3 shows the mechanical properties of a
quenched rod of 0.15 % C low alloy steel for rein-
forcing member and it shows the considerably high
TS and ductility.
Several kinds of heat treatment provided by the
new process have been mentioned and the summary
of their mechanical properties are shown in Table 3.
V. Summary
The cooling behavior of wire rod through boiling
phenomena in water was precisely observed and in-
vestigated and the factors which affect the cooling be-
havior and the mechanical properties were made clear.
(1) The oxidative gas-water mixed fluid has
substantially different characteristics from those of
simple water and it can be taken as a new coolant
for patenting and all the problems for manufacture
has been solved.
(2) The new multi-function direct heat treatment
equipment has been developed. Its principal tech-
nology is the new coolant and the new cooling method.
The equipment covers the very wide range of cooling
(50) Transactions ISIJ, Vol. 27, 1987

Table 3. Mechanical properties of rods treated by new process.

speeds 2 100°C/s. Therefore, each wire rod is DE Patent No. 1942731, (1980).
able to be subjected to the appropriate heat treatment 3) A. Tendler: Wire J., 14 (1981), 84.
according to the steel grade, uses and rod diameter. 4) H. Yada, T. Mori, M. Murakami, J. Tominaga and M.
Ochiai: Seitetsu Kenkyu, (1982), No. 310, 264.
(3) All the wire rods treated by the new process 5) K. Wakimoto, T. Inoue, K. Matsuoka, J. Tominaga and
have very high uniformity in mechanical properties K. Ito: Tetsu-to-Hagane, 69 (1983), 5570.
and metallurgical structure. 6) K. Nashimoto, K. Goto, Z. Tsutsumi, H. Kaneda, T.
Ninomiya, K. Azuma, K. Kawabata, T. Suzuki and M.
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