HANDBOOK QTB-JOB DP016901-rev.01

 DANIELI TECHNOLOGICAL
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WB setup changed
Date: 12.03.2007 Added quenched ASTM grades Rev: 01
Changes in blue
Job: DP016901
Compiled: C. Fabbro Checked: C. Fabbro Approved: F. Toschi
Date: 14.06.2005 Document: Rev: 00
Job: DP016901
Compiled: N. Redolfi Checked: N. Redolfi Approved:
AL YAMAMAH
DANIELI “QTB” PROCESS
FUNCTIONAL AND OPERATING MANUAL
Revision 01: 12.03.2007
Revision 00: 14.06.2005
TECHNOLOGICAL OFFICE
ROLLING MILL DEPARTMENT
HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 1

rev.01.doc
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF DANIELI & C. SPA NOT DISCLOSABLE, NOT REPRODUCIBLE. ALL RIGHTS RESERVED.
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1. Process description 3
1.1. Purpose of the process 3
1.2. Characteristic of the final product 5

1.2.1. Mechanical characteristics 5
1.2.2. Weldability 5
1.2.3. Fatigue load 5
1.2.4. Behaviour during fire 5
1.3. Basic metallurgical principles 6
1.4. Fundamental mechanism of surface hardening 8
1.5. Quenching in water boxes 9
2. Operative information 12
2.1. Rolling Conditions 12
2.2. Quenching Line 13

2.2.1. Water flow rates, nozzle inner diameter, number of cooling nozzles 13
2.2.2. General arrangement and hydraulic parameters 14
2.2.3. Water and air quality requirements 19
2.3. Temperature Measurements 20

2.3.1. Temperature upstream the quenching process 20
2.3.2. Temperature at Cooling Bed entry side 20
3. Maintenance 21
4. Method for set up and adjusting the process 23
4.1. General set up 23
4.2. Process adjustments 25

4.2.1. Adjustment of tensile properties 25
4.2.1.1. Too low tensile strength 25
4.2.1.2. Too high tensile strength: 25
4.2.2. Adjustments for chemical composition 26
4.2.3. Adjustments for rolling speed 27

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1. Process description
1.1. Purpose of the process
The purpose of the QTB process is to improve the mechanical properties of deformed bars
(re-bars), manufactured from very poor chemical composition. By applying the QTB
process to common low carbon steel, final technological characteristics even superior to
those of micro-alloyed steels or low alloyed steel are obtained at low production costs. For
steel grades, presenting yield strength equal to or higher than 500 MPa, it is possible to
save up to 18 % of the billet manufacturing cost, by the QTB process, compared to micro-
alloyed steel. Compared to low alloy steel the billet cost saving can be up to 8 %.
Moreover the QTB process allows the following advantages:
• Yield strength levels as required by the International Standards (ASTM, DIN, BS, etc.)
avoiding any further cold working practice.
• Good values of ductility and elongation, which results in optimum bendability.
• Improved weldability thanks to the very low content of alloying elements.
• Better homogeneity of the mechanical properties during time and repeatability as well.
• Less scale is produced on the treated bar in respect of standard production route.

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In Table 1.1.1 the required chemical compositions to guarantee the mechanical properties
of the QTB treated bars are listed.
Table 1.1.1. Composition table
%Mn/%S
Grade %C %Mn % Si %V
(* )
DIN 488 – Grade 500
0.18 – 0.24 0.60 – 1.00 0.15 – 0.30 - ≥ 25
( Quenched )
BS4449 – 1997 – Grade 460
0.18 – 0.24 0.60 – 1.00 0.15 – 0.30 - ≥ 25
( Quenched )
ASTM A615 – Grade 40
0.16 – 0.22 0.60 – 1.00 0.15 – 0.30 - ≥ 25
( Quenched )
0.18 – 0.24 0.60 – 1.00 0.15 – 0.30 - ≥ 25
( Quenched )
0.17 – 0.20 1.20 – 1.40 0.30 – 0.50 0.08 – 0.09 ≥ 25
( Not Quenched )
(*) = We suggest to have a ratio between Manganise and Sulfur in the range 25 - 27 to
avoid problems in the rolling mill ( Head opening and hot brittleness ).
Table 1.1.2. Mechanical properties
Grade Ys ( MPa ) UTS ( MPa ) El ( % ) UTS / Ys

DIN 488 – Grade 500
≥ 500 ≥ 550 ≥ 10 ( 10d ) ≥ 1.10
( Quenched )
BS4449 – 1997 – Grade
460 ≥ 460 ≥ 540 ≥ 14 ( 5d ) ≥ 1.08
( Quenched )
ASTM A615 – Grade 40 According to
≥ 280 ≥ 420 -
( Quenched ) ASTM Standard
≥ 400 ≥ 600 ≥ 1.08
( Quenched ) ASTM Standard
≥ 400 ≥ 600 ≥ 1.25
( Not Quenched ) ASTM Standard

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1.2. Characteristic of the final product
1.2.1. Mechanical characteristics
High yield strength characteristics can be achieved directly on the rolling line without the
need of addition of costly alloying elements or further cold working operations as cold
rolling or twisting.
1.2.2. Weldability
The possibility to maintain high yield strength characteristics with reduced carbon content
in the steel, means that QTB treated re-bars are easily weldable and no brittle spots are
generated during common welding procedures.
1.2.3. Fatigue load
The high stress resistance of the heat-treated surface layer, in combination with the
compressive stress state in the martensitic layer, implies favourable behaviour under
fatigue, thus allowing the use of QTB treated bars for dynamically loaded structural
components.
1.2.4. Behaviour during fire
Due to the high thermal stability of the heat-treated structure, its behaviour in the event of
fire can be well compared with the regular deformed bars.

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1.3. Basic metallurgical principles
QTB is a surface quenching and self-tempering process, executed directly from the rolling
heat, involving three stages described in the following paragraphs and exemplified in Fig
1.2.1.
COOLING CURVES OF TREATED BAR TROUGH THE THREE STAGES OF QTB TREATMENT
( THE CCT DIAGRAM FOR LOW CARBON STEEL ARE SUPERIMPOSED ON THE COOLING CURVES )
FERRITE + PEARLITE MIXED BAINITE

AUSTENITE
AUSTENITE
BAINITE TEMPERED
MARTENSITE MARTENSITE
1.000
900 BAR CORE
800
MIDDLE RADIUS
TEMPERATURE (°C )
700 F
600
P
500 B
400 BAR SURFACE F = FERRITE

P = PEARLITE
300 B = BAINITE
M M = MARTENSITE
200
100
STAGE 1 STAGE 2 STAGE 3
QUENCHING TEMPERING FINAL COOLING
TIME
QTB
Cooling bed
Fig. 1.2.1: Process description

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a) The first stage (surface quenching stage) consists of efficient water-cooling applied
to the bar as it leaves the finishing stand. The efficiency of the water cooling equipment
utilised in this stage has to be high enough to quench the surface of the bar faster than
the critical cooling rate for martensite formation, in order to obtain a surface layer of
crude martensite. This water-cooling is executed in an appropriate water box installed at
the finishing mill exit side.
The core temperature has to be maintained in the austenitic temperature range in order
to obtain a subsequent ferritic-pearlitic transformation (during the second and third
stages), thus giving sufficient ductility of the final product to withstand the bending test
requirements of the international standards.
At the end of the first stage, the bar microstructure is modified from the previous fully
austenitic structure into a 3-phase structure consisting of a surface layer of martensite,
an intermediate annular area consisting of a mixture of austenite, bainite and some
martensite, and a still austenitic core.
b) In the second stage (self-tempering stage), the bar leaves the water box and is
further naturally cooled in air. The heat flux from the still hot core re-heats the quenched
surface by conduction and the martensite formed in the first stage is self-tempered,
which ensures adequate ductility while maintaining a high yield strength level.
During the second stage, remaining non transformed austenite in the surface layer
transforms to bainite, whereas the core remains austenitic.
At the end of the second stage, the bar microstructure consists of a surface layer of
tempered martensite, an intermediate annular area consisting of a mixture of bainite,
austenite and some tempered martensite, and an austenitic core that starts to
transform.
c) The third stage (final cooling stage) occurs when the bar has been transferred to the
cooling bed and it consists of a quasi-isothermal transformation of the still non-
transformed austenite in the inner areas of the bar.
The product of this transformation is a mixture, either of ferrite and pearlite or of ferrite,
pearlite and bainite, depending mainly on chemical composition, bar diameter, finish
rolling temperature and the efficiency and duration of water cooling in the first stage.
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1.4. Fundamental mechanism of surface hardening
Fig. 1.2.1 is a schematic representation of the fundamental mechanisms of the QTB

process. Among the key parameters of the process only three can be considered as
independent control variables from the rolling mill operations point of view, namely:
• Finishing rolling temperature

• Quenching time
• Water flow rate
In spite of the fact that the microstructure of QTB treated bars continuously changes from
the surface to the core, it is possible to consider them as composed of two distinct parts,
the surface layer that mainly consists of tempered martensite, and the core, composed of
ferrite, pearlite and/or bainite.
The technological characteristics of the bar depend on the volume fraction of martensite,
the tensile properties of martensite and the tensile properties of the ferritic-
pearlititic/(bainitic) structure of the core.
The volume fraction of martensite depends on the temperature of the martensite

transformation start (Ms), which is function of the chemical composition, and of the
temperature field in the cross-section of the bar at the exit of the water box.
The following empirical formula shows the relationship between the chemical composition
and Ms:
MS (°C) = 512 – 453*C - 16,9*Ni + 15*Cr - 9,5*Mo + 217*C ² - 71,5*(C*Mn) - 67,6*(C*Cr)
The yield strength level of the martensitic layer depends on the chemical composition and
on the tempering temperature. The lower the tempering temperature, the higher the yield
strength and the lower the ductility.

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The tempering temperature is the maximum surface temperature achieved at the end of
the second stage and it is directly depending on the water quenching procedure adopted in
the first stage. The longer the first stage, the deeper the martensite layer, the lower the bar
temperature at the end of the first stage, and the lower the tempering temperature.
The mechanical properties of the core depend on two groups of parameters:
• The chemical composition of the steel giving specific {CCT diagrams}-{microstructure}-

{mechanical properties} relationship.
• The process conditions along the three stages of the process.
For a given chemical composition, the key factor determining the mechanical properties of
the QTB treated bars is the temperature path along the quenching stage.
The temperature path in quenching of a given diameter, can be modified by changing the
finishing rolling temperature, the duration of the quenching stage and the heat removal
from the bar surface by the cooling water during the quenching stage.
The heat removal from the bar surface depends on the hydrodynamic conditions in the
water box and is often characterised by the heat exchange factor.
1.5. Quenching in water boxes
The heat transfer coefficient between the bar surface and the cooling water is one of the
most important factors of the QTB process. It is a function of the surface temperature of
the bar, the design of the cooling device and of the cooling water pressure, flow rate and
temperature.
The water boxes are built up with a number of cooler pipes. The coolers are designed as
nozzles, with an internal annular slot, where the water enters the cooler pipe.

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As all nozzles, the coolers have certain characteristics, as shown in Figure 1.3.1.
Coolers consumption in function of Gap
50
45
40
35
30
25
20
15
10
Increasing gap
5
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Pressure ( Bar)
Fig 1.3.1: Cooler water consumption for a cooler size in function of gap
For a certain pressure each cooler size can give, and requires, a certain flow rate. By
changing the gap in the coolers, the flow rate for a given pressure is changed.
The important factors to reach a high heat exchange factor, necessary for the quenching
are:
• The pressure
• The flow rate,
• The filing factor.
The pressure is most important, since the impact of the water on the bar surface gives rise
to very efficient heat exchange, especially at the entry end of the coolers. The QTB
process is designed to operate with 12 bar, since less pressure gives lower heat exchange
and thus less cooling efficiency.
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However regulating the flow rate is done by means of pressure regulation and a certain
pressure range is necessary in order to obtain given mechanical properties.
Thus it must be controlled whenever the number of coolers or the gaps in the
coolers are changed, that the pressure never drops below 9 bar after the valve
bench.
As mentioned above, the flow rate is a function of pressure and gap setting. The influence
of flow rate on heat exchange comes partly from the pressure itself. Due to the high water
entry speed given by the pressure, a very intense turbulence is created at the entry of the
cooler. Also the relative velocity between the water and the quenched bar gives and not
negligible contribution to the heat exchange. This real relative speed is a very complicated
function. It includes all the components of turbulence in the pipe, but it has been shown
that the difference between the bar speed and the average linear water speed inside the
cooler gives a fairly good indication of the heat exchange at a given pressure. This relative
speed shall preferably not be less than 5 m/s.
The filling factor, defined as the square of the ratio between bar diameter and pipe
diameter, is another complex factor influencing the heat exchange. Beside the fact that the
relative speed normally decreases when the filling factor decreases, a low filling factor
allows for building up a “thick” boundary layer close to the bar. In such a boundary layer
there is no turbulence and the heat exchange is limited by the heat conduction in the
water, or in worst case, in a steam layer formed on the bar surface.

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2. Operative information
2.1. Rolling Conditions
Re-bars from 8 mm to 36 mm are quenched and tempered under conditions given in Table
2.1.1.
TABLE 2.1.1 –ROLLING CONDITIONS
Diameter Finishing speed Number of Strands

(mm) (m/s) #
8.0 35.0 2
10.0 28.85 2
12.0 20.0 2
14.0 14.9 2
16.0 22.5 1
18.0 18.0 1
20.0 14.4 1
22.0 11.9 1
25.0 9.22 1
32.0 5.63 1
36.0 4.45 1

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2.2. Quenching Line
2.2.1. Water flow rates, nozzle inner diameter, number of cooling nozzles
The surface quenching in the water box is executed by using an optimal number of cooling
nozzles, strippers and dryers. Two strippers and one dryer are placed at the exit end of the
water box while the number of cooling nozzles depends on the product, the steel
composition, the water temperature, and the desired final properties.
The dimensional range of products is divided into groups. For each group the same type of
cooling nozzles, strippers and dryers are used. The complete series of cooling elements
which is used for quenching one of these groups of diameters, is called a pipe set.
A pipe set is composed by:
Coolers (number variable) duty: quenching the bar
Strippers (2) duty: prohibit water leakage from the

water box
Dryer (1) duty: drying the bar surface
Entry/exit guide (2) duty: bar guiding at water box entry and exit
By-pass pipe (number variable) duty: substitution of coolers, which are not used
For the smaller SETS ( SET 18/20 and 25/28 mm ) a particular element called
Intermediate Stripper ( IS ) is provided. These elements are used for the small bar
diameter ( From 8 to 14 mm ) and are mounted in the middle part of the QTB waterbox after
the last cooler used ( See also Table 2.2.2.1 a, 2.2.2.1 b and 2.2.2.1 c).

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2.2.2. General arrangement and hydraulic parameters
The quenching line is used for:
• Quenching and tempering ( QTB Treatment – Quenched Product ) of rebars from 8.0 to
36 mm.
• Controlled cooling ( For not Quenched Product ) for the Grade ASTM A615 – Grade 60
Preliminary set up of the Cooling box for DIN 488 – Grade 500, BS 4449 – 1997 – Grade
460 and ASTM A615 – Grade 60 is shown in table 2.2.2.1 a.
Additional setup for the controlled cooling of ASTM A615 – Grade 60 is shown in table
2.2.2.1 b. For this kind of products the target temperature at the cooling bed entry side is
850 – 880 °C ( Only for small sizes ).
Preliminary set up of the Cooling box for ASTM A615 – Grade 40 is shown in the table
2.2.2.1 c.
The actual set-up for each steel grade and diameter will be reached and tuned during the
start-up of the installation.

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Table 2.2.2.1 a: Preliminary set up of the QTB water box ( DIN 488 – Grade 500, BS 4449 – 1997 – Grade 460 and ASTM A615 – Grade 60) –
Quenched product
• Line 1: Wire rod Blocks lines
Pipe Flow
Dimension Speed Gap Pressure
size C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 S S D rate
( Bar )
( mm ) ( m/s ) ( mm ) 3
(m /h)
( mm )
2x8 35.0 20 1.55 0 1 1 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B 570 12
2 x 10 28.85 20 1.55 0 1 1 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B 570 12
2 x 12 20.0 20 1.55 0 1 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B B 520 12
2 x 12 20.0 28 1.55 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B 720 12
2 x 14 14.9 28 1.55 0 1 1 1 1 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B 670 12
16 22.5 28 1.55 B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 560 12
18 18.0 28 1.55 B B B B B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 510 12
• Line 2: Single strand production
Operative
Dimension Speed Pipe size Gap Pressure
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 S S D Flow Rate
( mm ) ( m/s ) ( mm ) ( mm ) ( Bar )
( m3/h )
20.0 14.4 32 1.55 B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 330 12
20.0 14.4 40.3 1.55 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 590 12
22.0 11.9 40.3 1.55 B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 550 12
25.0 9.22 40.3 1.55 B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 510 12
32.0 5.63 56.1 1.55 B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 800 12
36.0 4.45 56.1 1.55 B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 740 12
1 = Cooler open – 0 = Cooler closed

B = Cooler bypassed – IS = Cooler substitute with Intermediate Stripper
HANDBOOK QTB-JOB DATE: 22/03/07 Page 15
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Table 2.2.2.1 b: Preliminary set up of the QTB water box ( ASTM A 615 – Grade 60 ) – Not Quenched Product (For high UTS / YS value)
Pipe Flow
( Bar )
( mm ) ( m/s ) ( mm ) 3
(m /h)
( mm )
2x8 35.0 20 1.55 1 B 1 B IS B B B B B B B B B B B B B B B B B B B B B B B 0 0 1 150 12
2 x 10 28.85 20 1.55 1 B 1 B 1 B IS B B B B B B B B B B B B B B B B B B B B B 0 0 1 210 12
2 x 12 20.0 20 1.55 1 B 1 B 1 B IS B B B B B B B B B B B B B B B B B B B B B 0 0 1 210 12
2 x 12 20.0 28 1.55 1 B 1 B 1 B 1 B IS B B B B B B B B B B B B B B B B B B B 0 0 1 260 12
2 x 14 14.9 28 1.55 1 B 1 B 1 B 1 B IS B B B B B B B B B B B B B B B B B B B 0 0 1 260 12
16 22.5 28 1.55 1 B 1 B 1 B 1 B 1 B IS B B B B B B B B B B B B B B B B B 0 0 1 160 12
18 18.0 28 1.55 1 B 1 B 1 B 1 B 1 B IS B B B B B B B B B B B B B B B B B 0 0 1 160 12
Operative
C C C C C C C C C C C C C C C S S D Flow Rate
( mm ) ( m/s ) ( mm ) ( mm ) ( Bar )
( m3/h )
20.0 14.4 32 1.55 B B B B B B B B B B B B B B B 0 0 0 - -
20.0 14.4 40.3 1.55 B B B B B B B B B B B B B B B 0 0 0 - -


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Table 2.2.2.1 c: Preliminary set up of the QTB water box (ASTM A615 – Grade 40) – Quenched product
Pipe Flow
( Bar )
( mm ) ( m/s ) ( mm ) 3
(m /h)
( mm )
2x8 35.0 20 1.55 0 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B B B B 430 12
2 x 10 28.85 20 1.55 0 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B B B 470 12
2 x 12 20.0 20 1.55 0 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B B B B 430 12
2 x 12 20.0 28 1.55 0 1 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B B 520 12
2 x 14 14.9 28 1.55 0 1 1 1 1 1 1 1 1 1 IS B B B B B B B B B B B B B B B B B B 470 12
16 22.5 28 1.55 B B B B B B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 440 12
18 18.0 28 1.55 B B B B B B B B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 390 12
Operative
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 S S D Flow Rate
( mm ) ( m/s ) ( mm ) ( mm ) ( Bar )
( m3/h )
20.0 14.4 32 1.55 B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 250 12
20.0 14.4 40.3 1.55 B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 470 12
22.0 11.9 40.3 1.55 B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 440 12
25.0 9.22 40.3 1.55 B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 400 12
32.0 5.63 56.1 1.55 B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 1 630 12
36.0 4.45 56.1 1.55 B B B B B 0 1 1 1 1 1 1 1 1 1 1 1 1 580 12


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On each cooling nozzle, stripper and dryer the flow of water or air can be tuned by the gap
distance and by valve bench regulation.
The gap distance of each cooler, dryer and stripper is the thoroidal slot through which the
water flows. Inserting a convenient number of shims between cursor and chamber, the gap
is changed. Table 2.2.2.2 and 2.2.2.3 shows the relationship between shim thickness and
gap size:
Table 2.2.2.2: Relation between shim thickness and gap size. Coolers
SHIM THICKNESS GAP OF COOLERS

2 mm 0.52 mm
3 mm 0.78 mm
4 mm 1.04 mm
5 mm 1.29 mm
6 mm 1.55 mm
7 mm 1.81 mm
8 mm 2.07 mm
9 mm 2.33 mm
10 mm 2.59 mm
Table 2.2.2.3: Relation between shim thickness and gap size. Strippers
SHIM THICKNESS GAP OF STRIPPERS/DRYERS

1.5 mm 0.50 mm
2.5 mm 0.90 mm
3.5 mm 1.20 mm
4.5 mm 1.50 mm
5.5 mm 1.90 mm
6.5 mm 2.20 mm
7.5 mm 2.60 mm
9.0 mm 3.10 mm
The choice of the gap is critical for the process and must be done during the start up time
according to the production mix and to the boundary conditions, first of them the
performances of valve bench. Then, during normal production, the gaps don’t need to be
changed. We suggest to start with a gap of 1.55 mm for the coolers and 0.9 mm for
strippers and dryers.

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2.2.3. Water and air quality requirements
In Table 2.2.3.1 some operative data regarding water and air requirements (DANIELI
STANDARDISATION - N° 2.4.3.305) are summarised.
Table 2.2.3.1
WATER LINE Depending on the

Flow rate m3/h
FEED dimensioning
REQUIREMENT Pressure 13 bar
Acidity 7÷9 pH
Calcium Hardness 30 ÷ 360 mg/l CaCO3
Magnesium
0 ÷ 120 mg/l MgCO3
Hardness
Alkalinity 50 ÷ 300 mg/l CaCO3
Chlorides max. 250 mg/l Cl -
Sulphates max. 200 mg/l SO4- -
QUALITY OF Iron Content max. 0,5 mg/l Fe
WATER Silica max. 75 mg/l SiO2- -
Total Dissolved
max. 1500 mg/l
Solid
Total Suspensed
50 ÷ 80 mg/l
Solid
Suspensed Solid
max. 200 µm
size
Oil Content max. 10 mg/l
bar (this pressure is requested
COMPRESSED Pressure 5.5 ÷ 6.0
for the electro-pneumatic valve)
AIR Total Suspensed
REQUIREMENT max. 15 mg/Nmc
Solid
Suspensed Solid
max. 50 µm
QUALITY OF size
AIR Oil Content max. 20 mg/Nmc
Dew Point max. 2 °C

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2.3. Temperature Measurements
2.3.1. Temperature upstream the quenching process
One pyrometer will by installed at stand 16 exit side

Two pyrometers ( One for each line ) will be installed at QTB entry side.
2.3.2. Temperature at Cooling Bed entry side
Two pyrometer ( One for each line ) will by installed at the cooling bed entry side
measuring the discharging temperature into the cooling bed.

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
3. Maintenance
In the present paragraph general trends and some hints for the maintenance of QTB lines
are given:
Water collecting box and piping
Only normal maintenance against excessive corrosion is necessary annually.
Water return circuit
Generally no scale removal in the water box is necessary. The scale particles transferred
from the bars to the cooling water have a size small enough to being carried away by the
water into the scale pit.
Valves, Pumps, Filters
Normal practice.
Water flow and pressure measuring devices
The zero drift of the transmitters and recorders shall be controlled monthly.
Complete calibration is repeated annually.

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
Radiation pyrometers
The following operations are necessary:
Optical alignment of the pyrometers in order to ensure precise targeting of the bar
∗ once/twice a week
∗ after each diameter change
Control of the cooling water and of the air blow protecting the lens
∗ once/twice a week
∗ after each diameter change
Cleaning of lens
∗ once a month
Calibration with a portable standard radiation pyrometer

∗ every second month
Note:
The pyrometer measuring the tempering temperature is of great importance for the
satisfactory performances of the QTB process. Consequently its maintenance has to be
carefully done.

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
4. Method for set up and adjusting the process
4.1. General set up
The first set up of the QTB process shall be done according to the following instructions,
for each bar size.
1) Make sure that the steel composition is in accordance with Table 1.1.1. If not, the
QTB process must be adjusted, as indicated below.
2) Make sure that the rolling speed is in accordance with Table 2.1.1. If not, the QTB
process must be adjusted, as indicated below.
3) Set the gaps in the coolers, strippers and dryers according to Table 2.2.2.1 a,
2.2.2.1 b and 2.2.2.1 c, by inserting the correct shims according to Table 2.2.2.2
and 2.2.2.3, between the cursors and chambers.
4) Set coolers, strippers and dryers in the water boxes, on the positions, shown in
Table 2.2.2.1 a, 2.2.2.1 b and 2.2.2.1 c.
5) Adjust the valve bench in order to reach the pressure and flow rate given Table
2.2.2.1 a, 2.2.2.1 b and 2.2.2.1 c.
6) Run one bar and check that the tempering temperature is within the range 560–650
°C. The desired tempering temperature for the production of grade DIN 488 –
Grade 500 are summarized in the following table:

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
Table for the tempering temperature
Diameter Cooling Bed entry Tempering temperature

(mm) temperature ( Into cooling Bed )
(°C) (°C)
8.0 590 - 610 650 – 660
10.0 – 12 580 - 600 640 - 650
14 - 16 575 - 585 635 - 645
18 - 20 570 - 590 630 - 640
22 - 25 560 – 580 600 - 620
28 - 36 540 – 550 580 – 600
7) After free cooling of the bar on the cooling bed, make tensile tests and check that
the mechanical properties are in accordance with the requirements.
NOTE: The sample for tensile testing must be naturally cooled on the cooling bed
after the QTB treatment.

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
4.2. Process adjustments
4.2.1. Adjustment of tensile properties
If the tensile properties are not correct, the QTB process must be adjusted according to
the following rules:
By all adjustments of the process, it must be made sure that the pressure never
drops below 9 bar
4.2.1.1. Too low tensile strength
• Add one cooler or more in each water box.

• Check that the pressure stays above 9 bar after the valve bench.
If it is not enough to add coolers, the gaps in the coolers can be increased.
4.2.1.2. Too high tensile strength:
• Take out one cooler or more from each water box.

• Check that the pressure stays above 9 bar after the valve bench.
If necessary, the gaps in the coolers can be reduced.
Note: In most cases there is only a lower limit on yield strength and tensile strength, but
there are also requirements on the ratio between tensile strength and yield strength.
This ratio is reduced when the tensile strength level is increased. A low ratio is
therefore an indication of too high tensile strength.

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
4.2.2. Adjustments for chemical composition
If the chemical composition is not in accordance with the requirements in Table 1.1.1, the
QTB set up shall be adjusted as follows:
If the composition is poorer than the standard compositions in Table 1.1.1 (lower content
of C, Si and Mn):
• Add one cooler or more to the set up in Table 2.2.2.1 a, 2.2.2.1 b and 2.2.2.1 c.
• Check the pressure and make necessary adjustments in order to maintain the pressure
in the range 9 - 12 bar after the valve bench.
• Check the tempering temperature that must be lower than the standard level.
• Check the mechanical properties of the product.
If the composition is richer than the standard compositions in Table 1.1.1 (higher content
of C, Si and Mn):
• Replace the first cooler in the set up in Table 2.2.2.1 a, 2.2.2.1 b and 2.2.2.1 c by a by-
pass pipe (if necessary also the second (third, forth) cooler can be replaced by by-pass
pipes.
• Check the tempering temperature that must be higher than the standard level.

rev.01.doc
TEAM
ROLLING MILLS
FOR LONG PRODUCTS
MORGÅRDSHAMMAR
4.2.3. Adjustments for rolling speed
If the rolling speed is not in accordance with in Table 2.1.1, the QTB set up shall be
adjusted as follows.
If the speed is higher than the design speed according to Table 2.1.1.
• Add one cooler or more to the set up in Table 2.2.2.1 a, 2.2.2.1 b and 2.2.2.1 c.
• Check the tempering temperature that shall be maintained on the standard level.
If the speed is lower than the design speed according to table 2.1.1:
• Replace the first (second, third) cooler in the set up in Table 2.2.2.1 a, 2.2.2.1 b and
2.2.2.1 c by a by-pass pipe.
• Check the tempering temperature that shall be maintained on the standard level.

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 DANIELI TECHNOLOGICAL

Date: 12.03.2007 Added quenched ASTM grades Rev: 01

Compiled: C. Fabbro Checked: C. Fabbro Approved: F. Toschi

Date: 14.06.2005 Document: Rev: 00

Compiled: N. Redolfi Checked: N. Redolfi Approved:

FUNCTIONAL AND OPERATING MANUAL

Revision 01: 12.03.2007

Revision 00: 14.06.2005

ROLLING MILL DEPARTMENT

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 1

1.1. Purpose of the process 3

1.2. Characteristic of the final product 5

1.3. Basic metallurgical principles 6

1.4. Fundamental mechanism of surface hardening 8

1.5. Quenching in water boxes 9

2.1. Rolling Conditions 12

2.2. Quenching Line 13

2.3. Temperature Measurements 20

4. Method for set up and adjusting the process 23

4.1. General set up 23

4.2. Process adjustments 25

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 2

1.1. Purpose of the process

Moreover the QTB process allows the following advantages:

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 3

Table 1.1.1. Composition table

Table 1.1.2. Mechanical properties

Grade Ys ( MPa ) UTS ( MPa ) El ( % ) UTS / Ys

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 4

1.2. Characteristic of the final product

1.2.1. Mechanical characteristics

1.2.3. Fatigue load

1.2.4. Behaviour during fire

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 5

1.3. Basic metallurgical principles

FERRITE + PEARLITE MIXED BAINITE

900 BAR CORE

400 BAR SURFACE F = FERRITE

STAGE 1 STAGE 2 STAGE 3

QUENCHING TEMPERING FINAL COOLING

Fig. 1.2.1: Process description

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 6

1.4. Fundamental mechanism of surface hardening

Fig. 1.2.1 is a schematic representation of the fundamental mechanisms of the QTB

• Finishing rolling temperature

The volume fraction of martensite depends on the temperature of the martensite

MS (°C) = 512 – 453*C - 16,9*Ni + 15*Cr - 9,5*Mo + 217*C ² - 71,5*(C*Mn) - 67,6*(C*Cr)

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 8

The mechanical properties of the core depend on two groups of parameters:

• The chemical composition of the steel giving specific {CCT diagrams}-{microstructure}-

1.5. Quenching in water boxes

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 9

Coolers consumption in function of Gap

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 11

2.1. Rolling Conditions

TABLE 2.1.1 –ROLLING CONDITIONS

Diameter Finishing speed Number of Strands

HANDBOOK QTB-JOB DP016901- DATE: 22/03/07 Page 12

MS (°C) = 512 – 453C - 16,9Ni + 15Cr - 9,5Mo + 217C ² - 71,5(CMn) - 67,6(C*Cr)