Improvements for Bar to Bar

Consistency
Contents

1. Introduction
2. Factor Affecting Bar to Bar Consistency
3. Venus Comments and Conclusion
Introduction
• Customer has raises the concerns regarding bar to
bar consistency.
• To address the concerns of Bar To Bar consistency
Venus has fixed the processing route and
employed process checks at various stages of
Manufacturing.
Factor Affecting Bar to Bar
Consistency
• Chemical Composition
• Degree of Purity
• Heat Treatment
• Secondary Mechanical Working
Factor Affecting Bar to Bar
Consistency
• Chemical Composition
Required Chemical Properties
C Si Mn P S Cr Ni Cu Mo N Nb Al
Min. - - - - 0.005 15.00 4.0 - 0.80 0.020 -

Max. 0.06
0
0.70 1.50 0.040 0.015 17.00 6.0 - 1.50 -

Targeted Chemical Properties

C Si Mn P S Cr Ni Cu Mo N Nb Al
Min. 0.02 0.3 0.6 0.005 15.30 4.6 0.8
300pp
m
-

Max. 500 To To
0.05 0.5 1.0 0.035 0.015 15.80 4.80 0.30 0.9
ppm report report

Benchmark Sample
0.02 0.37 0.84 0.02 0.013 15.39 4.7 0.2 0.9 0.06
Factor Affecting Bar to Bar
Consistency
• Degree of Purity
• Customer Requirement : K3 < 30 (DIN 50602)
• Targeted : K3 < 20
• Measure K0 level inclusions also to understand
current level of small micro inclusions in
different heats
• R/M inspection
• Diameter/size : 16.40 +/- 0.2 mm
• Roundness : 0.20 mm Max.
Factor Affecting Bar to Bar
Consistency
• Heat Treatment
• HT Condition: QT900
• Cycle Code : 15F
• UTS Requirement: 860- 920 MPa
• YS(0.2) Requirement: 770 MPa
• Hardness Requirement: 290-310BHN
• Elongation Requirement : 20.00 %
• Grain Size : 7.5-8
Factor Affecting Bar to Bar
Consistency
• Shot Blasting
• Time: 20 mins. +/- 5 mins
• Pickling
• Sequence: High pressure wash-DIP in 8-10% H2SO4 for 15-
20 min.-High pressure water wash-HF 1%+HNO3 8 %DIP
3-5 min –High Pressure wash (TDS<600 PPM)
• Over Pickling Not acceptable
• After Pickling wire rod inspection
• Surface shall be defect free after 0.3 mm grinding
Factor Affecting Bar to Bar
Consistency
• Cold Drawing and Cutting
• Machine:RP2B
• Drawing Size:14.95-15.02 mm
• Coating: ZEL 880 Traxit Germany
• Coating Temperature:80-100 º C
• Coating Strength: 15 % min.
• Drawing lubricant :Centwax
• Length:3-3.2 m
• Straightness:0.5 mm / m
• Fixed amount of cold reduction is Very important to
meet magnetic properties
Factor Affecting Bar to Bar
Consistency
• UT & Eddy Current Testing
• Equipment: Dr Foerster RO65 +ROWA B4/65 UT Line
• Eddy current Parameter
• Notch Depth : 0.10 mm
• Linear speed: 0.25 m/s
• Rotary Speed: 6200
• Setup verification: Once in 5T by Standard Bar
• Ultrasonic Test Parameter
• Static Calibration: 0.7 FBH
• Dynamic Calibration: 1.0 mm FBH
• Field : AC
• Curent:3-5 A
• Frequency: 512 MHZ
• Setup verification: Once in 5T by Standard Bar
Factor Affecting Bar to Bar
Consistency
• Final Inspection
• Diameter : All bars 2 location by digital micrometer
• Ovality: 3 Bars/ 1 MT, 1 location by V anvil micrometer
• Mechanical Properties: Sample to be checked by lab
• Metallurgical Properties: Samples to be checked by lab
• Chamfering: Required dimension check 1 sample per 1Mt
Thank You