Agenda

Overview of Process Discussion of Caster in detail

Defects and preventative measures

Discussion of inspection procedures

UT ASTM A578

Questions

Steelmaking Process

Melt Shop: Scrap

Melt Shop: EAF

Tapping EAF

Melt Shop: Twin LMF

Melt Shop: LMF

Meltshop: Casting

Casting Liquid into a Slab

Slab

Roll Mill: Reheat Furnace

Roll Mill: Rolling Mill

Roll Mill: Hot Shear

Roll Mill: Leveler

Cooling Bed

Roll Mill: Cold Shear

Mechanical Testing Lab

Impact Testing Tensile Testing

Product Traceability
Die Stamping Paint Marking

On-Site Metallurgical Facilities

Scanning Electron Microscope Electrolytic Macro-etch

Shipping

Discussion of Internal imperfections

Segregation Voids Streaks Laminations

Slab Defects

Segregation

Solidification

Solidification

Grain Structure

Ways to minimize segregation

Lower carbon Control superheat Control bulging Lower cast speed to be able to do more soft reduction Lower Hydrogen Minimize Chemistry Higher reduction ratios

What is Soft Reduction?

Squeeze at final point of solidification

Localized

Final point of solidification moves down with increasing casting speed

Linear

Superheat Monitoring

Voids and Laminations

Caused by similar factors as segregation
Superheat Dissolved gases Misalignment in machine Steel shrinks as it solidifies.

Voids considered normal Laminations not considered normal.

Radial Streaks

Ways to minimize streaking

Excellent roll alignment Control bulging Lower Hydrogen Minimize Chemistry Higher reduction ratios to heal any streaks Uniform cooling

Rolling process
Rolling Direction

Equiaxed Grains

Elongated Grains Very high strength and low ductility

Nucor In-House Quality Checks

Nucor-Hertford Inspection of Bridge Grades
All weathering grades > 1.25, each end for 24 All grade 50 > 1.50, each end for 24 All grade 36 > 1.50, each end for 24

Nucor vs Industry Standard for Internal Soundness

Industry Standard
ASTM A578 or A435, only when ordered
Flaw size permitted, up to 3 diameter with total loss of back reflection

Nucor Standard
Rejection criteria is more stringent than ASTM

Nucor-Hertford UT Acceptance Criteria

Level

Criteria

Bridge

Other Structural

Level 1

Less than 10% Screen Height

Pass

Pass

Level 2

10%-30% Screen Height

Pass

Pass

Level 3

30%-50% Screen Height

Pass

Pass

Level 4

50% Screen Height Indication Less than 1

Fail

Pass

Level 5

50% Screen Height Indication Greater than 1

Fail

Fail

Typical UT Indication on a 2 plate

100

80
Screen Height (%)

60

40

20

0.5

1
Distance (in.)

1.5

ASTM UT Reject at Mid-Thickness of 2 Plate

100

80
Screen Height (%)

60

40

20

0.5

1
Distance (in.)

1.5

Nucor Hertford UT Rejection

100

80
Screen Height (%)

60

40

20

0
0 0.5 1
Distance (in.)

1.5

Mannesman Class 1

Class 2

Class 5

Short and Long term plans

Short term
Machine alignment Increased inspection when a problem is found Reduced cast speed Degassing

Speed Restrictions
Since 2008, Nucor has 62 grades that have speed restrictions to help with centerline and porosity(35% of our grades and mix).
Speed restriction cause solidification higher in the machine and allows for more time to perform soft reduction 60% of all greater than 1 material has speed restrictions. 95% of all greater than 2 material has speed restrictions.

Work done on improving surface quality

2010 revised our soft reduction tables 2011 set up routine macro sampling Added personnel to do this Helps identify problems in machine sooner 2011 Improved superheat control 2012 Installed Degasser Started up July of 2012 Now degassing 20-25% of our product

Results of Quality Improvements

Year
2008 2009 2010 2011 2012 Internal Soundness 0.21% 0.31% 0.42% 0.24% 0.17%

Porosity
0.04% 0.01% 0.12% 0.04% 0.02%

Total
0.25% 0.32% 0.55% 0.28% 0.18%

* Results are summary across all gauges/grades and include non degassed material.

Long term plans

Long term
Replace segments to improve cooling patterns
Current segments leave non-uniform soldification patterns

Danieli new anti-bulging program Investigating on-line UT