Title

Date
Time
Venue

: Introduction to steel
: 13/11/2013
: 6.30-7.30PM
: Conference room

Steel making process

Global Statistics:
According to the World Steel Association, in 2011 global
crude steel production reached a new record high at 1.527
billion metric tonnes. Of this, approximately two-thirds was
produced using BOS plants, while EAF facilities accounted
for the remaining third
The largest steel producing countries in 2011 were China,
Japan, US, and India. China currently supplies about 45%
of the world's steel. The world's largest steel producers
include Arcelor Mittal, Baosteel, POSCO and Nippon Steel.

Steel making process

Iron making:
the raw inputs iron ore, coke and lime are melted in a blast
furnace.
The resulting molten iron - also referred to as 'hot metal' - still
contains 4-4.5% carbon and other impurities that make it
brittle.
Primary Steelmaking:
differ between BOS and EAF methods.
BOS methods add recycled scrap steel to the molten iron in a
converter.
At high temperatures, oxygen is blown through the metal,
which reduces the carbon content to between 0-1.5%.
EAF methods, alternatively, feed recycled steel scrap through
use high power electric arcs (temperatures up to 1650 C) to
melt the metal and convert it to high quality steel.

Secondary Steelmaking:
involves treating the molten steel produced from both BOS and
EAF routes to adjust the steel composition.
This is done by adding or removing certain elements and/or
manipulating the temperature and production environment
Continuous Casting:
the molten steel is cast into a cooled mold causing a thin steel
shell to solidify.
The shell strand is withdrawn using guided rolls and fully
cooled and solidified.
The strand is cut into desired lengths depending on application;
slabs for flat products (plate and strip), blooms for sections
(beams), billets for long products

Steel making process

What is coke

Blast furnace

Steel finishing

Steel finishing

Type of steel
Carbon Steels:
Carbon steels contain trace amounts of alloying elements and account
for 90% of total steel production. Carbon steels can be further
categorized into three groups depending on their carbon content:
Low Carbon Steels/Mild Steels contain up to 0.3% carbon
Medium Carbon Steels contain 0.3 0.6% carbon
High Carbon Steels contain more than 0.6% carbon
Alloy Steels
Alloy steels contain alloying elements (e.g. manganese,
silicon, nickel, titanium, copper, chromium and aluminum) in varying
proportions in order to manipulate the steel's properties, such as
its hardenability, corrosion resistance, strength, formability, weldability
or ductility.
Applications for alloys steel include pipelines, auto parts,
transformers, power generators and electric motors.

Stainless Steels:
Stainless steels generally contain between 10-20% chromium as the main
alloying element and are valued for high corrosion resistance. With over
11% chromium, steel is about 200 times more resistant to corrosion than
mild steel.
Austenitic
non-magnetic and non heat-treatable,
generally contain 18% chromium, 8% nickel and less than 0.8% carbon.
304, 316, 316L
Ferritic
contain trace amounts of nickel, 12-17% chromium, less than 0.1%
carbon, along with other alloying elements, such as molybdenum,
aluminum or titanium.
These magnetic steels cannot be hardened with heat treatment, but can
be strengthened by cold works.
resistant to chloride stress corrosion cracking, and have high strength.
405, 409

Martensitic:
Martensitic steels contain 11-17% chromium, less than 0.4% nickel and up to
1.2% carbon.
not as corrosion-resistant
These magnetic and heat-treatable steels are used in knives, cutting tools,
as well as dental and surgical equipment and Swiss Army knife
17-4PH
Duplex Stainless Steel
having both austenite and ferrite in their microstructure
roughly twice the strength compared to austenitic stainless steels and also
improved resistance to localized corrosion.

Element Function
Carbon (C) :
An essential alloying element in most steels.
Added to increase solid-solution strength and hardness as well as to
Increase hardenability.
Dissolves in iron to form ferrite and austenite. Combines with iron to
form a carbide (cementite-Fe3C). The carbide is a component of pearlite.

Manganese (Mn) :
An essential alloying element in most steels.
Added to increase solid-solution strength and hardness as well as to increase
hardenability.
A weak carbide former (greater than iron).
Counteracts brittleness caused by sulfur (iron sulfide) through the formation of
a manganese sulfide (MnS).
High levels of manganese produce an austenitic steel with improved wear and
abrasion resistance.

Phosphorus (P)
considered an impurity in most steels.
Can be added to low-carbon steels to increase strength and hardness.
Improves machinability of free-machining steels. Promotes temper
embrittlement.
Forms an undesirable iron phosphide (Fe3P) at high phosphorus levels
(especially in cast irons)

Sulfur (S)
Usually considered an impurity in steel.
Added to special steels for improved machinability

Silicon (Si)
An essential alloying element in most steels.
Added to increase solid-solution strength and hardness as well as to increase
hardenability.
Is added to molten steel to remove oxygen (deoxidize).
Does not form a carbide in steels. Improves oxidation resistance.
Added to special steels to improve electrical and magnetic properties as well as
hardenability.
Increases susceptibility to decarburization. Promotes graphitization in cast irons

Deoxidized steel
Deoxidized steel :
steel that has a some or all of the oxygen removed from the melt during
the steelmaking process
Liquid steels contain dissolved oxygen after their conversion from
molten iron, but the solubility of oxygen in steel decreases with
temperature.
As steel cools, excess oxygen can cause blowholes or precipitate FeO.
Types
Fully killed
steel that has been completely deoxidized by the addition of an agent
before casting.
deoxidizing agents include aluminum, ferrosilicon and manganese.

Semi-killed
I. mostly deoxidized steel, but the carbon monoxide left leaves
blowhole type porosity distributed throughout the ingot.
Rimmed
I. has little to no deoxidizing agent added to it during casting
which causes carbon monoxide to evolve rapidly from the ingot
II. causes small blow holes in the surface that are later closed up
in the hot rolling process
Capped
I. starts as rimmed steel but part way through the solidification
the ingot is capped
II. done by literally covering the ingot mold or by adding a
deoxidizing agent

Formal Classification Systems

The American Iron and Steel Institute (AISI) and Society of
Automotive Engineers (SAE) System.
In the four- or five-digit code designation, the last two or three
digits represent the carbon content (three digits for steels with
a carbon content of 1.00% and above), and the first two digits
represent the compositional class.

example of AISI/SAE 1040, the 10 represents the class of

plain carbon steels, and the 40 represents the carbon content
of 0.40% C.

 The American Society for Testing and Materials (ASTM)

System.
not based on composition but on the steel product and
application.
devised a system of specifications that contain composition,
mechanical properties, and other required characteristics of
steels and cast irons.
The American Society of Mechanical Engineers (ASME) devised
a similar system, but it is generally limited to boiler and heat
exchanger steels and other materials that are covered by the
boiler code specifications.

 The Unified Numbering System (UNS).

1. Created because of the confusion of different systems
2. The system fully incorporates the AISI/SAE system.
3. G: carbon and alloy steels. F: cast irons D:steels with specific
mechanical properties. S: heat- and corrosion resistant steels.
T: for tool steels. H: for steels with enhanced hardenability.
European Standards (ENs)
Prepared and issued by CEN (European Committee and
Standardization)
E.g. EN 10025-2004 ; standard for structural steel

MILL CERT

TYPE OF INSPECTION
Refer EN 10204 : 2004

Material identification
Heat Number/ Ladle number/Cast number
1. An identification number that is stamped on a material plate after it
is removed from the ladle and rolled at a steel mill.
2. The only way to trace a steel plate back to its Mill Cert
3. similar to a lot number, which is used to identify production runs of
any other product for quality control purposes.

Type of chemical analysis

Ladle/heat analysis
1. chemical analysis obtained from a sample taken during
pouring of steel.
2. Ladle analysis is representative of the heat of steel and is
reported to the purchase
Product/check analysis
1. analysis of the metal after it has been rolled or forged into
semi-finished or finished forms. It is not a check on the ladle
analysis, but is a check against the chemistry ordered.
2. Check analysis of known heats is justified only where a high
degree of uniformity of composition is essential

Charpy impact test

To determine the resistance of a material against shocks. The
resistance does decrease with decreasing temperature.
There are 2 types of Charpy tests:
1. U-notch, called Charpy U
2. V-notch, called Charpy V.

Hardness test
Hardness definition: resistance to local penetration to
scratching, to machining, to wear or abrasion, and to yielding.
Type of hardness test:
Brinell
Rockwell
Vickers
Refer ASTM E140 for
Hardness conversion

Stress strain diagram

Yield strength: max stress/load can be applied without
permanent deformation.
Tensile strength (UTS): max stress/load can be sustained by the
specimen.

Tensile test (ASTM A370)

Material compliance

Material traceability
General Requirement
All the material must have physical traceability from the steel
manufacturer except for the subdivided material.

All the data (HN, grade, Manufacturer) for the subdivided

material must be transferred on the material (refer ASTM A6
for more detail)

Special project requirement

Any special requirement for the material, purchaser will trigger
the supplier for the specification needed.

Example
ASME BPV requirement
1. for all the plate for pressure vessel, the requirement must
comply with the purchase specification (refer below) provided by
purchaser

2. DNV 2.7-1 Offshore Container

All the material must comply with the Para 3 in DNV 2.7-1

COMMON ISSUE IN MILL

CERT

1. No cert and heat number

HN number not
available

Cert number
not
available

2. No mechanical data

Please dont provide

material without
mechanical data
(basic YS, TS, EL)

3. Unclear mill cert

4. Company logo and name not visible.

Manufacturer??

5. Different units used in part description

mm and inch in one item

dimension

MVR contains:

Project detail
Material grade (spec and actual)
Purchase dimension
Mechanical properties (spec and
actual)
Chemical properties (spec and actual)

WHY MVR IMPORTANT

Make sure the material comply with customer spec-green light to
purchaser to purchase the material
Make sure qc personnel receive correct material-heat number must
tally between material, mill cert received and MVR.

Spec comparison
Either using customer MS or standard industrial spec.
For customer MS, all the chemical and mechanical properties
must comply with the spec.
Any value less or exceed from the spec it will be rejected.
Purchasing will liaise with project personnel if the need to raise a
concession/deviation
For customer spec that using standard industrial spec, the mill
cert will review base the mentioned spec.
Any value that less or exceed the standard, it will be rejected
unless got some tolerance for that.

PSL, drawing and BOM received

FLOW
CHART

JO internal raise by
engineering

mill cert receive from Purchasing

Dept.

MVR

Purchasing Dept. will source other material

no

MVR approved

yes
Purchasing Dept. Ask project to
raise a waiver

no

Send to Purchasing Dept. to purchase the

material

yes
Waiver approved

Thank you

Reference

DNV 2.7-1
EN 10204-2004
Steel Metallurgy for the Non-Metallurgist by John D. Verhoeven
Mechanical Metallurgy by George E. Dieter]
wikipedia
Engineering Handbook