Sindoh D200 Series User manual
BAR DATA HANDBOOK
AISI/SAE
Chemical Compositions
and Metallurgical Data
8000 North County Road 225 East | Pittsboro, Indiana 46167
(877) 683-2277 | f: (317) 892-7005
SECOND EDITION
1
TABLE OF CONTENTS
INTRODUCTION
SDI OVERVIEW 3
COMPANY HISTORY 4
PRODUCTS AND SERVICES 5
PROCESS DESCRIPTION AND CAPABILITIES 7
STEEL CHEMISTRIES
MAJOR STEEL GROUPS 11
AISI-SAE GRADE SERIES OVERVIEW 12
STANDARD CARBON STEELS 15
RESULFURIZED CARBON STEELS 16
REPHOSPHURIZED AND RESULFURIZED CARBON STEELS 16
HIGH MANGANESE CARBON STEELS 17
CARBON AND CARBON-BORON H-STEELS 17
CHEMICAL RANGES AND LIMITS OF CARBON STEELS 18
PERMISSIBLE VARIATIONS OF CARBON STEEL 19
STANDARD ALLOY STEELS 20
STANDARD ALLOY H-STEELS 24
STANDARD ALLOY RH-STEELS 29
SAE POTENTIAL STANDARD STEELS 31
FORMER SAE EX AND PS STEELS 33
FORMER STANDARD SAE STEELS 37
BEARING QUALITY STEELS 50
ASTM A105 55
ASTM A182 56
ASTM A193 58
ASTM A213 59
ASTM A350 61
ASTM A572 62
ASTM A588 63
ASTM A920 64
CHEMICAL RANGES AND LIMITS OF ALLOY STEELS 65
PERMISSIBLE VARIATIONS OF ALLOY STEELS 66
SELECT AEROSPACE SPECIFICATIONS 67
SELECT DIN SPECIFICATIONS 70
HARDENABILITY
STANDARD HARDENABILITY REQUIREMENTS 83
RESTRICTED HARDENABILITY REQUIREMENTS 107
SELECT DIN HARDENABILITY REQUIREMENTS 114
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TABLE OF CONTENTS
MECHANICAL PROPERTIES
ASTM A105 131
ASTM A350 131
ASTM A434 132
ASTM A182 133
ASTM A193 135
ASTM A572 136
ASTM A588 136
ASTM A615 137
ESTIMATED MECHANICAL PROPERTIES OF STEEL BARS 139
MECHANICAL PROPERTY VARIATIONS WITH CARBON CONENT 150
BAR PROPERTIES
COLD DRAWN OR TURNED AND POLISHED TOLERANCES 151
RECOMMENDED COLD SHEARING LIMITATIONS 152
CARBURIZING RATES 156
RECOMMENDED MAXIMUM HOT WORKING TEMPERATURES 157
CRITICAL TRANSFORMATION TEMPERATURES 158
PERMISSIBLE VARATIONS IN HOT ROLLED BAR CROSS SECTIONS 160
NOMINAL CORNER RADII OF RCS BARS 160
PERMISSIBLE VARIATIONS IN HOT ROLLED LENGTH 161
PERMISSIBLE VARIATIONS IN HOT ROLLED BAR STRAIGHTNESS 161
EQUIVALENT CROSS SECTION BY BAR SIZE AND SHAPE 163
HOT ROLLED BAR WEIGHTS 164
HOT ROLLED BAR REDUCTION RATIOS AT SDI 167
STEEL PROPERTIES
GRAIN SIZE 171
EFFECTS OF ALLOYING ELEMENTS ON STEEL PROPERTIES 172
PRACTICAL INFORMATION
GLOSSARY OF METALLURGICAL TERMS 175
ROLES OF ALLOYING ELEMENTS IN STEEL 176
HEAT TREATING TERMS 180
MECHANICAL PROPERTY TERMS 183
MICROSTRUCTURAL TERMS 185
STEEL DEFECT TERMS 187
HARDNESS CONVERSION TABLE 189
COMMON COVERSION FACTORS 191
3
STEEL DYNAMICS ENGINEERED BAR PRODUCTS
COMPANY OVERVIEW
Steel Dynamics Incorporated (SDI) Engineered Bar Products Division is a
world class supplier of Special Bar Quality steel. The Engineered Bar
Products Division is located in Pittsboro, Indiana, which is just west of
Indianapolis. The Engineered Bar Products facility offers a wide range
of carbon, alloy, and custom designed steel grades to meet exacting
customer demands.
The major markets that are served by the Engineered Bar Products
Division include off highway construction equipment, agricultural
applications, heavy truck, automotive, forging operations, and the gas
and oil well industry.
The Engineered Bar Products Division employs approximately 390
employees and has an annual capacity of 625,000 tons.
MISSION STATEMENT
Steel Dynamics is committed to product and process improvement.
Our mission statement is:
To meet or exceed customer expectations with regard to quality,
service, and price
To be a world-class supplier by continually improving our
processes, equipment, and systems
To be a safe working environment for all employees
To continue to enhance the skills of our employees through
ongoing training and education
ISO 9001 CERTIFICATION
Steel Dynamics Engineered Bar Products Division attained ISO
9001:2000 certification in September 2004.
In January 2010, Steel Dynamics achieved ISO 9001:2008 certification.
4
COMPANY HISTORY
SDI purchased the mill in Pittsboro, Indiana, out of bankruptcy from
Qualitech LLC in February 2003. Qualitech declared bankruptcy in 1999
and ceased operations in 2001.
A significant capital investment was undertaken to bring the existing
facility up to SDI standards, which included the following:
Completely rebuilding the ladle metallurgy facility and the
addition of new ladle cars
New carbon and lime system and baghouse upgrades at the
Electric Arc Furnace
The continuous caster was modified to allow for the capacity to
cast 7”x7” billets
An 8 stand Morgardshammar finishing mill was added to the
existing Pomini mill
Upgrades were made to the shipping department, which handles
incoming scrap, as well as finished inventory and outgoing
products
An additional 40 acres was purchased for rail infrastructure and
scrap storage
The Engineered Bar Products Division made its first shipments of SBQ
products in December 2003, and the facility became profitable in April
2004.
An additional upgrade was made in mid 2006 to add a 150,000 square
foot bar finishing facility with the capability to offer value added
services such as heat treatment, straightening, turning and polishing,
bar inspection, and precision cutting. The free-standing facility has the
capacity to finish 160,000 tons of bars annually.
5
PRODUCTS AND SERVICES
SDI produces special bar quality (SBQ) and merchant bar quality (MBQ)
steel in rounds ranging in diameter from 1 to 9 inches and round
cornered squares (RCS) ranging in diameter from 2-1/2 to 8 inches. The
facility also has the ability to produce rebar in sizes 5 through 11. The
production and availability of rebar is based on market conditions.
SDI produces a wide range of carbon and low alloy steels, such as:
Plain carbon steels (AISI series 10xx)
Resulfurized carbon steels (AISI series 11xx)
Rephosphorized and Resulfurized carbon steels (AISI series 12xx)
High Manganese carbon steels (AISI series 13xx and 15xx)
Cr Alloy Steels (AISI series 51xx and 52xx)
Cr-Mo Alloy Steels (AISI series 41xx)
Ni-Cr-Mo Alloy Steels (AISI Series 43xx, 47xx, 86xx, and 88xx)
Vanadium micro-alloy steels (10V45, 11V41)
Boron Treated Steels
Structural Grades ASTM A36 and A572 Grade 50
Low Alloy Tube and Flange Grades (T2/F2, T11/F11, T22/F22)
The grades listed above are a summary of those produced at the
Engineered Bar Products facility. Please inquire for grades not listed
above or for custom designed grades.
Hot-Rolled cut lengths are available between 16 and 40 feet. Steel
Dynamics can maintain all ASTM tolerances for diameter, length, and
straightness on all hot rolled products.
The Engineered Bar Products Rolling Mill metallurgical lab has the
capability to provide the full spectrum of metallurgical testing including
tensile, hardness, charpy impact, grain size, jominy, microcleanliness,
macrocleanliness, and aircraft quality testing.
6
The Engineered Bar Products Bar Finishing facility is equipped to
perform heat treating operations such as Quench and Temper,
Normalizing, and Annealing (LP, Spheroidize, Cold Shear, Stress
Relieve). In addition to heat treating, the Bar Finishing facility can
provide additional services such as:
Straightening
Turning and Polishing
Cutting to Length
Shot Blasting
Non Destructive Testing
The Bar Finishing Metallurgical Lab at Steel Dynamics has the capability
to provide metallurgical testing such as tensile, hardness, and charpy
impact following heat treatment. The lab is also equipped with a
scanning electron microscope that is used for research and product
evaluation purposes.
7
PROCESS DESCRIPTION AND CAPABILITIES
MELTING AND CASTING
SDI is equipped with one Electric Arc Furnace (EAF). The EAF is charged
with approximately 115 tons of primarily scrap metal in order to yield
an aim tapped heat size of 100 tons. Heats are killed following tap with
a Silicon-Manganese addition.
Following tap, heats are treated at a Ladle Metallurgy Facility (LMF). At
the LMF, slag additions and modifiers are used to work the slag and
trap inclusions. Alloy additions are made at the LMF, as well as re-
heating the steel for further processing or shipment to the caster.
Heats that require degas treatment have the slag layer removed by
means of a mechanical rake. These heats are then treated at the
Vacuum Tank Degasser (VTD). Typical gas levels following VTD
treatment are 2 ppm H2, 80 ppm N2, and 20 ppm O2.
The continuous caster is a three strand, vertical curved radius machine.
Each strand is equipped with automatic mould level control and
electromagnetic stirring. Five withdrawal straightener units are used to
straighten the strands and also apply soft reduction. The dimensions of
the semi-finished bloom are 10.3 x 14.1 inches.
ROLLING
The rolling mill is equipped with a walking beam furnace with a capacity
of 125 tons per hour. Blooms are de-scaled after exiting the furnace,
and then proceed through a five stand roughing mill, a six stand
intermediate mill, and an eight stand finishing mill. Dimensional control
is maintained by optical laser gauges and manual micrometer checks.
Bars are sheared after reaching their final dimension onto a 125 feet
long walking beam cooling bed. Bars are then trimmed to the specified
cut length and bundled together for shipment.
8
HEAT TREATING
The Bar Finishing facility is equipped with five Sauder Energy Car
Bottom furnaces. There is one high temperature furnace capable of
reaching 2100°F, while the others are capable of reaching 1800°F. The
furnaces are limited to a maximum bar length of 33 feet. The quench
tank has a 30,000 gallon capacity and is capable of providing agitation
and temperature control. Water is the only quench media used at the
Bar Finishing facility. The minimum bar diameter that can be quenched
is 2.5 inches.
BAR INSPECTION
There are two inspection lines at the Bar Finishing facility, a small bar
inspection line (SBIL) and a large bar inspection line (LBIL). The SBIL can
accommodate round bars ranging in diameter from one to five inches
while the LBIL can accommodate round bars from 2.5 to 9 inches and
round cornered squares from 2.5 to 8 inches. Both lines can
accommodate bar lengths of 15 to 45 feet.
At the SBIL, bars are rotary straightened and chamfered prior to
inspection. Surface inspection is performed via a Forester Magnetic
Flux Leakage unit, capable of 100% surface coverage with seam
detection of 0.3 mm for smaller bars and 0.5 mm for larger bars.
Ultrasonic inspection is performed via a rotary immersion UT inspection
unit, capable of 100% volumetric coverage using normal incidence and
shear waves. Ultrasonic inspection is capable of detecting 1mm wide
defects. The SBIL is also equipped with a 100% Eddy Current grade
verification coil.
On the LBIL, bars are shot blasted and pass through an Eddy Current
grade verification coil. Surface inspection is performed via an Eddy
Current surface inspection unit, capable of 100% surface coverage with
seam detection of 0.5mm. Ultrasonic inspection is performed via a
Magnetic Analysis Corp 48 channel transducer with four fixed heads,
capable of 100% volumetric coverage. Ultrasonic inspection is capable
of detecting 1mm wide defects.
9
TURNING AND POLISHING
The turning line has a capacity of 1.031 inch to 4.25 inch incoming
diameter, and is capable of meeting ASTM A108 tolerances. The line
can accommodate bar lengths ranging from 14 to 25 feet. The line is
equipped with bar chamfering, facing, and etching capabilities. The
straightener/polisher is capable of attaining greater than 25Ra surface
finish. The turning line is equipped with an Eddy Current tester for
surface inspection.
STRAIGHTENING
The bar finishing facility has a Bronx Nine Roll straightener and a #5
Medart Two Roll straightener. The units are capable of meeting both
standard and special straightness tolerances as listed in ASTM A29.
MULT CUT-TO-LENGTH SAWING
Cut-to-length sawing is accomplished with two Nishijimax Precision
Carbide Rotary Saws, with a capacity of 1.00 to 5.9 inch rounds. The
saws can produce cut lengths from 0.5 to 118 inches, with a standard
length tolerance of +/- 0.010” or 0.25 mm.
A Hem High Speed Double Column band saw line is also available. It has
a capacity of 4 to 25 inch rounds as well as being able to cut bundles.
Cut lengths are available from 5 to 24 feet, with a tolerance of -0/+0.25
inches.
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