Posted on

Superalloys – Facts you must know

Supperalloy

To match the demands of the vast growing industries, high-performance materials are needed for the highest efficiency. Ordinary steels and alloys are incapable of that higher performance. That’s where the complex and high-performance alloys come into the scenario. They have a high tolerance to oxidizing environments and high temperatures. Those are named superalloys

These superalloys are mainly classified according to their predominant matrix elements which are nickel, cobalt, or iron. They also contain multiple alloying elements including the refractory metals (Nb, Mo, W, Ta), Chromium, and Titanium. Especially at high temperatures, they exhibit high mechanical strength, creep resistance, and corrosion resistance. For these properties, they become more challenging to produce and costlier than other alloys. But they are very critical for components in the aerospace industries

SOME PROPERTIES OF SUPERALLOYS –

As superalloys are used for high-temperature applications,they need to maintain their shapes at elevated temperatures close to their melting points (above 650ᵒC or 1200ᵒF). At extreme temperatures, being alloyed with certain elements, superalloys can maintain high strength, stability, and corrosion and oxidation resistance.

EXAMPLES OF SUPERALLOYS –

By alloying the matrix element (Ni, Co, or Fe) with various other elements such as Chromium (Cr), Titanium (Ti), Aluminum (Al), and Boron (B), the high-temperature properties of superalloys are produced. In some cases, some refractory metals are also added, such as Molybdenum (Mo), Cobalt (Co), Niobium (Nb), and Zirconium (Zr) amongst others

PROCESSING OF SUPERALLOYS –

Generally, Superalloys are processed by two separate methods which are Casting and Powder Metallurgy.

Investment Casting

Wax models or replicas are used to create a casing for the molten metals and are mainly
used for complex shapes. To improve upon the formerly prevalent cold-rolling
techniques, it was the first method.

Vacuum Induction Melting (VIM)

Using electric currents, raw metallic materials are melted within a vacuum. As the
control over chemical composition is greater in this method, this is also called an
improvement upon investment casting.

Secondary Melting

After the VIM process, an additional melting process is applied to increase the
homogeneity. It reduces problems associated with the initial process.

Conversion

To make the superalloy ingots produced by secondary melting suitable for mechanical
applications, this process is involved. It consists of several stages of thermal deformation.

Direct Solidification

By the presence of a thermal gradient, the alloy is allowed to nucleate on a lowtemperature surface. Greater creep resistance along the grain direction is produced.

Single Crystal Growth

A monocrystalline superalloy component is slowly grown from a seed crystal.

Powder Metallurgy (P/M)

For producing alloys used in critical fatigue applications a group of processes is
completed. Superalloys are formed from a mixture of metal powders. Chemical pressures
are applied to bond these metal powders into parts.

Powder Metallurgy (P/M)

For producing alloys used in critical fatigue applications a group of processes is
completed. Superalloys are formed from a mixture of metal powders. Chemical pressures
are applied to bond these metal powders into parts.

Applications of Superalloys

Superalloy applications mainly consist of aircraft components, petrochemical equipments,
automobile equipments, chemical plant, and power plant equipments.

Future Trends of Superalloys

The future scopes in this field include decreasing the high cost of producing unique and complex
parts, and the synthesis of nanoparticles.

Posted on

Wire Mesh vs Rebar

Wire Mesh vs Rebar

Often projects involve the usage of concrete to create long-lasting construction results. Whether you are building walls, roads or other structures like bridges, pathways etc., you can consider using Rebar or Wire Mesh under your concrete structure. Using any of these supporters provides significant reinforcement and has a long-lasting effect. But before using that, it is quite necessary to understand the difference between Wire Mesh and Rebar. So let’s take a look at how these methods are a robust option to make your concrete projects durable.

WHAT IS WIRE MESH?

Wire Mesh, also known as wire cloth or wire fabric, is a highly versatile product that can be used in countless applications. Depending upon the manufacturing capabilities, wire mesh can be made with an endless combination of opening sizes and diameter wires, which is either woven or welded as per the requirements. They are woven metal fabric created in varying degrees of coarseness, weight, and aperture.

When using Wire Mesh for concrete, it gives a significant advantage that allows a certain amount of shaping of concrete which is not possible with Rebar. Wire mesh comes in various materials such as plain steel, galvanized, or stainless steel products that are resistant to corrosion, which is why it is convenient to use.

WHAT IS REBAR?

Rebar is a structured steel bar that is primarily used in concrete construction. With the help of these reinforcing steel bars, the reinforced concrete surface is prepared. They are often used on floor slabs, walls or posts. It helps keep cracks that protect the surface from falling apart. It also provides structural strength to the structure. When opting for Rebar, various grades and sizes of steel for whatever strength level are required.

HOW IS WIRE MESH AND REBAR MADE?

To make Wire Mesh, metal wires are woven on industrial weaving looms. They are made as per a precise specification, leaving either square or rectangular gaps between the wires. The wire mesh is created by weaving metal on automatic rapier-style looms that give precise control over the number of wires used to make the finished mesh. This closely regulates the approach that is required to maintain consistency in both aperture size and mesh thickness.

To make Rebar, steel (carbon or alloy) is melted down to liquid form. Once melted, the liquid steel is pulled through small round openings to create a rebar structure. While unfinished steel is the cheapest form of Rebar; however, sometimes epoxy-coated or stainless steel is also used. Epoxy-coated rebars are expensive as compared to other material rebar. After the steel has been properly shaped, it is twisted and grooved on the metal to ensure the stability of the structure. Their ends are protected with plastic caps to prevent accidental harm to workers. During construction, the rebars are bent through hydraulic benders and cutter on the basis of the requirements and sizes.

WHERE ARE WIRE MESH AND REBAR USED?

Wire mesh and Rebar are commonly used for a myriad of industrial uses. Wire mesh is widely used in industrial filtration, sieving, shielding, sorting, sifting, screening and separation procedures. Woven mesh is a highly flexible and malleable material. It can be shaped to suit precise requirements and edged to fit any structure. Wire Mesh is often used in industrial applications when separation and filtration is required. It is used in commercial applications like insect screening or animal fencing. They also provide various type of security, like in window machines, stairwell panel guards, fireplace screens, ventilation, RFI shielding, etc.

On the other hand, Rebar is used to provide resistance to support design loads. They are used for durability and aesthetic purposes, as well. They are commonly used in floor slabs, stairs, and roof construction. A heavier fabrication of welded wire fabric can be used in walls and structural floor slabs. This is commonly used in road pavement, box culverts, drainage structures, and small concrete canals.

Sunflag Steel offers a wide range of wire mesh and rebar products designed to cater to standard industrial processes and regular work. We can develop custom solutions to meet your unique requirements, as well. Please connect to us anytime for the perfect products for your needs.

Posted on

Received the prestigious NEI Supplier Award at the NEI Supplier Conference in Jaipur

Sunflag Steel has been honored with the ‘Best in Class for Raw Material Quality & Delivery’ award at the NEI Supplier Conference. This esteemed event, held in Jaipur on March 22, 2024, brought together leading industry suppliers to celebrate outstanding achievements and innovation.

Receiving this accolade is a testament to our unwavering commitment to excellence in raw material quality and timely delivery. It highlights our dedication to maintaining the highest standards and consistently delivering superior products to our valued clients.

This achievement would not have been possible without the hard work and dedication of our incredible team. Their relentless pursuit of quality and efficiency has been instrumental in earning this recognition. We extend our heartfelt thanks to each member of the Sunflag Steel family for their invaluable contributions.

As we celebrate this milestone, we remain committed to upholding our standards of excellence and continuing to drive innovation in the steel industry. Thank you to NEI for this honor, and to our clients and partners for their ongoing support.