Research And Develoment centre & Automatic inspection facilities

research


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RESEARCH
AND DEVELOPMENT

R & D division of Sunflag Iron Steel Co. Ltd. Plays a pivotal role in retaining and consolidating Sunflags‘ leadership position in automobile industry.

 

R & D focus on development of new steel grades, process improvement, continous up-gradation of Quality, Customer Satisfaction through customized products matching with their specific requirement.

Sunflag R&D lab is equipped with following state of the art equipment:

  • Scanning Electron Microscope with Energy Dispersive X—Ray Spectroscope (SEM—EDS) of Make — JOEL
  • Immersion Ultrasonic Testing Facility of Make — Olympus / Blue Star
  • Optical Microscope with Automatic Multiaxis stage Movement and Image Analysis software
  • Micro—hardness tester
  • Ferritometer
  • NABL Certified Testing Lab
  • R & D Centre Recognised DSIR Government of India

SCANNING ELECTRON
MICROSCOPE WITH EDS

  • Key Function

– Microstructure analysis
– Quantitative and qualitative Analysis of Inclusions

  • Failure Analysis
  • Fractography
  • Inclusion with quantitative elemental analysis

Salient Features

  • Fully automatic system comprising of Turbo molecular rotary pump
  • Automatic stage movement

IMMERSION ULTRASONIC
TESTING MACHINE

  • Key Function: Inspection of cleanliness levels (macro inclusions) in steel

Salient Features.

  • Dimension of samples that can be tested :

– Round Bars :

  • Size 15-120 mm die.
  • Length 800mm

– Round Corner Square Bars:

  • Size 60 – 120 mm
  • Length 800 mm

UST Prob: 10 MHz — 6mm as per Sep1927

  • Automatic data saving and reporting
  • A scan and C scan analysis with real time display

Quality Highlights

Inclusion Mapping with 100% volume as Sep 1927 Class I to 5

magnetic-flux

UPRIGHT METALLURGICAL MICROSCOPE
WITH CLEMEX SOFTWARE

  • Automatic Motorised Stage & Auto Focus
  • Clemex Automated Inclusion Rating Analysis As per

– ASTME 45 Method A, C, D, E
– Din 50602 Method K, M,
– JlS G 0555,
– ISO 4967 compliant (DS)
– EN 10247 Complete analysis by all above
methods simultaneously

  • Automated Grain Size measurement
  • Phase analysis


AUTOMATIC MAGNETIC FLUX LEAKAGE TESTING (MFLT)

  • Highly sensitive test method for detection of longitudinal defects on steel bars
  • No Coupling Liquid
  • Reliable and reproducible test results
  • Automatic marking and sorting of defective bars during testing
  • High production speed
  • Real time display of inspection results

MFLT SALIENT FEATURES

Diameter Range 5 to 140 mm
Channels 8
Probes up to 16
Channel Width 5.0 mm
AC Frequency 7 KHz
Rotation max.1.800 rpm
Test Speed up to 2 m/s for 100% Material Scanning

AUTOMATIC EDDY CURRENT TESTING (ECT)
FOR BAR & WIRE RODS

ECT is a non-destructive testing technique making use of electromagnetic induction to detect and
characterize surface and subsurface flaws for bright bars.

SALIENT FEATURES

ECT For Bars

  • Automatic bar feeding system
  • Automatic marking and sorting of defective bars during testing
  • Size range: 6 to 60 mm
  • Inspection of Longitudinal / Circular Surface defects
  • Detectability of ECT: 0.05mm depth flaw with length 5mm
  • Reliable and reproducible test results
  • High production speed

ECT For Wire Rod Coils

  • Online Eddy Current Testing facility
  • Automatic marking of defects during testing
  • Size range: 5.5 to 26 mm
  • Inspection of Longitudinal / Circular Surface defects
  • Detectability of ECT: 0.05mm depth flaw with length 5mm
  • Reliable and reproducible test results
  • High production speed


PHASED ARRAY AUTO ULTRASONIC TESTING

SALIENT FEATURES

Phased Array Technology

Phased Array testing is a specialized type of ultrasonic testing that uses sophisticated multi- element array transducers and powerful instrumentation/software to steer ultrasonic beams through the test piece and map returning echoes.

No rotating movement, only electronic scanning is done:

Depth focalization for bar volume inspection (LW)
Electronic steering for bar surface inspection (SW)

Quality Highlights:

Capacity — 15 to 120 mm dia. Full bar volume inspection

Acceptance Criteria

Minimum defect depth and length (FBH)

  • 0.7 mm FBH from 15—60 mm dia

 

  • 1.2 mm FBH above 60 dia

 
Minimum defect depth and length (SDH)

  • 0.5 mm x 10 mm {from 15—120 mm dia)
  • 0.3 mm SDH sensitivity can deduced by
    extrapolation depending material SNR.



Bearing steels are special class of low alloy steels, typically with 1% carbon and 1.4% chromium. Manganese and Molybdenum are added in certain special cases.

Recent brochure

Tool Steels

What Is Tool Steel - Type of Tool Steel


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Tool steels are high quality steels made to controlled chemical composition and processed to develop properties useful for working and shaping of other materials.The carbon content in tool steel may range from as low as 0.1% to as high as more than 1.6%. They are alloyed with elements such as Chromium, Molybdenum,Vanadium Tungsten etc.

At Sunflag Tool Steels are produced through specially designed steel making process via Electric Arc Furnace followed by Ladle Refining and Vacuum Degassing and processed through ESR / VAR for ensuring homogeneous properties &Ultra clean material. Stringent control is practiced during designing of chemical composition and other process parameters during casting, rolling/forging and heattreatment.



Type & application of tool steels:

  1. Water hardening tool steel(e.g. cold heading, cutting tools, knives, reamers and cutlery etc)
  2. Shock resisting tool steel (e.g. chisel for hot and cold cutting, chuckiaws, gripper, cold shear, hot shear etc.)
  3. Cold worktool steel [3 types]:
  • Oil hardening cold worktool steel(thread cutting, die blanking, cold-forming, cold trimming, gauges etc.)
  • Medium alloy air hardening cold worktool steel (blanking, coining, cold forming, cold swaging, cold trimming
    tools, gauges etc.)
  • High carbon, high chromium cold work tool steel(die inserts, cold—forming, cold shaping, thread roll, cold
    trimming, wire drawing etc.)
  1. Low alloy special purpose tool steel(forging dies, die casing, file cutting, paper cutter, die bending, blanking and
    coining etc.)
  2. Mold tool steel(plastic mold)
  3. Hot work tool steel (die casting dies, hot extrusion dies, hot forging dies, hot swaging, hot trimming, hot shear,
    hot gripper etc).
  4. High Speed Steels (Single point cutting tools, broach insert, tap, drill, reamers, milling cutters, saws)



Supply Conditions

From Bloom, lngot or ESR Remelted ingot

Supply Condition
Forged, Annealed & Proof Machined
Forged & Annealed
Rolled & Annealed
Rolled,Annealed,Peeled&Ground
As Forged
As Rolled
Heading #1 Heading #2 Heading #3 Heading #4 Heading #5 Heading #6
Simple content Simple content Simple content Simple content Simple content Simple content
Simple content Simple content Simple content

Sizes

Hot Rolled Rounds 15 to 250 mm
Forged Rounds 160 to 500 mm
Flats/Plates 150 mm(T) * 450 mm (W)
Peeled & Ground 5 to 100 mm
Drawn & Ground 5 to 34mm
Forged Blocks 350(T)*600(W)*5460(L)
Flats/Plates can also be supplied in the following Thickness:
12,14,16,28,32,35,40,42,48,50,55,60,65,70,75,80,85,90,95,100,110,120,130,140,150

Grades of Tool Steels

Water-hardening tool steels

Shock-resisting steels

Oil-hardening cold-work steels

Air-hardening, medium-alloy, cold-work steels

High-carbon, high-chromium, cold-work steels

Low-alloy special-purpose tool steels

AISI UNS C Mn Si Cr Ni Mo W V Co
L2 T61202 0.45-1.00 0.10-0.90 0.50 max 0.70-1.20 0.25 max 0.10-0.30
L6 T61206 0.65-0.75 0.25-0.80 0.50 max 0.60-1.20 1.25-2.00 0.50 max 0.20-0.30

Low-carbon mold steels

Chromium hot-work steels

Tungsten hot-work steels

Molybdenum hot-work steels

AISI UNS C Mn Si Cr Ni Mo W V Co
H42 T20842 0.55-0.70 0.15-0.40 3.75-4.50 0.30 max 4.505.50 5.50-6.75 1.75-2.20

Molybdenum high-speed steels

Tungsten high-speed steels

Intermediate high – speed steels

AISI UNS C Mn Si Cr Ni Mo W V Co
M50 T11350 0.78-0.88 0.15-0.45 0.20-0.60 3.75-4.50 0.30 max 3.90-4.75 0.80-1.25
M52 T11352 0.85-0.95 0.15-0.45 0.20-0.60 3.50-4.30 0.30 max 4.00-4.90 0.75-1.50 1.65-2.25

Testing Facilities at Sunflag Steel

Unique Facilities at Sunflag










Tool steels are high quality steels made to controlled chemical composition and processed to develop properties useful for working and shaping of other materials. The carbon content in tool steel may range from as low as o.2 to as high as more than 1.6% They are alloyed with elements such as Chromium, Molybdenum, Vanadium Tungsten etc.

Recent brochure

Super Alloys

Superalloys, High Performance Alloys


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India is fast developing economy with population over 120 million with vast border. To meet the growing demand of our population and protect our border, growth of technology is inevitable. The growth of technology is relevant to sectors like Biomedical, Aerospace, Petrochemical, Thermal and Nuclear Plants, Defense, Arnament, Transport etc. To attain high level of perfection in this sectors depends, on availability of stringent quality of rawmaterial. As on date most of raw material is imported.

Government of India has embarked upon ambitious program of self reliance through make in India program. Sunflag widely accepted as marque company in supplying high quality material to automobile and general Engg industries wish to enter this high tech area. The fast developing electrical vehicle technology may also require these advanced high tech material in high volume.

These hi tech material are used in making Aircraft Parts, Bio Medical Implants, Industrial and Vehicle Gas Turbines, Super Critical Power Plants Parts, Space Vehicles and Rocket Engines, Submarine Parts, Nuclear Reactor, Missiles and Arnaments etc.

The high performance high tech alloys required by these industries are required to be operated at a load and temperature above 500 degree centigrade with resistance to oxidation and environmental attack, that are usually prevalent at this temp. Hence the raw material used for this high sectors requires low level of impurities and meeting with stringent spec.

In nature, we rarely come across very pure material and it contains metallic impurities like lead, bismuth, etc, non metallic impurities like sulphur. phosphorous etc, residual gases like oxygen. hydrogen and nitrogen and nonmetallic impurities like oxides, nitrides. Sulphide etc.

The above impurities considerably reduced in conventional technology of arc furnace, AOD, LRF and VOD and the low level of impurities required by these hi-tech industries can be achieved only by melting at Vacuum Induction Melting [VIM], Electro Slag Refining [ESR] and Vaccum Arc Re-melting furnace [VAR] etc apart from other specialised melting.

Sunflag has put up VIM, ESR, VAR facility at Bhandara Plant near Nagpur. These equipment have latest technology and supplied by the World Leaders in this field, Sunflag also have tie up with DAIDO Japan, who are well known have equity participation with Sunflag. DAIDO also provide inputs for improvement in the technology.

Sunflag other facilities include Concast, Blooming Mill, specialised Rolling Mill, Heat Treatment facilities and Bright Bar and Centerless Grinding Facility.

To test these high tech material, most modern lab equiped with good analytical instruments, metallographic equipments, mechanical testing equipment for testing RT, LT and HT specimens. Online Phase Arrey Machines for testing UT, eddy current, MPl and FPT tests also available to test the product to various national and international standards

Sunflag has trained manpower who have specialised skill to operate these most modern equipments & control.

SUNFLAG HI TECH GRADES

SUNFLAG HI TECH GRADES

TYPICAL PROPERTIES OF SOME GRADES







SUPER ALLOYS DIVISION

Infrastructure for Manufacture of Super Alloys

EQUIPMENT Make Capacity (M T)
Vaccum Induction Melting (VIM)  CONSARC (USA) 6.5 MT
Vaccum Arc Re-Melting (VAR) CONSARC (USA) & ALD (GERMANY) 2.2 MT & 16 MT
Electro Slag Re-melting (ESR) CONSARC (USA) & ALD (GERMANY) 1.8 MT & 22 MT

ELECTRO SLAG REMELTING (ESR)

ProductRange:1.8MT to 22MT

Salient Features :

  • Automatic Electrode Feed Control System.
  • Real Time Automatic melt Control System through pre defined recipe.
  • Full automatic operation
  • Automatic start phase of the furnace by a defined power/time profile
  • Realtime Melting rate control through maintaining melting rate or melting power profile with
    respect to the consumed weight of electrode
  • Automatic hot topping as per recipe defined power/time profile
  • Pre—defined profiles for various stages of processing e.g. slag resistance
    set point profile or swing set point profiles.
  • Digital Operator Interface and data acquisition system
  • Furnace head provided with x—y angular corrections of electrode and
    total sealed system for argon shielded melting
  • Fume exhaust and environment protection hood
  • Fully coaxial high current feedings system


Vacuum Arc Remelting (VAR)

Product Range:2 MT to 16 MT

Salient Features :

  • Fully computerized automatic melt control system based or dynamic electrode feed control system with arc voltage
    control/drip short pulse rate control
  • Real Time Automatic melt Control System through pre-defined recipe
  • Full automatic operation
  • Automatic start phase of the furnace by a defined power/time profile
  • Realtime Melting rate control through maintaining melting rate or

    melting power profile with respect to the consumed weight of electrode

  • Automatic hot topping as per recipe defined power/time profile
  • Recipe defined profiles for electrode control feed systems for star‘t-melt—hot topping phase.
  • Digital Operator Interface and data acquisition system
  • Furnace head provided with X—y angular corrections of electrode and total sealed system
  • Fume exhaust and environment protection hood
  • Fully coaxial high current feedings system
  • Ultimate vacuum level of 1×10–3 mbar

Vacuum Induction Melting (VIM)

Product Range: 1 MT to 6 MT

Salient Features:

  1. Furnace equipped with mould height 4000 MM
  2. Facility for Rapid exchange of crucible
  3. Multiple mould pouring
  4. Facility for bulk and additional charging of mix under vacuum
  5. Sampling and temperature measurements under vacuum.
  6. Fully Rollaway head for facilitating cleaning of melt chamber.
  7. Ultimate vacuum level of 1×10–4 mbar .

Vacuum Induction Melting Furnace

6.5 Ton x 4000 mm (Tall Vacuum Induction Melting & Casting Furnace for lngot elctrode Production) Vacuum Induction Melting (VIM) is the melting of metal via electromagnetic induction under vacuum. An induction furnace containing a refractory lined crucible surrounded by an induction coil is located inside a vacuum chamber. The induction furnace is connected to an AC Power source a frequency precisely correlating to the furnace size and material being melted.

 

VIM is a process used to make super alloys, stainless steels, magnetic alloys, electronic alloys, and other demanding high value alloys.


India is fast developing economy with population over 120 million with vast border. To meet the growing demand of our population and protect our border, growth of technology is inevitable. The growth of technology is relevant to sectors like Biomedical, Aerospace, Petrochemical, Thermal and Nuclear Plants, Defense, Armament, Transport etc. To attain high level of perfection in this sectors depends on availability of stringent quality of raw material. As on date most of raw material is imported.

Recent brochure

Automatic Phased Array Ultrasonic Machine


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Automatic Phased Array Ultrasonic Machine

Salient Features

Phased Array Technology

Phased Array testing is a specialized type of ultrasonic testing that uses sophisticated multi-element array transducers and powerful instrumentation software to steer ultrasonic beams through the test piece and map returning echoes.


Quick Scan LT PA

The electronic configuration of the solution for Phased Array inspection is based on the Quick Scan LT FA (1513355 or 32255) unit.

Phased Array Ultrasound Concept – Round

No rotating movement. only electronic scanning is done.

Depth focalization for bar volume inspection {LW} Electronic steering for bar surface inspection {SW}

Longitudinal Wave

Shear Wave

Advanced Floating Head Mechanism

Floating head system is immersed in the UT tank and bar passes through centering devices, which guide the floating head and maintain constant position of probes with respect to bar surface.



Phased Array probes are mounted in cassettes with pre-defined mechanical overlap between each of them depending on the diameter of the bar for 360°coverage on round products.

SPECIFICATIONS

  • Immersion Tank Type
  • Diameter range 15 to 120mm Location {Depth}
  • Full Bar Volume Inspection

REFERENCE DEFECTS

    • SDH {diameter in function of Size Range)

– SDH 1 -At 50% of nominal diameter
– SDH 2 —At 2mm from back wall
– SDH 3 —At 5mm from back wall
– SDH 4 —At 3mm from back wall

  • SDH 0.5mm(0.3mm can be guaranteed by extrapolation}

ACCEPTANCE CRITERIA

    • FBH (diameter in function of Size Range) Location (Depth)

– FBH 1 —At 40% of nominal diameter
– FBH 2 —At 5mm from back wall

  • FBH 0.7 mm up to 60 mm diameter
  • FBH 1.2mm for 60 to 120mm diameter

Phased Array testing is a specialized type of ultrasonic testing that uses sophisticated multi-element array transducers and powerful instrumentation/ software to steer ultrasonic beams.

Recent brochure

Stainless Steel Rebar 550


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About Us

Sunflag Iron & Steel Co. Ltd.. lNDIA is a part of the renowned Sunflag Group. The sunflag Group was founded in Kenya in 1937. It has a diversified range of‘activities in Kenya,Tanzania Nigeria, Comeroon,The United Kingdom & India employing over 10,000 people.

In India Sunflag Iron & Steel Co. Ltd. (SlSCO) activity is divided into two business segment : Steel and Stainless Steel products and power sector. SISCO has set—up an integrated steel plant with technical know-how and major equipments from MANNESMANN DEMAG and KRUPP of Germany. It is most modern plant, the first integrated steel plant of its kind in India with a capacity of 0.5 million tonnes per annum of rolled products, which are comparable to the best in the world. This plant produces alloy steels, special steels and stainless steels, which are also supplied to major automobile manufacturers in India and a large part of our production is exported. SISCO has its own captive thermal power plant to meet the requirement of steel plant.

With ISO 9001/ IATF16949 organisation we provide best quality of steel to our customers.


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Reinforcement Stainless Steel Rebars (Ferritic)
Grade G of IS 16651:2017

What is SS Rebar Grade G?

It is a new kind of stainless steel rebar first introduced in India by Sunflag Steel. SS Rebar Grade G is a low cost stainless containing 11-13.5% Chromium rebar that has a good corrosion resistance. SS REBAR GRADE G is a new age building material which increase the life of the building because of its better corrosion resistance properties compared to TMT, Epoxy coated or Zinc coated rebars.

Why SS Rebar Grade G?

Like any other rebar SS REBAR GRADE G does the job of reinforcement. The concrete inner structure of any building is made of steel . Due to formation of chromium oxide layer on the surface when exposed to atmosphere the SS REBAR GRADE G rebar does not get corroded. This protective oxide layer improves the life of rebar in concrete. In twenty first century SS REBAR GRADE G is a gift to builder, architect and consumer for corrosion free structure.

Corrosion in Concrete Structure

The corrosion of reinforcing bar can result in cost maintenance and repair of concrete structures. Corrosion may occur as a result of carbonation of the concrete, which destroys the protective passive layer surrounding the reinforcing bar. In marine environments, chemical and mineral processing plants etc., corrosion is usually caused by the ingress of highly corrosive chloride ions through the concrete to the reinforcing bar. The products of Corrosion (Iron salts and oxides) of the reinforcing bar occupy a considerably greater volume than the original steel resulting in the cracking and subsequent spalling of the concrete. The corrosive attack on the reinforcement then becomes very rapid as the steel is no longer protected by the concrete cover.

 

The structure will soon weaken to the point where it will become unserviceable or dangerous.

Carbon Steel

Iron expansion inside due to increase in volume of rusting product from reinforced bar and thus the cracking and spalling.

RSST (F) G IS 16651:2017

Passive layer of chromium oxide prevents rusting.

To protect the concrete structure from corrosion few techniques have been adopted without much success.

  • Coatings on the steel bars.
  • Using Alloy Steel in the place of Carbon Steel.
  • Cathodic Protection
  • Addition of lnhibitors in the concrete.
  • Increase concrete cover thickness.
  • Reduced water /cement ratios

Though application of coatings to rebar is an easy route, damage of coatings during handling is the main limitation. Effect of inhibitors is temporary and short-lived. Cathodic protection is perhaps the perfect method but is difficult to implement and requires post maintenance and monitoring (Stainless steel is therefore the only solution for enhancing corrosion protection of concrete).

Low alloy steel with alloy concentration – 1% or so are also not the answer, where the concrete is exposed to both high levels of urban pollution and aggressive marine environment.

What Type of Stainless Steel Can be Used In the
Reinforcement of Concrete?

A wide range of stainless steel alloy types is available for rebar selection, to meet the mechanical design aspects and the expected corrosivity of the environment. Stainless Steels are available mainly in five main groups. Austenitic, Ferritic, Duplex, Martensite and Precipitation hardened steels. Depending upon several factors such as relative corrsion, longevity, life cycle cost the SS REBAR GRADE G Stainless Steel is a desirable material. SS REBAR GRADE  G is currently used by Orbit Buildcon & Reality [P] Ltd. in Mumbai for their premium housing projects. Orbit Buildcon is a famous construction company located in Mumbai.

 






Stainless Steel Rebar SSR 550

Intrinsic Properties of SS Rebar Grade G

Carbon and Nitrogen control the mechanical properties of StainlessSteel. Higher Carbon and Nitrogen contents are harmful for reinforcement purposes,since these result in a steel with low weldability and low toughness (Control of Carbon content to 300 ppm max and Nitrogen content to 300 ppm max). resuIts in the formation of a fine equiaxed ferritic steel with good toughness and adequate mechanical properties .That makes SSR 550, Grade G of is 16651:2017 the best stainless steel for reinforcement of concrete.

Chemical composition of SS Rebar Grade G

Chemical C Ni Mn Si P S Cr N
Min% 0.0 11
Max% 0.03 0.60 1.0 1.0 0.04 0.030 13.50

Properties of SS Rebar Grade G


Equivalent Standards

SS REBAR GRADE G falls in IS I6551:2017 and also A;LSzO Conforms to all requirements of equivalent grade in JIS G 4322: 2008

Physical Properties


Size & Mass

Nominal Diameter (mm) Nominal Mass/M (kg/m) Nominal Sectional Area (mm2) Cirumference(mm)
8 0.395 50.27 25.13
10 0.167 78.54 31.42
12 0.888 113.10 37.70
16 1.578 201.10 50.27
25 2.466 490.90 78.53
32 6.313 804.20 100.50

Cutting

SS REBAR GRADE G has good cutting property and can be easily cut by a mechanical shear or abrasive disc with less tool/disc wear but it is advised not to cut by an oxy-acetylene flame.

Welding

SS REBAR GRADE G has good weldability because of its fine grained structure. Filler material such as AFRIX RSSR (F) G IS 16651:2017, or austenitic stainless steel filler materials such as R309L or 316L are preferred.

 

in marine environments, chemical and mineral processing plants etc., corrosion is usually caused by the ingress of highly corrosive chloride ions through the concrete to the reinforcing bar. The products of corrosion (lron salts and oxides) of the reinforcing bar occupy a considerably greater volume than the original steel resulting in the cracking and subsequent spelling of the concrete.
Immersion tests in various solutions show eligible corrosion rate (Table 1) of SS Rebar Grade G.

Table 1


Stainless Steel Rebar SSR 550 (G)

Advantages of SS Rebar Grade G

    • SS REBAR GRADE G has inherently good corrosion
      resistance like any other stainless steel due to chromium oxide layer on the surface.

 

    • It has good high and low temperature tensile as well as yield strength to match or exceed carbon steel.

 

    • In RSSR (F) G IS 16651:2017, no cathodic protection is
      required.

 

    • It has got good weldability due to very low percentage of carbon content {i.e.,0.03% max.)

 

    • It has very good ductility.

 

    • No coating is required here to have adequate corrosion resistance.

 

    • It can be shipped, handled and bent without any problem.

 

    • SS Rebar GRADE G excellent earthquake resistance
      due in high percentage of elongation and ductility.

 

  • Establish Examples of use of similar Stainless Steel Rebars

In South Africa

A Similar Product 3CR12 has been used extensively for many projects in bridges, building……

Switzerland & Part of Europe

In the region it is produced and promoted by SWISS steel under the brand name of  TOP 12.

Japan

In Japan ferritic stainless steel rebar is being  produced by Nippon Steel & Sumikin Stainles Steel Corporation under the brand name of NSSD410—295 External Wall of Nippon Keidanren Building of NSSD  410-295

Stainless Rebar

Life Cycle Cost

Life cycle costing estimates the total cost of product from initial outlay , through all related future cots may be incurred as Consequence of initial investment decisions. While making any building or RCC structure the inital investment is going to be higher as there is price gap between Carbon Steel Rebar and SS Rebar Grade G . But in the long run there will be a major savings as building made by SS REBAR GRADE  G does not need any maintenance/replacement. Hence, higher investment cost gets offset due to low maintenance.

 


The cost of adequate prevention carried out during the stages of design and execution are minimal
compared to the savings they make possible during the service life

SS Rebar Grade G Rebars are Characterized by Superior Mechanical Properties, Ductility & Enhanced Life. It’s Built to Last Longer

Certificates




It is a new kind of stainless steel rebar first introduced in India by Sunflag Steel. SS Rebar Grade G is a low cost stainless containing 11-13.5 % Chromium rebar.

Recent brochure

Magnetic Flux Leakage Testing (MLFT) System


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Magnetic Flux Leakage Testing System

Advantages of Flux leakage testing :

    • Highly sensitive test method for the detection of longitudinal defects on steel bars

 

    • No coupling liquid

 

    • Quick to install and easy to operate

 

    • Reliable and reproducible test results

 

    • Automatic marking and sorting of the tested bars

 

    • High production speeds

 

    • Several reporting options

 

AC flux leakage principle

RFL – Probe Arm

Magnetic Flux Leakage Testing (MFLT)

    • Based on automated Flux leakage inspection system.

 

    • Uses high energy A.C. Magnetic Leak fields for detection of longitudinal flaws.

 

    • Real time display of ongoing inspection.

 

  • Fully automated defective marking & sorting of the material.

MFLT SALIENT FEATURES

Diameter Range 5 to 140 mm
Channels 8
Probes up to 16
Channel Width 5.0 mm
AC Frequency 7 KHz
Rotation max.1.800 rpm
Test Speed up to 2 m/s for 100% material scanning

Signal transmission by contact less inductive transformer

RFL – Probes


Probe unit with connecting cable 4 or 8 probes per Probe Arm Channel Width 5 mm

Model RFL 140
Diameter Range 15-140 mm (0.4-5.5 inch)
Material Round ferromagnetic bright or black steel bars
Max. Inspection speed up to 0.3ms (9.8 ft/S) Scanning width 100 mm
Installed Test Heads 2
Number of Probes 16
Number of Test Channel 8
Channel Width 5.0 mm
Magnetizing Frequency 7KHz
Setup Time Rotating Head 3 Min.
Set-up time with automatic Dimension Adjustment 2.0 min.
Additional set up time with Inner Roller guide for small Material Diameter 1.5-3 Min.
2 Sorting Classes SO (good) / S1 (repairable)
Defect Sensitivity 0.20 mm depth & 0.10 mm width 20 mm length (for black bars)

Magnetic flux leakage is a magnetic method of nondestructive testing that is used to detect corrosion and pitting in steel structures.

Recent brochure

Spring Steels


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Edge Radius

Flats can be supplied with an edge radius “R” which is equal to either “T’ or “T/2″, where “T” is equal to thickness.

General Length

We cater to orders in standard and specific length:

 

    1. a)Standard length 4 to 6 mtrs with 10% shorts down to 1 mtr.

 

    1. b) Customer’s specific lengths with tolerance + 50/-Omm.

Straightness

Bars hot rolled 3 mm/mtr (max) & hot rolled & machine straightened 1 mm/mtr (max)

Quality

Surface Condition: On visual inspection, surface is free from harmful defects, eg. Crack, lap, fold, scratch, roll/pass marks, pits etc.

SIZES AND CONDITIONS OF SUPPLY

Condition of Supply Shapes Sizes
Hot Rolled Flat(W*T) 50*5 mm-125*34 mm
Hot Rolled Round 5.5 to 250 mm
Drawn Round 5-50 mm
Peeled and Ground Round 5-100 mm

Decarburization

Decarburization Full Partial Total
Flats (upto 80*13) Nil 0.15 0.15 mm (max)
Flats (above 80*13) 0.03 0.25 0.25 mm (max)
Hot Rolled Round 0.8% 0.8% of the size (max)

Grain Size

5.8 (As per ASTME-112)

As Rolled Hardness

310 BHN (max)

Inclusion Rating

As per IS-4163/ASTME-45  :THIN: 2.5 A, B, C, D max

                                                      HEAVY : 1.5 A, B, C, D Max

 

                 As per JIS G-0555 :  % dA – 0.15 max

                                                       % dB + dC – 0.10 max

                                                       % d Tot – 0.20 max

Delivery Conditions

All bundles tied with wire/strapping at 3/4 places. 

Approx. bundle weight : 2 MT. max

Grade/HT. No. identification : By painted colour code and Heat Number written on each bundle / bar

Standard shapes and sizes of Spring Steel Flat Bars

1. RE Type

The conventional type is of Round Edge (RE) type, having edge radius approximately equivalent to thickness but not specified.

2. FL Type

Feather leaf type Spring Steel flats have edge radius of half of thickness and also have many advantages over RE type in terms of economical and technical aspects. Size – wise edge radius is be mutually agreed.

DIMENSIONAL TOLERANCES

Flats:

ROUNDS (HOT ROLLED)

ROUNDS (BRIGHT BARS)

FATIGUE GUARANTEED SPRING STEELS

Sunflag Steel, a pioneer in making Spring Steel, has come up with products in this category, which ensure the required fatique life to springs used in vehicles, in the most demanding situations.

THE SALIENT FEATURES OF THESE PRODUCTS ARE :

  1. Use of virgin inputs in steel making such as DRI, Pig Iron which are free from undesirable tramp elements.
  2. Carefully planned, steel making refining vacuum degassing and casting processes.
    .
  3. Well controlled reheating and rolling process.
  4. Closely monitored cooling parameters of rolled products.
  5. Thorough inspection and testing.
  6. Proper packing, stacking and storage for despatch.
  7. Wide size range.

CHEMICAL COMPOSITION OF TYPICAL
SPRING STEEL OF VARIOUS INTERNATIONAL STANDARDS



Spring steel is used for manufacturing various types of springs and components, for the suspension mechanism in Automobiles and railways.

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Stainless Steel


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Sunflag – The Group

The Sunflag Group founded in 1937 in Kenya is today a diversified global conglomerate with manufacturing facilities spread across eight countries and business operations in most others, across the globe.

Set up on strong foundations of business ethics and commitment to quality. the USD 600 million group has emerged as a leader and world-best, in its chosen diversified businesses of Steel Products,  Textiles, Fashion Garments, Artificial Leather, Agriculture Agro and Forest based produce, Power Generation, Financing & Project Consultancy. With 20 group companies, the group today employs over 10,000 people.



Sunflag – The Stellar Steel Story

The Group’s focus on engineering competencies has seen it emerge as one of the major players in the steel industry.

Sunflag Iron & Steel Company Limited, the Group’s flagship company, set up a state-of—the-art integrated steel plant in technical collaboration with Krupp, Mannessmann Demag and Hamburger Stahlwerke, Germany. This is one of the world’s most advanced and integrated steel plants located at Bhandara, India, in verv close proximity to its raw materials and has a capacity to produce over 5,00,000 tonnes per annum of high quality steel of a varied product mix. using iron ore and non coking coal as basic raw materials.

Sunflag Steel today caters to the demand of various core sector industries like automobiles, railways, defense, agriculture, engineering etc. It is approved as an OEM authorized supplier of high quality steel by major companies in India and overseas, including General Motors, for worldwide supplies of their spring steel requirements.

The varied product mix of specialized steel includes a wide range of Carbon Steels, Alloy Steels, Free Cutting Steels, Spring Steels, Ball Bearing Steels, Micro Alloyed Steel, valve Steels & Stainless Steel. These are manufactured in strict confirmation to lndian & International standards like, DlN/ SAE AISI/ ASTM/ EN, JIS. GOST and BIS.

A 30 MW captive power plant using waste gases and coal-fired burners ensures consistent and quality power supply, as well as cost competitiveness.

Stainless Steel

Stainless steel is steel containing 10.5% or more of chromium. which imparts it with corrosion resistant properties,by the formation of an impervious layer of chromium oxide on the surface.

Stainless Steel finds many applications,which include:

  • Construction industry
  • Boiler industry
  • Pumps and Shaft applications
  • Flanges
  • Surgical applications
  • Cutlery
  • Weaving and Knitting Wires
  • High Temperature Corrosion Resistance Chemical and Petrochemical industries
  • Springs etc.

Types Of Stainless Steel

S. No. Types of SS Typical Properties Broad Applications
1 Martensitic High Hardness,
Strength with corrosion and Wear Resistance
Scissors, Shears, Knives,
Forks, Medical Instruments, Boiler and Pumps, Cutlery items.
2 Austenitic Corrosion resistance
Good ductility
Chemical industries, Utensils, Flat products
3 Ferritic Magnetic Properties
Corrosion resistance
Cores of Electrical Equipments, Ribbed Bars, Exhaust systems of automobiles
4 Duplex Very High Strength High Pressure pipeline Parts, Chemical Industry equipments, Ribbed bars for special Applications
5 Precipitation Hardened High Strength and
Corrosion resistance
Petrochemical industry

Stainless Steel Manufactured at SunilagSteeI


Similar other grades  can be produce with different desigination & chemistries

Stainless Steel Bright Bars

Cold Drawn and Polished. CD+ P
Cold Drawn and Centreless Ground CD+CG
Rough Turned RT
Smooth Turned and Polished ST +P
Smooth Turned& Centreless Ground ST+CG
Forged and Turned FT

Bright Bar Capability

Cold Drawn and Polished . 4.5 -32 mm (coil route) 14- 50 mm (straight bar route)
Cold Drawn and Centreless Ground 10 – 32 mm (coil route) 14 – 50 mm (straight bar route)
Rough Turned 15 – 250 mm
Smooth Turned and Polished 15 – 200 mm
Smooth Turned& Centreless Ground 15 – 100 mm

Stainless Steel Billets-As Cast & Rolled

Supply Condition As Cast
Spot Ground
Four Face Ground
Hot Rolled Annealed and Pickled
As Cast Billet Sizes 130 x 130 mm
160 x 160 mm
210 x 230mm
240 x 280mm
280 x 320 mm
Rolled Billet Sizes 50 mm x 50 mm x 6 m
55 mm x 55mm x 6m
60mm x 60 mm x 6m
63 mm x 63 mm 6m
75 mm x 75mm x 6m
80 mm x 80 mm x 6m

Stainless Steel As Cast Billets

As Rolled Straight Length Bars
Round 15mm to 200mm
Round Cornered Square 50, 55, 60, 63, 75, 80, 95, 98 mm

Stainless Steel As Ingots

Ingot Size (mm) Wt (MT)
290 X 445 X 1700 1.8 MT
323 X 412 X 1700 2.7 MT
480 X 637 X 1700 4.2 MT

Stainless Steel Rebars

Condition Size Range Size Range
As rolled 6, 8, 10 mm Coils
As rolled and descaled 12 – 32 mm

Straight length Bars,

Length 12 Mtr.

Stainless Steel Wire Rods

Hot Rolled Annealed and Pickled Wire Rods*
Coil Weight 900 kgs to 1500 Kgs
Coil ID 850 mm min.
Coil OD 1250 mm max.
Size Range 5.5- 38 mm Dia – Rounds 
13.3 – 27.5 mm A/F Hexagons

Stainless Steel Round Edge Flat Bars

Width 50 mm minimum
150 mm maximum
Thickness 5 mm minimum
28 mm maximum

QMS Certification and Approvals

The guiding Philosophy in Sunflag Steel is enhancing customer satisfaction through continual improvemnet.

To continuously achieve higher level of performance in these areas sunflag had adopted and effectively implemented various Quality Management system

OMS system Scope Certification Body
ISO 9001 Complete plant operation Ul D0S Germany
IATF 16494 Complete plant operation TUV Nord, Germany
AD 2000 – MerkblattWO Pressure equipment directives TUV NORD, Germany
ISO 14001 Environmental management certification TUV NORD, Germany
ISO 45001 Occupational Health & Safety Management systems TUV NORD, Germany
NABL Certification Sunflag chemical & mechanical laboratories NABL India





Process Route



Stainless steel is steel containing 10.5% or more of chromium, which imparts it with corrosion resistant properties, by the formation of an impervious layer of chromium oxide.

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Free Cutting Steels


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Quality Requirement for Free Cutting Steels

  • Uniform distribution of MnS
  • Hardness
  • Microstructure
  • Dimentional quality
  • Straightness

Typical Co-Relation of Machining Parameters With Elemental Levels

Machining (Force) Torque

Effect of ‘s‘ content on the machining torque.

Surface Hardness HB

Free machining steels are generally used after cold processing such as drawing, peeling, grinding etc. The extent of cold work employed in converting black bar of free machining steel into bright bar, decides its surface hardness,which in turn is responsible for its machining performance.

Certification of Quality

  • Surface condition : Free from defects
  • Macro etch test (ASTM: E-381)
  • Spark/Spectral test — 100% bars
  • As rolled hardness – Free Cutting Steels <150 BHN
  • Inclusion rating – (ASTM – E-45) 2.5 max each – B, C,D
  • Micro structure – Sulphide morphology (Aspect Ratio)

International Specifications of Free Cutting Steels


International Specifications of Semi Free Cutting Steels


Sizes and Conditions of Supply

Condition of Supply Shapes Sizes

1. Black

Hex 15.5 mm — 38 mm A/F
2. Black Round 5.5 mm — 100 mm dia
3. Black WRD 5.5 mm — 38 mm dia
4. Drawn Hex 14 mm – 36 mm A/F
5. Drawn Round 10mm — 50 mm die
6. Peeled & Ground Round 10 mm — 90 mm dia

Free machining steels are generally used after cold processing such as drawing, peeling, grinding etc.

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Forging Quality Steels


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Forging Quality Steels are widely used in automobile, defence, railways and various manufacturing industries. Automobile industry is the single largest user of forgings. Components produced through forging are generally used in the transmission systems of an automobile where large forces get transferred between different parts,
hence they are of vital importance.

Quality requirements for Forging Quality Steels

  • Close control on chemistry
  • Freedom from harmful internal and surface defects
  • Dimentional tolerance IS 3739 grade ‘I
  • High degree of cleanliness
  • Fine and Uniform Grain Size

These steels are widely used in automobile, defence, railways and various manufacturing industries.

Gears | Axles | Crankshaft | Camshaft | Connecting Rod | Pinions | Crown Wheels

Automobile industry is the single largest user of forgings. Forging are generally used in the transmission systems of an automobile, where large forces get transferred between different parts, hence they are of vital importance.

Sizes and Condition of Supply

Supply Condition Shapes Sizes
Hot rolled, Round Bars 15 to 350mm
Hot rolled annealed, Round Corner 50 to 350mm
Peeled & ground, Square Bar
Peeled & reeled,
Drawn

Dimensional Tolerance as per IS 3739 specification

Certification Standard Fetures

  • Chemistry
  • Internal Soundness (Macro Quality)
  • Cleanliness Levels (Inclusion)
  • Grain Size
  • Hardness
  • Magna-flux
  • Microstructure
  • Anti Mix—up Test

In Addition to the standard features, following additional testscan be performed and certified as per customer’s requirement

  • Ultrasonic Test
  • Step Down Test
  • Blue fracture Test
  • Jominy Hardenability
  • Mechanical Properties — Tensile, Elongation, Reduction in Area, Hardness (on heat treated sample)
  • Impact Test (at desired temperatures (—80°C to Room Temperature)
  • Any other special test as per end application of the product

Bearing Steel

Typical Forging Quality Steel Grades


Bearing steels are special class of low alloy steels, typically with 1% carbon and 1.4% chromium. Manganese and Molybdenum are added in certain special cases.

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