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
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.
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:
Water hardening tool steel(e.g. cold heading, cutting tools, knives, reamers and cutlery etc)
Shock resisting tool steel (e.g. chisel for hot and cold cutting, chuckiaws, gripper, cold shear, hot shear etc.)
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.
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:
Furnace equipped with mould height 4000 MM
Facility for Rapid exchange of crucible
Multiple mould pouring
Facility for bulk and additional charging of mix under vacuum
Sampling and temperature measurements under vacuum.
Fully Rollaway head for facilitating cleaning of melt chamber.
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.
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.
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.
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:
a)Standard length 4 to 6 mtrs with 10% shorts down to 1 mtr.
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 :
Use of virgin inputs in steel making such as DRI, Pig Iron which are free from undesirable tramp elements.
Carefully planned, steel making refining vacuum degassing and casting processes.
.
Well controlled reheating and rolling process.
Closely monitored cooling parameters of rolled products.
Thorough inspection and testing.
Proper packing, stacking and storage for despatch.
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.
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.
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
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.
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
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.
