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Salient Features of Ingots

With Modern facilities already existing for refining, degassing and continuous casting of steel, Sunflag considered it is important to widen the current product mix to cater the needs of specific application segments where ingots are preferred over continuous cast blooms. Accordingly, Sunflag has commissioned new setup for casting Wide End Up — Bottom Poured Ingots, Our ingot casting facility is capable of producing steel for critical applications like Tool and Die, Railways, Defence and Aerospace sector.

Ingot Dimension – Phase 1

Ingot Size (mm)	Ingot Weight, MT
810x610x1970mm	7.2MT
637x480x1700mm	4.2MT
500x402x1700mm	2.7MT
412x323x1700mm	1.8 MT

Grades

• I Regularly Carbon, Cr, Cr—MO & Crw-Ni—Mo grades, as per popular standards like AlSI, BS, EN, DIN, GOST, JIS, etc.
• Also against specific TDSs of Customers.

Stainless Steel Grades

• AISI 410, 420 — Majority for export market (indirect).
• X22, X20, X5, X18, X19 – Energy (Turbine Blades)
• AISI 304, 316, 304L – Defence, Aerospace

Other Value Added Steel Grades

• En36C, EnB9B, AMS 6418 — Mining / Boring Tools
• En52, 21-4N, SUH ’11 — Valve Stems
• Din 1.2174, H11, H13 – Die Blocks
• En41 B – Screw / Barrels for injection Moulding M/c.

Rolled Products from Ingots
Straight Length Rounds	Round Corner Squares
Single Rolling 200 to 250mm dia.	Single Rolling 160 to 340mm RCS
Double Rolling 50 to 180mm dia.	Double Rolling 50 to 150mm RCS

• Slow cooling pits are available for control cooling of rolled product.
• Sufficient Top (8%) & bottom (2%) discards are given on rolled bars.
• We guarantee a Minimum Reduction ratio of 6:1 for Round products.

Unique Advantages of Sunflag Ingots

• Homogenized chemistry within narrow ranges
• Treatment of liquid steel through Vacuum Degassed (VD) / Argon Oxygen Decarburization (AOD)
• Mould powder bags are hung in ingots for better surface finish of ingots (1.5Kg powder / MT of liquid metal)
• Argon flushing of trumpet before cast start
• Argon shrouding of metal flow from ladle to trumpet
• Bricks St Hot Tops preheated for 24hrs at 200°C
• Uphill teaming with central trumpet, with high alumina runner bricks
• Specially designed moulds for ingots to control micro—segregation
• Dressing of ingots before reheating
• Reheating furnace with soaking capacity of 16 ingots
• Slow cooling pits available for controlled cooling
• Sufficient Top (8%) and Bottom (2%) end discards are provided on rolled bars
• Minimum reduction ratio of 6:1 for rolled products

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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Microalloyed Steels

Introduction

The use of MICRO ALLOYED STEELS (MAS) originally developed for high strength low alloysteel sheets (HSLA) for automobile bodies has shown steady and significant growth in Long products also for manufacture of forged components. The Indian steel manufacturers as well as forged components manufacturers have adapted themselves to manufacture and use MAS components for AUTO sector.

MAS grades not only helps in avoiding use of costly alloying elements but also eliminates the need for heat treatment of forged components. Plain carbon steels having closely controlled chemistry (to maintain Carbon Equivalent) alongwith small additions of microalloying elements such as V, Nb and Ti (to promote Precipitation Strengthening) can achieve the desired strength levels after forging without heat treatment. Optimum Sulphur levels and maintained to promote machinability.

These steels are covered by EN spec10267 as general spec, which can be fine tuned to meet specific customer requirements.

Sunflag melting and refining process has capability to meet close range chemistry with help of controlled addition of Microalloying Elements like V, Nb, Ti and special wire injection facilities for sulphur and aluminium addition.

Nitrogen can also be closely maintained in the range of 100 to 200 ppm as specified by customer.

Microalloyed Grades Being Produced

Sr.no.	Grades	End Application
1	C70S6	Fracture splitable connecting rod
2	38MnSiVS5	Crank shaft, Outer ball joint, inner insert
3	30MnVS6	Housing shaft and socket
4	SAE 11V41	Yoke
5	SAE 1137V	Transmission components
6	MT-15	Link application
7	S48CS1V	Crank shaft
8	S45CS1V	Rack bar
9	38MnVS5	Crank shaft
10	40MnSiVS6	Tubular and spherical rails
11	36MnVS4	Connecting Rod
12	SCr420HV-SG	Transmission Shaft

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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MANUFACTURING ROUTE OF
ENGINE VALVE STEELS

Martensitic Grades

Austenitic Grades

Inspection and Testing

• Surface Quality by M.P.I/ Zyglo/ECT
• Internal Soundness by Ultrasonic Testing
• Dimension & Length Controls
• Metallurgical Testing (Hardness, Microstructure. Inclusion, Grain Size etc.)

International Standards of Valve Steels

Chemical Composition

Product Details

Size Range :
Bright Bars	Dia 5.00 mm to 100 mm
Hot Rolled Annealed Wire Rod	Dia 5.50 mm to 38 mm
Hot Rol. Annealed Bars	Dia 15 mm to 160 mm
Standard Length	4000+50/-00 mm or as per Customer Specified Length
Supply Conditions :
Dimensional Tolerance: ISO h9, h11, +0.05/-0.00, +0.05/-0.05, + 0.10. Black Bar as per IS-3739
Martensitic Grades	Hot Rolled, Annealed or Hardened &Tempered
	Drawn &Ground, Peeled &Ground and Black bar
Austenitic Grades	Hot Rolled, Solution Annealed, Peeled &Ground and Black Bar

Mechanical Properties

Grade	Condition	Yield Strength N/mm2	Tensile Strength N/mm2	% Elongation min	% Reduction in Area min	HRC
EN-52/X45CrSi9-3	H & T	700	900-1100	14	40	25-35
SUH-11	H &T	700	900-1100	14	40	25-35
SUH-3	H &T	700	900-1100	14	40	25-35
X85CrMoV18-2	H &T	800	1000-1200	7	12	25-35
21-2N	Solution Annealed	550	900-1150	8	10	30-40
21-4N	Solution Annealed	580	950-1200	8	10	30-40
21-12N	Solution Annealed	400	800-1200	35	45	23-25
21-43N	Solution Annealed	580	950-1150	10	12	30 min
23-8N	Solution Annealed	550	850-1100	25	30	26 min
Inconel 751	Solution Annealed	630-850	1100-1300	12	20	32-40

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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Material quality requirements for cold heading steels

• Excellent surface quality ensuring zero-defect situation so that forged components have no defects
• Good control over ovality to ensure smooth forging process.
• Good control over mechanical properties such as tensile strength and reduction is to ensure proper cold forgeability and productivity
• Completely descaled surface to avoid forging defects such as scale pits and resultant surface roughness.
• Suitable metallurgical structure to ensure proper machinability level.
• Good and uniform response to heat treatment since the components are always treated in bulk.

Category	SAE/AISI	DIN	IS	EN
Low Carbon & Medium Carbon Grades	1008	–	–	–
	1010	CK-10	C10	–
	1012	CK-10	C10	EN2A
	1015	CK-15	–	EN32B
	1018	–	C-15Mn75	EN2C
	1020	C-20	C-2SMn75	EN3A
	1025	–	–	–
	1040	–	–	–
	1045	–	–	–
Carbon Manganese	1541	36Mn7	37C15	EN1S
Boron Grades	10B21	–	21C10BT	–
	15B25	–	26C1OBT	–
	15B41	–	–	–
Crome-Moly	4135	–	–	–
	4140	–	40CR4MO3	EN-19

Dimensional Specifications (As rolled)*

Diameter Range	Ovality	Permissible Tolerance
5.5-9.0 mm	0.2 mm max	± 0.15 mm
10-25 mm	0.3 mm max	± 0.20 mm
26-36 mm	0.4 mm max	± 0.30 mm

* In specific cases stricter specifications can be met.

Particulars	Block Route (5.5 mm to 11 mm dia)	Garret Route(12 mm to 36 mm dia)
Coil Weight	1500 kgs max	1500 kgs max
Coil Inner Diameter	800 mm	800 mm
Coil Outer Diameter	1200 mm	1500 mm
Coil Height	900 mm	1100 mm
Binding	Strap	Strap

Wire Rods Rolled Sizes :

CHEMICAL COMPOSlTIONS or TYPICAL COLD FORGING QUALITY GRADES :

CARBON STEELS

BORON STEELS

ALLOY STEELS

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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Bearing Steels are special class of low alloy steels, typically with 1% Carbon and 1.4% Chromium. In special cases, Manganese and Molybdenum are also added. These steels find applications in automobiles, railways, earth moving, defense, aircraft, power generations, compressors, and other moving machinery parts. In view of the continuous fatigue strain during service, this steel and its components demand a high level of process discipline during manufacturing.

The components for these applications are manufactured either through hot forging route or through Spheroidized annealing followed by cold forging route. At Sunflag, all the necessary facilities for manufacturing and testing of bearing steel grades have been established. Various controls are exercised during manufacturing, right from selection of raw materials and ferro alloys required to meet the stringent quality parameter of the various customer.

• Fatigue Life
• Uniform heat treatment response
• Compact Structure with uniform grain flow and fine grain size
  imparting high impact toughness

Inspection activities before dispatch are designed to address the verification of all the quality requirements of bearing steels. Any deviation observed during production process and quality testing is recorded and analysed for taking suitable corrective and preventive actions to meet the quality requirements of this critical Steel grade.

Size and Condition of Supply

No.	Size(mm)	Shape	Supply Condition
1	15 to 160 dia.	Straight Length Round	Hot Rolled, Annealed
2	12 to 60 dia.	Straight Length Round	Stress Rehef/Spherodlsed Annealed
3	10 to 56 dia.	Straight Length Round	Spherodised Annealed,Peeled and Gmund
4	5.5m to 38 dia.	Wire Rod Rounds	Spherodised Annealed.

More shapes sizes with a combination of different supply condition can be developed as per specific requirement by customers

International Specifications Of Ball Bearing Steels

Certification of Quality

Following important quality features are tested and certified on all Bearing heats made at Sunflag.

Chemistry	As per international standards with low tramp levels (low titanium)
Gas	02, N2 and H2
Internal Soundness	As per ASTM E-381.
Dimensional Tolerances	As per IS 3739: Grade 1
Decarburization Level	Less than 1% of diameter.
Surface quality	100% surface of bar inspected through automatic MFLT / MPI
Non — Metallic Inclusions	As per ASTM E45 A and B: 1.0 (max), C: 0.0, D: 0.5 (max)
Microstructure (Banding)	As per SEP-1520 DIN Standard Chart

Any other special testing requirement found desirable by the customer can be satisfied.

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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SUNFLAG IRON & STEEL CO. LTD

SUNFLAG IRON & STEEL CO. LTD. belongs to the Sunflag Group which has diversified business interests in Steel, Synthetic Yarns Fabrics and non-wovens textiles, spanning across the globe.

Steel being one of the core products for industrial development Sunflag ventured into steel sector in 1989 with setting up of an integrated steel plant at Bhandara near Nagpur using state of art technology in steel making. Today Sunflag operates a 0.5 million tonnes per annum capacity plant manufacturing high quality steel products including a wide range of special, alloy and stainless steels.

With a constant endeavour to enhance its Technology and to be best in the industry Sunflag has successfully embraced “Clean Steel Technology” transferred by Daido Steel Japan and has developed steel with high cleanliness, low gas and low inclusion content that are used in critical applications.

With a vision on future, Sunflag has recently made investment in ESR/VAR/VIM and ventured in production of high performance material & super alloys for aviation, space, defence, Power sector and medical implants.

The guiding philosophy of SUNFLAG STEEL is to ever evolve while ensuring customer satisfaction at all the times. We have achieved success through sheer dint of hard work, support of our valued customers and with a passion to be the best!