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Research And Develoment centre & Automatic inspection facilities

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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.

Research And Develoment centre & Automatic inspection facilities

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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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Connect with us:

For a project, as a partner or as a talent:
admin@sunflagsteel.com
For sales enquiries:
mktg@sunflagsteel.com
Address: REGD & HEAD OFFICE 33,
Mount Road, Sadar,
Nagpur - 440 001

+91-712 -2520356
+91-712 -2524661