Basics Types of Steel &

Characteristics

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 1

Pure Metals and Alloys
Metal that are not mixed with any other materials are known
as pure metals. Metals listed in the Periodic Table are pure
metals
E.g. Iron (Fe), Copper (Cu) and Zinc (Zn)

Alloys are mixtures of two or more metals formed together

with other elements/materials to create new metals with
improved Mechanical Properties and other properties
of the base metal.

E.g. Brass (Copper and Zinc),

Stainless steel (steel and chromium)

Alloy = metal A + metal B + … + other elements

2
Ferrous Metals & Non-Ferrous Metals

Ferrous metals are metals that contain iron

E.g. Steel (iron and carbon)

Non-ferrous metals are metals that do not contain iron

E.g. Zinc (pure metal), Bronze (Copper and tin)
(non-ferrous may contain slight traces of iron)

Ferrous Metal = alloy metals that contains iron

( Primary base metal is iron)

Non-ferrous Metal = alloy metals that do not contain iron

Primary base metal does not contain iron)

3
Classification

Metals can be divided into 2 groups

Metals
Ferrous Metals Non- Ferrous Metals

Iron Aluminum

Low Carbon Steel Copper

Medium Carbon Steel Brass

High Carbon Steel Bronze

Cast Iron Zinc

Stainless Steel Lead

Tool Steels Tin

Others Others

4
Extraction of Iron

•Iron is found in iron oxide in the earth.

•Three primary iron ores: magnetite, hematite, taconite

•Iron is extracted using blast furnace

•Steps in extraction of iron
Ores is washed, crushed and mixed with
limestone and coke
The mixture is fed into the furnace and is then melted
Coke(a product of coal, mainly carbon) is
used to convert the iron oxides to iron

5
Extraction of Iron

Limestone helps to separate

the impurities from the metal

The liquid waste is known as slag

that floats on the molten iron

They are then tapped off (separated)

The iron produced is only about 90% to 95% pure.

The iron is then further refined using the

basic oxygen furnace and the electric arc
furnace to produce steel which is widely
used now.

6
Blast Furnace Temperatures

7
 iron (III) oxide + carbon monoxide iron + carbon dioxide

REDUCTION

Fe2O3(s) + 3 CO(g) 2 Fe(s) + 3 CO2(g)

Because the furnace temperature is in the region of 1500oC, the metal is

produced in a molten state and this runs down to the base of the furnace.
The furnace temperature is also high enough to decompose limestone into
calcium oxide ( Limestone: A Blast Furnace raw material that removes
impurities such as silica from the ore. Mainly made from calcium
carbonate, CaCO3 )

calcium carbonate calcium oxide + carbon dioxide

CaCO3(s) CaO(s) + CO2(g)

This oxide helps to remove some of the acidic impurities from the ore
calcium oxide + silica calcium silicate

CaO(s) + SiO2(s) CaSiO3(l)

The impurities are removed react with calcium oxide to make a liquid slag that
floats on top of the molten iron. The slag is collected after the denser iron has
been run out of a tap hole near the bottom of the furnace.
The production of iron in a Blast Furnace is a continuous process. The furnace
is heated constantly and is re-charged with raw materials from the top while it
is being tapped from the bottom. Iron making in the furnace usually continues
for about ten years before the furnace linings have to be renewed.

The energy costs of the operation are kept to a minimum by collecting and
cleaning the hot gas that leaves the furnace. This gas contains a lot of carbon
monoxide. It can be re-used as a fuel for other steelmaking processes or to
heat up the air blast to the furnace.

Refining iron
The metal that leaves the Blast Furnace contains between 4% and 5% of
carbon. This much carbon makes a very hard but brittle metal which is not
much use. The next step in the production of steel is to reduce the levels of
carbon and other impurity elements in the hot metal.
 Routes to steel
Two methods of making steel are dominant in modern
steel industries all over the world.
Route 1 Basic Oxygen Steelmaking (BOS)
The hot metal from the Blast Furnace contains up to 4.5% of carbon.
Steelmaking reduces the carbon content to a level that matches the
customer’s requirements. This is often less than 0.1%. Basic Oxygen
Steelmaking (BOS) makes steel from Blast Furnace iron and small
amounts of scrap metal.

blast furnace iron +

steel
scrap

Basic Oxygen Furnace A furnace in which steel is produced by blowing air

(BOF) through a mixture of scrap steel and molten iron.
The Basic Oxygen Process furnace (PROCESS)
The Basic Oxygen Steelmaking Process is the method for making steel.
Modern furnaces will take a charge of up to 350 tonnes and convert it into
steel in less than 40 minutes.

The diagram shows oxygen being blown into the furnace or BOS vessel
through a water cooled oxygen lance. This oxidises carbon and the other
unwanted elements in the hot metal. Carbon is oxidised to carbon
monoxide gas, which passes from the converter to a cleaning plant. After
cleaning, it can be re-used as a fuel gas. The rest of the elements in the
metal are converted to acidic oxides. They combine with the lime and
other fluxes that are added during the blow. This produces a slag that
floats on the surface of the metal.

The steel is tapped from the furnace when it is at the correct temperature
and composition. The furnace is tilted and the molten metal is run out via
the taphole into a ladle. Once the steel has been removed, the furnace is
turned upside down and the slag that is left inside runs into another ladle.
The solidified slag can be used in the production of cement and as an
aggregate in road building.
The Basic Oxygen Process furnace
FLUXES & COOLANT
FUMES TO CLEANING PLANT

WATER COOLED FUME HOOD

CATCHES THE GASES
TO BE RECYCLED
MOVABLE SEAL

WATER COOLED LANCE

TAP HOLE

STEEL SHEEL
REFACTORY LINING
 The Basic Oxygen Process furnace (STEPS)

(up to 300 tonnes)

20 minutes
 Route 2 Electric Arc Furnace Steelmaking (EAF)
Electric Arc Furnace (EAF). This is an electrically heated furnace
that makes steel from scrap metal only.

scrap steel

Electric Arc Furnace An electrically heated steelmaking furnace, in which

(EAF) steel is made entirely from scrap metal.

Most of the metal that is made in the BOS furnace is sold as bulk steel. More
specialist steels are made in the Electric Arc Furnace, although this furnace is
also capable of producing large volumes of other types of steel.

Unlike the manufacture of iron, steel production is not a continuous process. As

we have already seen, there are different types of steel and the exact
composition of a steel will depend on the customer’s specification. This is why
steelmaking has to be a batch process.
Indian Steel Making Routing
Pie chart to show relative amounts of steel produced by EAF
and BOS methods. The numbers are in millions of metric tonnes

AS PER YEAR 2000 TOTAL PRODUCTION DATA

TOTAL=18.10 TONNES
Steel sections can be produced in the
three basic shapes: slabs, blooms
and billets.
Types of Steel
Steel

•Low carbon steel (mild steel)

•Medium carbon steel
•High carbon steel (tool steels)
•Cast iron

Alloy Steels

•Stainless steel
•High speed steel

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Low Carbon Steel

Also known as mild steel

Contain 0.05% -0.32% carbon

Tough, ductile and malleable

Easily joined and welded
Poor resistance to corrosion
Often used a general purpose material

Nails, screws, car bodies,

Structural Steel used in the construction industry

23
Medium Carbon Steel
Contains 0.35% - 0.5% of carbon

Offer more strength and hardness BUT

less ductile and malleable

Structural steel, rails and garden tools

24
 High Carbon Steel

Also known as ‘tool steel’

Contain 0.55%-1.5% carbon

Very hard but offers Higher

Strength Less ductile
and less malleable

Hand tools (chisels, punches)

Saw blades

25
 Cast Iron
Contains 2%-4% of carbon

Very hard and brittle

Strong under compression
Suitable for casting [can be pour at a relatively
low temperature]

Engine block, engineer vices, machine parts

26
 Stainless Steel
Steel alloyed with
chromium (18%), nickel (8%), magnesium (8%)
Hard and tough
Corrosion resistance
Comes in different grades
Sinks, cooking utensils, surgical instruments

27
Stainless Steels

Main types:

Ferritic chromium:
very formable, relatively weak;
used in architectural trim, kitchen range hoods, jewelry,
decorations, utensils Grades 409, 430, and other 400

Austenitic nickel-chromium:
non-magnetic, machinable, weldable, relatively weak;
used in architectural products, curtain walls, storefronts,
doors & windows, railings; chemical processing, food
utensils, kitchen applications.
series. Grades 301, 302, 303, 304, 316, and other 300
series.

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Stainless Steels

Martensitic chromium:
High strength, hardness, resistance to abrasion; used in
turbine parts, bearings, knives, cutlery and generally
Magnetic. Grades 17-4, 410, 416, 420, 440 and other
400 series

Maraging (super alloys):

High strength, high Temperature alloy used in structural
applications, aircraft components and are generally
magnetic. Alloys containing around 18% Nickel.

29
High Speed Steel
Medium Carbon steel alloyed with
Tungsten, chromium, vanadium

Very hard
Resistant to frictional heat even at high temperature
Can only be ground

Machine cutting tools (lathe and milling)

Drills

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Types of Steel
Various steel alloys are commonly identified with the SAE-AISI numbers,
Classification of Tool Steels
Description or Notable
Designation
Properties
W Water hardening
S Shock resisting
O Oil hardening
A Air hardening
D Die steel, air hardening, high chromium
Hot work, chromium, tungsten, and/or
H
molybdenum
T Tungsten alloy, high speed steel
M Molybdenum alloy, high speed steel
L Low alloy, special purpose
F Carbon-tungsten, special purpose
P Mild steels, low carbon and other types
Classification of Steel

AISI - SAE Classification System AISI XXXX

American Iron and Steel Institute (AISI)

• classifies alloys by chemistry
• 4 digit number
– 1st number is the major alloying element
– 2nd number designates the subgroup alloying
element OR the relative percent of primary
alloying element.
– last two numbers approximate amount of carbon
(expresses in 0.01%)
Classification of Steel

Examples:
2350
2550
4140
1060
Common Carbon and Alloy Steels:
AISI - SAE Classification System

• letter prefix to designate the process used to produce the steel

– E = electric furnace
– X = indicates permissible variations
• If a letter is inserted between the 2nd and 3rd number
– B = boron has been added
– L = lead has been added
• Letter suffix
– H = when hardenability is a major requirement
• Other designation organizations
– ASTM and MIL
Classification of steels (EN 10020)

• Non-alloy steels (carbon steels)

• Alloy steels

Inclusions, % Non-alloy steels Alloy steels

(carbon steels)
Mn ≤ 1,65 > 1,8
Si ≤ 0,5 > 0,5
Cr ≤ 0,3 > 0,5
Ni ≤ 0,3 > 0,5
Ti ≤ 0,05 > 0,12
V ≤ 0,1 > 0,12
Non-alloy and alloy steels classification (1)

Non-alloy steels (carbon steels) Alloy steels

C content based Alloying degree based
- low C-steels (<0,25%) - low alloy steels (<2,5%)

- medium C-steels (0,3…0,6%) - medium alloy steels (<5%)

- high C-steels (>0,6%) - high alloy steels (>5%)

Alloying degree based

- Cr steels
- Mn steels
- Cr-Ni steels etc.
Designation of steels (1)

Steels (EN10027) Notch impact energy

Designations (1)
• Mechanical properties based on: Re KU, J
°C
– steels for steel constructions S355J0 27 40 60
– steels for pressure vessel P265B
+20 JR KR LR
– steels for machine constructions E295
– steels for pipes L360QB 0 J0 K0 L0
– concrete reinforcing steel B500N -20 J2 K2 L2
-30 J3 K3 L3
• Based on: Rm -40 J4 K4 L4
– rail steels -50 J5 K5 L5
RO880Mn -60 J6 K6 L6
– prestressing steels Y1770C
 Designations (2)
• Chemical composition based
– C (non-alloy steels (carbon steels), ex free cutting steels
C35E
G-C35E (cast steel)
35 – C%x100 (E – max S-content)
– C, alloying elements (low- medium alloy steels,
all. elem., ≤5%, non-alloy steels (carbon steels) Mn ≥1%,
non-alloy free cutting steels)
28Mn6 Alloying
G-28Mn6 Factor
element
– C, all. elem. (high alloy steels, Cr, Co, Mn, 4
all. elem. >5%) Si, Ni, W
X5CrNi18-10 Al, Cu, Mo, 10
– All. elem. (high speed steels) Nb, Ti, V, Zr
HS 12-9-1-8 Ce, P, S 100
W-Mo-V-Co B 1000
Designations (3)
Materials numbers (EN 10027)
1. XX XX (XX)
Material group
Steel class
Order in class
Additional numbers
Pos. 2 and 3
Ordinary grade steels 00...90 Tool steels 20...29
High quality grade Special steels 40...49
10 – spec. phyc. prop. steels (stainless and heat resistant. etc.)
11 – construction and machine
construction steell
12 – machine contruct. steels
13 – spec. constr. and ja machine constr. steels
High quality 01...91 – structural steels
02...92 – non heat treatable structural steels
07...97 – high P- ja S-cont. steels
Pos. 4 and 5
Order no. in class
Structural steels (1)

Non-alloy structural steels (C = 0,2...0,65%)

• ordinary (quality) steels
• quality steels C15E (max S), C15R (S range)
• high quality steels (S, P ≤ 0,025%)

• Free cutting steels (C = 0,12...0,4%; g 0,2% S)

– 10S20, 35S20
• Cast steels (C = 0,15...0,55%) – GE250, G28Mn6
Structural steels (2)
Alloy structural steels (C = 0,2...0,7%, wear resistant steels
0,9...1,3%)
• low alloy steels (all. elem. g 2,5%)
–structural steels
–cold forming steels
–spring steels (C = 0,5...0,7%, Si = 1...2%)
–ball bearing steels (C ≈ 1%, Cr = 0,5...0,6%)
• medium alloy steels (all. elem. 2,5...5%)
– cementizing steels
– quenching and tempering steels
– nitriding steels
• high alloy steels (leg. el. > 5%) – steels with specific properties
– corrosion resistant steels
– high temperature strength steels
– wear resistant steels
Structural steels (3)
Low alloy steels (1)
Steels for structural construction
Low alloy carbon steels C≤0,22%; 1...2% Si, Mn
Requirements:
• Cold brittleness: low TBCT, T50
high toughness (h impact energy KU, KV)
• Weldability
CE%=C%+Mn%/6+(Cr%+Mo%+V%)/5+(Ni%+Cu%)/15
CE≤0,40% - satisfactory weldability
CE≥0,40% - special means: preheating, low annealing.
Alloying principles: iP,S gi TBCT
Simultaneous alloying with V,NgTBCT -80°C
Structural steels (5)
Low alloy steels (3)

Spring steels
high Re, σR, modulus of elasticity E
C = 0,5...0,7%
Mn-steels (1...2% Mn)
Si-steels (2...3% Si)
Cr-V-steels
TT: Hardening + mid. temp. (300...400°C) g Trostite structure
Ball bearing steels
High hardness (≥ 62 HRC)
C ≈ 1%; Cr = 0,6...1,5% – 105 Cr6
Ball races (63...64 HRC), balls (61...62 HRC)
Structural steels (6)
Medium alloy steels (1)

Cementizing (case hardening)

steels (0,1...0,25% C)
• Cr-steels
• Cr-Mn-steels
• Cr-Ni-steels
• B-steels
HT: Tcem + hard. + low. temp.
Surface (Cg0,8) – 58...62 HRC
Core (C = 0,1...0,25) – 30...42 HRC
Structural steels (7)
Medium alloy steels (2)

Quenching and tempering steels

Requirements:
• Reliability ( Rm, Rp0,2; acceptable KU and TBCT)
• High hardenability (D50, D95, T50)
Principles pf alloying:
• Alloying hardenability (Ma, Ml) (all exc. Al and Co)
• At solution in F,  Rm and TBCT, alloying degree as low
as possible (for D50)
Structural steels (8)
Medium alloy steels (3)

Quenching and tempering steels (0,3...0,5% C; 3...5% all.elem.)

D95, mm T50, °C
I gr – non-alloy steels (carbon
10...15 20
steels)
II gr – Si-Mn/Cr-steels (~1%) 20 -30...-50
III gr – Mn-Cr-steels 25 -60
IV gr – Ni-Mo-steels 40 -80
V gr – Ni-refractory. (W, Mo, V jt.) 100 -100

Rm g1200 N/mm2; Rp0,2 g 1100 N/mm2; A = 10...12%; KUg40J

Structural steels (9)
Medium alloy steels (4)

Nitriding steels (C-, all. elem. – same as in hard. and temp.

steels)
Tnitr 500...600°C (differently from cem.)
All. elem. Cr, Mo, Al + N g CrN, MoN, AlN

Properties:
Hardness: surface – alloy steels 950...1150 HV,
non-alloy steels (carbon steels) 400...500 HV
Core 250...300 HB
High fatigue strength ( by comp. stresses induced nitrides)
 THCM Material Grade
Equivalent Material (Acceptable by HITACHI experts)
S.No In JAPAN In INDIA Remarks (If any)
1 S20C C-20 Bar only, except support for carbody, swing pins
2 S25C 25C8, IS-9175 Pin Stopper
3 45C8, IS-5517 For hardening & tempering (Quenching)
S45C
4 45C8, IS-3930 For Flame hardening & Induction Hardening
5 S35C 35C8, IS-5517 Pin,Bush,Idler(Forge)
6 S38C Pin, Bush, Idler(Forge)
40C8, IS-5517
7 S40C Washer
8 S50C 50C8, IS-5517 Pin
9 S53C 55C8, IS-5517 Pin
10 SCM-415 EN354 Gear
11 SCM-420 AISI / SAE 4320/SAE 8620/EN 353 Gear
12 SCM-435 Gear
40Cr4Mo3, IS-5517/En 19/SAE 4147
13 SCM-440 Gear
14 SCR-440 40Cr4 type C, IS-5517 Gear
15 SS 41 / SS ST42S, IS-226 t < 3b
16 ST42 ST42W, IS-2062 3b <= t
17 SM50 ST52-3, DIN 7100-80 Plate
18 ST52 TISTEN52, TISCO Plate
19 SM58 WELTEN 80 Plate
20 FCD 40 SG400/10, IS-1865 Casting
for X2018381 (link) only
21 FCD 45 P&H 2 and SG 450/10 for X201484 (coller), X2015299 (big), X1005309
(yoke) and other similar parts
22 FCD 48 and FCD 50 SG 500/7 Casting
23 STKM 11A Gr 17 ERW HTS, IS-3601 thrust plate , pin
24 STKM 13A Gr 25 ERW HTS, IS-3601 thrust plate , pin
25 STKM 16A Gr 32 ERW HTS, IS-3601 thrust plate , pin
26 SGP IS-2139 Thrust Plate
27 SK 5M T 80, IS-1570 ; EN42J Thrust Plate
28 SPCC IS 513, CR 1 Thrust Plate
29 SPCE Deep drawing type Thrust Plate
30 Welten 60RE TI / Welten 80 temporary

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 50

 THCM Material Grade
31 SCM 415 20MnCr5, IS-4432 for Carburizing Bushing
32 SS41 / S200 CL2, IS-1875 for Forging parts
for front attachment bushing which requires
33 STKM16A 20Mncr5, IS-4432 internal dia induction hardening (to be
carburized in TELCON)
for shafts & axles requiring surface hardness 51 -
34 S50C-N 45C8 with Q&T
56 HRC and core~ 197 BHN
For Pins:
UH083:- Z3022121, X302212, X3022125,
35 S45VC-M 45C8 with Q&T X302226,X3023649, X302566, X3027916, X1115293
UH103:- X3026301, X302630, X3026303, X302630,
X3026322, X302632
36 JSMA No5 Part I, Grade B, IS-4454 Drg No- X4093809 (bar: torsion)
37 WELTEN- 70R T1 / WELTEN 80 PLATE
38 SAPH 45 ISDD 1079 for UH083 Oil tank cover (Drg No- 3021331)
39 SM5CA ST 52.3, DIN 17100-80 same as SM50
40 STS 38 Pipe
Seamless, BS 778-66
41 STPG 38 Pipe
42 STPG 38 Grade CDS I (b), IS-3074 sheets
43 SPC1 IS 1079 Grade D same as SPCC
44 SS41B-D SS 400/Fe 410 WA same as SGD41-D
45 SCMn2B TELCO, Fdy, TRO3 with Q&T HT, T.S, etc same as in drawings
46 WT 60RE / SM 5B TISTEN 60 Killed, TISCO Plate
47 WT 80P
48 Wt 80C
WELTOn 80 (imported) Plate
49 HT 80
50 HT 80K
51 HT 50 SAILMA 350, SM 50A, ST 52 Plate
SM 58, SAILMA 450, WELDOX
52 HT 60 Plate
500,WELTON 60RE,WELTON 590
Head Guard (6005900)
53 70.5 X 70.5 X 4.05 SQ Tube UH501, Head Guard
75X75X3.2 SQ Tube
Except internal parts, hyd aggregate (pumps,
54 FCD 50 GGG 50/7
motors,etc)
55 FCD 60 GGG 60/3 CASTING
56 S45C-D 45C8 with Q&T same as S45C, m/c to size & use, I/H
57 S22C 25C8, IS-9175 Misc.
58 SECO DD grade, IS-1079 only for Fuel tank phosphating is done
59 S38BC P&H 11 with Normalised sprocket
60 S35BCh P&H 11 with Normalised sprocket
61 S40BC 15B41,15B25 QT , EN 19 QT Washer
62 S48C S48C Pin
63 SCMn2B TR03 QT EX-1200 Arm Casting

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 51

 THCM Material Grade
CHEMICAL COMPOSITION.

Grade %C %Mn %Si %S %P %Cr %Ni %Mo %V

TRO1 0.08-0.12 0.5-0.6 0.3-0.6 0.035Max. 0.035Max. 0.25Max. 0.40Max. 0.15Max. 0.05Max.

TRO3 0.27-0.32 1.2-1.5 0.3-0.6 0.035Max. 0.035Max. 0.25Max. 0.40Max. 0.15Max. 0.05Max.

PH 1 0.20-0.35 0.50-0.90 0.20-0.60 0.06Max. 0.05Max. 0.2 0.5 0.2 Cu=0.30

PH 2 0.40-0.50 0.50-0.90 0.20-0.60 0.06Max. 0.05Max. 0.4 0.5 0.2 Cu=0.30

PH 73 3.25-3.50 0.60-0.90 2.00-2.30 0.15Max. 0.20Max. ------ ------- ------- --------

PH 76 3.10-3.30 0.60-0.90 1.80-2.10 0.15Max. 0.12Max. ------ 0.60-0.85 0.50-0.65 --------

PH11 0.35-0.42 1.1-1.5 0.3-0.6 0.035Max. 0.035Max. 0.25Max. 0.40Max. 0.15-0.30 0.05Max.

PH6 0.35-0.45 0.6-0.9 0.3-0.6 0.035Max. 0.035max. 0.8-1.10 0.40Max. 0.15-0.30 0.05Max.

GGG50(FCD50) 3.5-3.7 0.1-0.8 1.8-2.8 0.010Max. 0.10Max. 0.08Max. Mg 0.035-0.07 --------- ------

GG25(FC250) 3.0-3.3 0.6-0.8 1.8-2.5 0.13Max. 0.30Max. ----- Cu 0.4-0.55 ------- -------

Electro Steel 0.08-0.13 0.3 0.3 0.035Max. 0.035Max.

40Cr4(Grade-B) 0.35-0.4 0.6-0.9 0.1-0.35 0.035 0.035 1.05-1.2 0.2max.

40Cr4(Grade-C) 0.4-0.45 0.7-0.9 0.1-0.35 0.035 0.035 1.05-1.2 not present

EN 6 0.4 0.5-0.9 0.05-0.35 0.06 0.06

EN 6A 0.35 0.5-0.9 0.05-0.35 0.06 0.06

S35C 0.32-0.38 0.6-0.9 0.15-0.35 0.035 0.035

S45C 0.42-0.48 0.6-0.9 0.15-0.35 0.035 0.035

S25C 0.22-0.28 0.30-0.60 0.15-0.30 0.035 0.035

AISI4320 0.17-0.22 0.45-0.65 0.2-0.35 0.04 0.04 0.4-0.6 1.65-2 0.2-0.3

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 52

 Steel Plate
Specifications for Steel Plates
CHEMICAL COMPOSITION MECHANICAL PROPERTIES SIZE
Y.S UTS HARDNE HEAT RANGE
SL# GRADE %C %Si %Mn %S %P %Ni %Mo OTHER EQUIVALENT SUPPLIER
CE (Mpa) (Mpa) %E min Impact SS TREATMENT MM
MAX MAX MAX MAX MAX MAX MAX MAX
min min (BHN) (TELCON
AS
IS2062 27 J SAIL/JSPL/
1 0.22 0.4 1.5 0.045 0.05 - - - 0.42 250 410 23 120-150 ROLLED/NOR FE410, SS400, SGD 41,SS 41 5-100
E250 BR @R/T TATA STEEL
MALISED
150-180 SAILMA 350, HT 50, IS 2062
2 ST 52 0.22 0.55 1.6 0.05 0.05 - - - 0.4 350 490 20 - NORMALISED - IMPORTED
BHN E350C, SM 490A/B
IS 2062 Nb+V+Ti 27 J @ - SAIL/JSPL/
3 0.20 - 1.5 0.04 0.04 - - - 350 490 22 150-180 AS ROLLED ST 52, HT 50 6-65
E350C =0.3 20 °C TATA STEEL
4 SM 490A 0.22 0.35 1.5 0.035 0.04 - - - 0.44 325 490-610 18 - 150-180 AS ROLLED IS 2062 E350C/HT 490 - IMPORTED

5 SM 490B 0.18 0.35 1.5 0.035 0.04 - - - 0.44 325 490-610 17 - 150-180 AS ROLLED IS 2062 E350C/HT 490 - IMPORTED
27 J @ - HT 490/ IS 2062 E350C/
6 HT 50 0.20 0.55 1.5 0.05 0.05 - - - 0.38 294 490 19 150-180 NORMALISED - HITEN JFE
27 °C SAILMA 350, SM 50A, ST 52
Cr=0.7 47 J @ -
7 HT 590 0.16 0.35 1.2 0.015 0.03 1.00 0.5 0.57 450 590-710 20 170-200 Q&T IS 2062 E450BR/Weldox 500 HITEN JFE
V=0.08 10 °C
WELTON 47 J @ -5 WELTON 590/IS 2062
8 0.16 0.55 1.6 0.03 0.03 - - - - 450 588 20 160-205 TMT 50
590 °C E450BR
SAILMA 450, SM 58, IS 2062
9 HT 60 0.16 0.55 1.6 0.03 0.03 - - - - 450 588 20 170-200 Q&T - IMPORTED
E450BR, WELDOX 500
HT60, WELDOX
IS 2062 Nb+V+Ti 47 J @ -
10 0.2 - 1.5 0.04 0.04 - - - 450 570 19 170-210 AS ROLLED 500,WELTON 60RE/ IS 2062 6-32 SAIL/JSPL
E450 =0.3 20 °C
E450BR/A
Nb=0.05 THERMOMEC
WELDOX 40 J @ - Optim 500 ML RUKKI SSAB &
11 0.17 0.55 1.7 0.02 0.02 - - , V=0.12, 0.42 500 570-720 16 162-205 HANICALLY 36-60
500 20 °C WELDOX 500- SSAB Rukki
Ti=0.02 TREATED
Cr=0.7 47 J @ - WELTON 780/IS 2062 E650
12 HT 690 0.16 0.35 1.2 0.015 0.03 1 0.5 0.54 570 690-820 17 200-220 Q&T HITEN JFE
V=0.08 20 °C BR/A
THERMOMEC
V=0.2, 40 J @ -
13 DOMEX 600 0.12 0.1 1.9 0.01 0.03 - - 600 650-820 16 185-235 HANICALLY IS 2062 E550 BR/A - RUKKI
Ti=0.15 20 °C
TREATED
V= 0.2 THERMOMEC
14 HS 800 0.1 0.3 1.8 0.005 0.03 - - Al=0.02 - 600 800 14 - 170-230 HANICALLY IS 2062 E650 BR/A - TATA STEEL
min TREATED
Cr=0.8, WELDOX 700/JFE WELTON
47 J @ -
15 HT 80 0.16 0.35 1.2 0.03 0.03 1.5 0.6 V=0.1, 0.57 690 784-931 16 224-266 Q&T 780/IS 2062 E650 - HITEN JFE
20 °C
B=0.006 BR/A/SUMITEN 780-NIPPON
Nb+V+Ti
WELDOX 30 J @ - IS 2062 E650 BR/A, OPTIM
16 0.2 0.6 1.6 0.01 0.02 2 0.7 =0.2 0.64 690 770-940 14 224-266 Q&T 10-130 IMPORTED
700 40 °C 700MC-RUKKI
Cr=0.7
HARDOX CR=1, 45 J @ - QUENCHED Nippon-AR 400/JFE
17 0.18 0.7 1.6 0.01 0.03 0.25 0.25 0.48 1000 1240 16 370-430 5-20 IMPORTED
400 B=0.004 40 °C (Q&T) EH400/Hardox 400-SSAB

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 53

 UT Acceptance Criteria
Attachment of mail of mr. Mahesh Tripathy dated 30.12.2010
As per Standard Specification For Straight-Beam Ultrasonic Examination of Plain and
Clad Steel Plates for Special application (ASTM UT A 578-1)

7. Acceptance Standard- Level 1

7.1 ) Any area where one or more discontinuities produce a continuous total loss of back reflection accompanied
by continuous indication on the same plane that cannot be encompassed within a circle whose diameter is 3
in.(75mm) or half of the plate thickness , whichever is greater, is unacceptable.

7.2 ) In addition, two or more discontinuities smaller than described in 7.1 shall be unacceptable unless separated by
minimum distance equal to the greatest diameter of the larger discontinuity or unless they may be collectively
encompassed by the circle described in 7.1.

e.g. For 7.1

D Discontinuit If the largest length of the single discontinuity is D (fig.1)
then:

1. if D <= 75mm then the plate is acceptable.

2. if D> 75mm then the plate is unacceptable.

Fig. 1

e.g. for 7.2

For two or more discontinuities where A<=75mm and C<=75mm:
A B Also suppose A>=C then:

Fig. 2 C 1. if B>= A then the plate is acceptable.

2. if B< A and A+B+C <=75mm then the plate is acceptable.
A- largest length of 1st discontinuity 3. if B< A and A+B+C > 75mm then the plate is unacceptable.
C- largest length of 2nd discontinuity
B- Smallest distance between the discontinuities

Cases of laminations:
1. ) For spot or single lamination 7.1 is applicable.

2. ) For cluster lamination 7.2 is applicable.

3. ) For laminations occurring at the edges of the cut plates:

a. Check the length of the lamination with UT(normal probe). If it is acceptable as per standard then use the plate otherwise
reject it.

b. After welding, if weld defect is found during UT (angle probe) of the joint, then gouge the weld.

c. Again Check the length of the lamination with UT(normal probe). If it is acceptable as per standard then reweld the joint.

d. After rewelding the lamination should be checked again for ascertaining that the lamination is within acceptable limit.

e. If at any stage(steel yard,cutting,fitting,welding etc.) the discontinuity(lamination,slag inclusion etc.) is found beyond
the acceptable limit then the plate stands rejected.

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 54

 Approved Steel Suppliers- THCM
In-coming Inspection plan for Trader parts in THCM- JSR
Checking Frequency
Checking
Description Manufacturer Sources (Trader) End Use Application Approved Sources (Detl. Metallurgical Checking Method Remarks
Agency
analyis)
MSL, ISMT, Imported Maruti Metal 1. 100% chemical Test As per Technical Delivery
Pipes & Steel Tubes Structural fabrication Yes
ISMT, MSL, Imported Sterlite Metals 2. 1 Sample @ Heat No Condition (TDC)
R. K. Enterprises
RSB 1 Sample @ Heat Chemical, Microstructure,
Square Bar SAIL (Billet) Structural fabrication Yes
PSPL Steel No/Lot Size Macro-etching & Hardness

India Industries
R. K. Enterprises
Pins, Shafts & gears, Fixtures 1 Sample @ Heat
Rounds India Forging Yes Chemica (C.E) & Hardness
etc No/Lot Size
India Industrial Enterprise
Shyam Steel R. K. Enterprises
Sterlite Metals 1. Chemical Composition
Construction, tacking & 2. Hardness
Angles & Channels Jindal Steel, Essar, JSW, SAIL, Maruti Metal Yes 1 Sample @ Heat No Details analysis is done
Fixturing 3. Microstructure
Local Manufacturers PSPL In-house for New Development
4. Inclusion rating
India Industrial components
PSPL
Tata Steel
TSPDL
SAIL SAIL
JSPL JSPL
JSPL, SAIL, Tata Steel Shree Krishna As per TDC
(1. Tensile Properties
JFE Garg Engineers
Steel Plates Heavy Structural fabrication Yes 1 Sample @20 Lot Size 2. Impact test (if required)
JIANYING XING CHENG Marubeni Itochu
3. Microstructure
Volestalpine(Imp) A. N. Source 4. Chemical Composition)
NLMK NLMK
NSSCM (Imp) OHMI(Imp)
JFE (Imp) Metal one (Imp)
ESSAR (Imp) Champak Steel

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 55

 Types of Defects & preventive action through OPL
Description : Cavity/Impression Marks are found on surface of the plates (8-100 mm thick). OPL has been
prepared for the training of the operator so that the defects can easily caught at plate stage & defects free
plates are supplied to HMS.

NOT OK OK

Process Details:
Cavity/Impression marks are found on plate surface--> Free from any surface defects
at complete plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 56

 OPL-2
Description : Bend/Camber/Waviness are found on surface of the plates (8-100 mm thick). OPL has been
prepared for the training of the operator so that the defects can easily caught at plate stage & defects free
plates are supplied to HMS.

NOT OK OK

No Bend -->OK

Bend up-to 6-15 mm

Process Details:
Bend/Camber/Waviness found on plate--> at complete No Bend/Camber found- OK
plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 57

 OPL-3
Description : Heavy Grinding Marks are found on surface of the plates (8-100 mm thick). OPL has been
prepared for the training of the operator so that the defects can easily caught at plate stage & defects free
plates are supplied to HMS.

NOT OK OK

Process Details:
Heavy Grinding marks are found on plate surface--> at Free from Grinding marks on plate
complete plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 58

 OPL-4
Description : Pit Marks are found on surface of the plates (8-100 mm thick). OPL has been prepared for the
training of the operator so that the defects can easily caught at plate stage & defects free plates are
supplied to HMS.

NOT OK OK

Process Details:
Heavy Pit marks are found on plate surface--> at No Pit marks are found on plate
complete plate Stage
| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 59
 OPL-5
Description : Notch/Rolling Marks are found on surface of the plates (8-100 mm thick). OPL has been
prepared for the training of the operator so that the defects can easily caught at plate stage & defects free
plates are supplied to HMS.

NOT OK OK

Process Details:
Notch/Rolling marks are found on plate surface--> at Free from Notch marks on plate
complete plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 60

 OPL-6
Description : Silver (Silvers—Surface ruptures somewhat similar in appearance to skin laminations, but
usually more prominent) defects found on surface of the plates (8-100 mm thick). OPL has been prepared for
the training of the operator so that the defects can easily caught at plate stage & defects free plates are
supplied to HMS.
NOT OK OK

Process Details:
Silver Defects found on plate surface--> at complete Free from Silver on surface
plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 61

 OPL-7
Description : Scabs(Elongated patches of loosened metal which have been rolled into the surfacer
defects)found on surface of the plates (8-100 mm thick). OPL has been prepared for the training of the
operator so that the defects can easily caught at plate stage & defects free plates are supplied to HMS.

NOT OK OK

Process Details:
Scab Defects found on plate surface--> at complete Free from Scab on surface
plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 62

 OPL-8
Description : Stress Crack defects found on surface of the plates (8-100 mm thick). OPL has been prepared
for the training of the operator so that the defects can easily caught at plate stage & defects free plates are
supplied to HMS.

NOT OK OK

Process Details:
Stress Crack Defects found on plate surface--> at Free from Stress Crack on surface
complete plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 63

 OPL-9
Description : Seams- Open, broken surface running in straight longitudinal lines caused by the presence of
oxides near the surface defects found on surface of the plates (8-100 mm thick). OPL has been prepared for
the training of the operator so that the defects can easily caught at plate stage & defects free plates are
supplied to HMS.

NOT OK OK

Process Details:
Seam Defects found on plate surface--> at complete Free from Seam on surface
plate Stage

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 64

 OPL-10
Description : Crack found on surface of the plates (8-100 mm thick). OPL has been prepared for the training
of the operator so that the defects can easily caught at plate stage & defects free plates are supplied to
HMS.

NOT OK OK

Process Details:
Crack found on plate surface--> at complete plate Stage Free from Crack on surface

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 65

 Thank u

| Tata Hitachi Construction Machinery Company Pvt. Ltd. | 2016 66