oo SOE MN Si(sisiist! _ adeae ee ee Cf CCE ff PLESSUMIFLAG 57221 ‘What are forging quality steels ? Forging quality stels are defined as those having following important metallurgical propertics. Good surface quality ii) Good internal quality iii) Fineand uniform austenitic grain size iv) Good response to heat treatment y) vi) Good cleanliness ‘These steels are widely used in auto, defence, railways, and various manufaecuring industries. Following are the major categories of Forging Quality Steels 2) Phin Carbon b) Carbon Manganese 6) Phin Chrome dd) Chrome~ Manganese Chrome Moly £) Chrome~ Nickel -Moly FORGING QUALITY STEELS The forging process Forging isa process of converting steel or metal baror billet into a designed shape at a higher strain rate. As per the temperature of forging it can be classified as under i) Hotforging —- normally perf ata temperature of around 1200°C. ii) Warm forging --- normally performed at a temperature of 650'-750" C ie. below the recrystalisation temperature depending on steel grade. iii) Cold forging -- Performed at room temperatwe without any heating. Due to high strain rates employed, the quality requirements of steels for forging application are critical. Also duc to the critical nature ofthe actual end. use forging quality steels demand a close control over che manufacturing process atal sages. ‘The main steps involved in the hot forging operation are as under. Step Equipment Employed Blankcutting operation: Cold saw or Cold shear Heating of the blank to forging temperature Oillorgas fired furnace / Induction heating Forging to the defined shape: Forginghammer (pneumatic ormechanica) /Forgingpress “Trimming ofthe forging lash: ‘Trimming press Cooling of the hot forged component. “Traysor baskets Premachining ofthe forged component: ‘Simple turning/facing or drilling machine “Machining of the final shape (CNC Machines Heat treatment like surface hardening, through hardeningete. icing carbonieiding, quenching tempting Final inspection: “Magnetic particle inspection machine/visual inspection after shor blasting Fitting into the engine / machine Asper the application ‘The above ae general steps employed in manufacturing ofa forging. Each type of forging component demands more specialised treatments necessary for imparting special properties based on the end application of the forging. EEsusnalezary FORGING QUALITY STEELS STEEL Some of the popular forging applications are as under Gears, Axles, Crankshafts, Connecting Rods, Pinions, Crown Wheels, Camshafts etc. Automobile industry isthe single largest user of forgings. Forgings are gencrally used in the transmission system ofan automobile, where large forces get transferred between different parts, hence they are of most vital importance Process route for manufacture of forging quality steels Keeping in view the critical metallurgical requirements of the forging quality steels, proper process of manufacture is employed to achieve the same in the steel produced. At every step, precautions have to be taken to maintain good quality. Salient features of the process : Stage Control Parameters Mini Blast Furnace & Direct Reduction Plane _| * Use of ight raw material free of undesirable tramp elements Blectic Are Furnace * Low uamp elements * Low phosphorous level + Cortecetapping temperature and low oxygen attapping. + No canyover sagafterappingintotheladie Ladle Refining Furnace + Cortectchemical composition + Low S” level through refining + Deoxidation and corcect alumi + Contect temperature for vacuul level. assing operation, Vacuum Degassing Operation + Reduction of gas level + Reduction of sulphus level * Proper slag metal reaction and mixing + Complete chemical and thermal homogeneity * Flotation ofnon metallicand absorption ofthe samen slag, CaSiand'S' Cored Wite injection + Tomodify inclusion morphology to facilitate thet flotation. * Toatain desirable inclusion composition o enhance the machinability Rolling * Close dimensional conteo + Atain good surface quality + Maintain finished rolling temperacurein close range to atain sore of less uniform rolled barhardness Inspection, Heat Teeatmencand Finishing | * Checking surface and remove all surface flaws “hecking internal quality of bars, * Metallurgical esting for grain size, non metalics, metallographic seructure decarburisation level as per customer requirements * Colour coding & stickers for identification and grade check for 100% bars + Bundling by trapping and storage fordespatch, + For guaranteeing quali as per technical requirements ofthe customerSTZAL Certification + Macro quality - As per ASTM-E-381 method + Non metallic levels As per ASTM E-45 method, ‘+ Grain size -As per ASTM E- 112 method In addition to these st + Step down test ‘+ Blue fracture test ‘+ Jominy hardenabiliy test + Mechanical tests like hardness, tensile test ete (on heat treated samples) + Impact test (on heat treated samples) * Any other special test as per the end use Typical forging quality steel grades. suunilez at FORGING QUALITY STEELS dard tests, following additional tests are performed as per customer requirements Classification 1s EN DIN AIS / SAE Is Plain Carbon. 15C8, 358. | EN-8, EN-9 K-15, CK-30_ | 1015, 1040 S45C, $48C 4508 EN32 8B K-45, C35 Pb K | 1045, 1050 S55C, S35C, C15 PK $530 Carbon Manganese | 47Mn6, EN-14 40 Mad, 1522, 1526, SMn 4304, 37Mn6 EN-I5 28Mn6 1541, 1524, 1041F | $Mn 435H Plain Chrome 40Cx4, EN-18 34Cr4, 37Cr4 | 5120, 5140 SCr 50Cr4 IN-207 41Ce4 5145, 5150 420H, SCr415 Chrome Manganese | 16Mn5Cr4 16MnCrs, r 20MnSCr5 20MnCx5 Chrome Moly 40CrIMo28 | EN-19 42CMo4 4140, 4145 SCM 415H 4150 SCM 42011 A182 F12.C) SCM 435H Chrome Nickel | 40CxNi6_ | EN-36A, 15CeNiG . P 16Ni3Cx2__ | EN-36B 18CeNi8, - Chrome Nickel Moly] 20NiC12Mo2 | EN-353, EN-354, | 16CrNi4 (Pb) | 4340, 8620 EN.355, EN-36C | 17CrNiMo6 8640, 8627 30CrNiMo3 | 8615, 8617 " 34CrNiMo6 20Cr Nid ‘Moly-Man 35Mn6Mo3_| EN-16D 35 Mn6Mo$ | EN-17 ————EE ‘ear &prade by ala Aerie, Ps 712 AGED, 776869, 9CR06505