KALYANI

DRIVING INNOVATION
THE GROUP
KALYANI GROUP
INTRODUCTION

Established in mid 1960s, we are an Indian multi-national with advanced technology,

engineering & manufacturing capability across critical sectors such as Engineering Steel,
Automotive, Industrial, Renewable Energy, Urban Infrastructure and Specialty Chemicals.

As a Group, we have an annual turnover of over $ 3 Billion and market capitalization of

our listed entities stand at approximately $ 4 Billion.

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 World’s largest forging unit - Automotive, Defence, Railways, Energy,
Bharat Forge Ltd
Marine.

Bharat Forge Kilsta

Bharat Forge CDP Europe based forging units - Heavy Trucks, Tool & Die, Industrial Machinery
BF Aluminiumtechnik
KALYANI GROUP

Kalyani Steels Low & Medium Alloy Steels (through Blast Furnace route)
COMPANIES

Kalyani Carpenter
Medium & High Alloy Steels (through Electric Arc Furnace route)
Special Steels

Kalyani Technoforge Automotive Forging

Automotive Axles Ltd Axles Manufacturer with technology support from Meritor USA

Kenersys GmbH Wind Energy

Hikal Speciality Chemicals

Kalyani Global Urban Infrastructure

Kalyani Lemmerz Automotive Wheels

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 Largest Forging Company Largest Exporter of Forgings
in the world From India

Today, Kalyani Group is the

market leader in all respective
business segments
KALYANI GROUP

Leading Engineering Steel Leader in Axle Aggregates

HIGHLIGHTS

manufacturer in India in India

JV with Meritor JV with Maxion Wheels

[Automotive Axles Ltd] [Kalyani Lemmerz]

The Group has Joint Ventures with

World Leaders in respective fields

JV with Alstom JV with Carpenter Technology

[Alstom Bharat Forge] [Kalyani Carpenter Special Steels]

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 Kalyani Centre for Technology and Innovation (KCTI)
RESEARCH & DEVELOPMENT
Established in Pune with an investment of USD 14 Million.
Recognized by Department of Scientific & Industrial Research (DSIR), Government of
India.
KALYANI GROUP

KCTI augments group’s employee knowledge and skills through three areas:
— Advanced Technical training
— Advanced Academic Courses
— Research and Development

Activities at KCTI

— Modelling and Simulation

— Performance Testing and Validation
— Investigation and Failure Analysis
— Training and Development
— Partnership with Premiere Academic Institutes

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INTERNATIONAL PRESENCE
KALYANI GROUP

USA GERMANY INDIA

Upcoming Manufacturing
facility for Auto Components
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Automotive Components Engineering Steel
Aluminium Forgings Automotive Components
Industrial Equipment Energy
Wind Energy Infrastructure
Chemicals
SWEDEN
Automotive Components
 Our Core Objective
is to be committed to listening and responding to the needs of
our customers, associates and business partners,
CORE OBJECTIVE
KALYANI GROUP

and honoring their individual value.

To be committed to an entrepreneurial spirit

that fuels the growth of our companies

and increases shareholder value.

B N Kalyani

Group Chairman

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KALYANI STEELS
KALYANI STEELS
INTRODUCTION

Kalyani Steels was established in 1973 as a part of Kalyani Group.

Today, we are a prominent Indian manufacturer of Forging and Engineering quality

carbon & alloy steels using the Blast Furnace route, with a sharp focus on Quality
and a strong R&D backup.

With four decades of experience in Alloy Steels, we have acquired for ourselves the
status of preferred supplier for leading national and international OEMs in the space
of Automotive, Engineering, Energy, Aluminium Smelting, Defence and so on.
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APPLICATIONS
INDUSTRY SEGMENTS AUTOMOTIVE FORGINGS

CONSTRUCTION EQUIPMENT
APPLICATIONS

BEARINGS

SEAMLESS TUBES

ALUMINIUM SMELTING

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 STEEL BARS FORGING MACHINING
APPLICATIONS
AUTOMOTIVE

A preferred supplier of Forging Quality steel for a variety of Automotive Applications –

crankshaft, camshaft, connecting rods, gears, transmission shafts, axle beams, steering
knuckles and so on. Our steel finds use in Commercial Vehicles, Passenger Cars as well
Farm and Construction Equipment.

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 We manufacture a range of grades for
Crankshaft, Camshaft, Connecting Rods, Piston
Pins, Diesel Injection Rails and other critical
components of automotive engines.
– Improved Toughness – fine grain material
(6+)
AUTOMOTIVE : ENGINE
APPLICATIONS

– Improved Fatigue – clean steel

– Consistent hardening response and better
distortion control – close band Jominy
– Use of Micro-Alloyed Steel

Grades

EN18, EN19, SAE4140, 42CrMo4, SCM440, EN19B,

39Cr5, SAE1541, S48C, SAE1548, CMA-1, 40CrMo4H,
2CrMo, C38+N2, 38MnSiVS5, 38MnS6, 46Mn5, 38MnSiVS5,
C70S6, S48CS1

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 Our case hardening and micro-alloyed grades
find usage in Gears, Input Shaft, Output Shaft
and other transmission components.
AUTOMOTIVE : TRANSMMISSION

– Improved Toughness – fine grain material

(6+)
– Improved Bending Fatigue - reduced internal
APPLICATIONS

oxidation (controlled Si Levels, optimized S

levels)
– Improved Fatigue – clean steel
– Consistent surface hardening response and
low distortion upon quenching – close band
Jominy
– Shortened Carburizing time – high
temperature carburizing (optimized Al:N
Grades ratio)

SAE8620, SAE8625, SAE8627, ETN22, ETN25, ETN27, 16MnCr5,

20MnCr5, SCM 420, SAE4120, EN353, EN354, SAE8822H,
815M17

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AUTOMOTIVE : AXLE PARTS
APPLICATIONS

Our steel bears the load in the Axles Beams

and Shafts of Light, Medium and Heavy
Commercial Vehicles, as well as that of Farm
and Construction Equipment

Grades

SAE1045M, 709M40, SAES322, 40Cr4C, 41CrS4, S58C, SS4510/HMnTi,

30MnVS6+Ti, EN15A, SAE1041, SAE1541

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 Our steels that go into Bearings have high stability to withstand fatigue, distortion,
speed and temperature

We produce Case Carburizing, Through Hardening and Hub Bearing grades

– Improved Toughness : Fine Grain Material (6+)

– Improved Fatigue – clean steel (low O2, Ti, other
APPLICATIONS

tramp elements)
– Consistent surface hardening response.
BEARINGS

– Low distortion upon quenching (close band

Jominy)
– Shortened Carburizing time – high temperature
carburizing (optimized Al:N ratio)
– Low Decarb – gas fired reheating (homogenous
heating)
– Low Banding and Carbide Segregation
– Good roller contact fatigue
Grades

Case Carburizing: SAE8620, 20MnCr5, 5120, 17CrNi3

Through Hardening: SAE52100, 100Cr6, SUJ2, SUJ3
Hub Bearing: S53C, CF53, CF55, C56E2
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SEAMLESS TUBES
APPLICATIONS

We are a leading producer of round casts for supply to manufacturers of seamless

tubes. These are for usage in Oil & Gas industries and High Pressure Critical Boilers.
Our plant is approved by Indian Boiler Regulation as
– Well-known steel maker for supply of boiler grade quality steel.
– Creep resistant steel grades like SA213-T11 & SA213-T22, for use at elevated
temperatures.

We offer range of carbon alloy steel as per major international specifications such as
SAE, BS, DIN, JIS and API.
Grades

SA210 Gr.A1, SA210 Gr.C, SA106 Gr.C , SA192, T11, T12, T22, BS3059
Gr.440, SAE1537(V), SAE1010, SAE1018

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 We offer Low Electrical Resistivity (LER) steel, developed specifically for primary
aluminium industry to reduce level of electrical resistance within the steel during the
electrolysis process of aluminium smelting.
ALUMINIUM SMELTING

LER Steel was developed after extensive tests with large numbers of steel grades at
the premiere technological & academic institute – IIT Mumbai – as a product that
offers considerable reduction in electrical resistance under elevated temperatures up
APPLICATIONS

to 800° Celsius, over other grades commonly used for this application.

We can supply machined and drilled cathode bars for direct use as per technical
drawings provided by the customer.

Grades

LER, ASTM-A36, ASTM-A663Gr.60

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PRODUCT RANGE
 AISI / SAE DIN B.S. JIS

1010 CK10 EN2A S10C

1015 CK15 EN32B S15C
1025 CK25 EN3B S25C
Carbon Steel 1035 CK35 EN8, EN8A S35C
1045 CK45 EN43B S45C
1055 CK55 EN9 S55C
1065 CK65 EN43D S58C
GRADE FAMILIES
PRODUCT RANGE

1541 28Mn6 EN15 SMn420H

Carbon – Manganese - 40Mn4 - SMn433H
1137, 1141 - EN15AM SMn433H, SUM41
5130 34Cr4 EN18A, EN18C SCR435
Chrome Steel
5140 41Cr4 SCR440
1541 16MnCr5 - SCR415, SUM420
Chrome – Manganese
- 20MnCr5 - -
Chrome – Nickel 1320 15CrNiM06 EN352 -
4130 25CrM04 EN19C SCM440H
Chrome – Moly 4135 34CrM04 - SCM435, SCM420
4140 42CrM04 - -
8620 - EN353, EN354 SNCM420H
Chrome – Nickel – Moly
4320 17CrNiM06 EN36C, EN -
(Low Carbon)
- - 361, 362, 363 -
Chrome – Nickel – Moly SNCM431, SNCM439,
4340 - EN24
(Medium Carbon) SNCM447
SAE52100 100Cr6 EN31 SUJ1, SUJ2 etc
Bearing Steel
SAE5160 - EN45A SUP6, SUP9, SUP11

Above are the Grade Families and some grades that we commonly produce.
In addition, we regularly undertake ‘New Product Development’ initiatives jointly with
our customers to develop tailor-made / application-specific grades.
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 Carbon, High Carbon, C-Mn, C-Mn-Si, C-Mn-Cr, Cr, Cr-Mn, Cr-Mo,
Forging Quality
Cr-Mo-B, Cr-V, Cr-W, Mn, Mn-N2, Mo, Ni-Cr, Ni-Cr-Mo, Micro Alloyed

Categories
ASTM-A213-T11/T12, SA210Gr.A1/C, SA192, SA106Gr.C, SAE1010, SAE4042, MSL-
For Seamless Tube
I/IA/II/IV/7/8, BS3059, Gr440, SAE1537(V)
APPLICATION & SIZE RANGE

For Bearings SAE52100, 100Cr6, SUJ2/3, CF53, CF55, C56E2, 20MnCr5, 5120, 17CrNi3
PRODUCT RANGE

For Cathode Bar ASTM-A36, ASTM-A663, Gr60, LER, SAE1006/8

Cast Rounds 160 Dia, 200 Dia, 220Dia

Size Range (mm)

Cast Billets 125 x 125, 160 x 160, 200 x 200, 210 x 230, 240 x 280

36, 38, 40, 42, 45, 48, 50, 52, 53, 54, 55, 56, 58, 60, 62, 63, 65, 66, 68, 70, 72, 73,
Rolled Rounds (DIA)
75, 80, 83, 85, 88, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135

45, 55, 60, 63, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 122, 125, 130,
Rolled Squares (RCS)
140, 160, 180

Rolled Flats 160x70, 180x80, 160x140, 170x130, 170 x 140, 140x100, 150x100, 160x100

We can roll smaller sections (down to 5mm dia) in our alternative facilities within Kalyani
Group. We can also develop any intermediate size suited for customer’s application
based on business volume and potential.
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 Soft
Annealed
ANNEALING Isothermal
Black Bars
Spheroidized

Annealed
Bright Bars
VALUE ADDED PRODUCTS
PRODUCT RANGE

HOT ROLLED BARS

As Rolled
PEELING
Bright Bars

Heat Treated
Bright Bars

Hard & Temper

HEAT Air
TREATMENT Quench & Heat Treated
Water
Temper Black Bars
Oil

Post Rolling Value Addition Finished Goods

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STEELMAKING
QUALITY ASPECTS
STEELMAKING

QUALITY POLICY

We are committed to improve Manufacturing Process & Products

on continual basis
through
effective Quality Management Systems
for
achieving Customer Satisfaction

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 Phosphorus ≤ 0.015%
Sulphur ≤ 0.010 % in Seamless Tube & CHQ grades
Inclusion Level - Heavy Thin
Oxides 0.5 1.5
QUALITY ASPECTS

Aluminates Nil Nil

Silicates Nil 0.5
STEELMAKING

Oxygen Level -
Case Carburizing Grades 15 ppm max
Through Hardening Grades 15 ppm max
Ball Bearing Grades 10 ppm max
Hydrogen level < 2.0 ppm
Banding Within Acceptable Limits
Decarb 0.3mm
Streaks in Blue Facture Test Nil
Streaks in Step Down Test Nil
Narrow Range of Chemical Composition
Four Point Range of Hardenability

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 Mini Blast Furnace - 3 Nos (250m3x2 + 350m3x1)

Manufacturing Facilities
Energy Optimizing Furnace - 50 MT
Ladle Furnace - 50 MT x 2
Vacuum Degassing Unit - 50 MT x 2
Bloom Caster - Three Stands
Billet Caster - Three Stands
STEELMAKING

Blooming Mill - Reversible Type

FACILITIES

H.V. Mill - Six Stands

Electron emission spectrometers Pneumatic sample carrier.

Oxygen, Nitrogen & Hydrogen Analyzer Jominy hardenability.
Computerized Brinnel Hardness Tester C & S Analyzer.
Testing Facilities

Inverted Metallurgical Microscope. Forging Hammer.

Digital Rockwell Hardness Tester XRF
BHN & Rockwell hardness tester. Image Analyzer
MPI sample testing facilities. Mobile spectrometer
Ultrasonic testing machine. Brugger Test Equipment
Universal testing machine. Auto UST (Phase Array)
Hydrogen Analyzer Auto MFL inspection line
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 Automatic UST (Phase Array) Inspection Line
(20 - 130 mm round & 45 – 130 RCS)
Equipment Type Ultrasonic Testing Machine (Phase Array)
Make Olympus NDT , Canada
Round bars – 15 mm to 130mmØ & 45 – 130 mm RCS
Size
Length - 2.5 meters and more
Test Frequency 5 MHz
Each element size - 0.6 to 0.8mm,
Probe size
Total 128elements in each probe.
STEELMAKING

0.5 – 1.5 meters/sec - for SDH method

Speed
0.1 - 0.5 meters/sec - for FBH method
FACILITIES

SDH - 0.5 (capability down to 0.3mm)

Defect detection Sensitivity
FBH - 0.7 to 1.5mm

Automatic MFL Inspection Line

(Round Bar, 20 - 130 mm)
Equipment Type Magnetic Leakage Flux
Make Pruftechnik NDT GmbH
20 mm to 130 mm diameter
Size
length up to 6meter
Speed Up to 2.4 m/sec max
Frequency 7KHz (Typically 6KHz)
No. of Testing Channels 8 Channel
Depth – 0.30mm - in hot rolled black bar (capability down to
Defect detection Sensitivity 0.15mm)
Depth – 0.10mm - in peeled bar

All material inspected through above are Shot blasted and Machine Straightened
with 0.2mm/meter (0.2%) straightness [Capability up to 0.1mm/meter]
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 Coke Iron Ore Sinter Fluxes Ore Fines /
Sludge / Mill Scale

INPUT
Pre heated Air
STEELMAKING
P R O C E S S 1/2

WASTE RECYCLING
Stove
Blast Furnace Blast Furnace Gas
IRON MAKING

Captive Power Plant

Hot Metal Slag
& Billet re-heating

Cement Plant

To Steel Making

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 From Iron Making

Air Separation Plant

INPUT
Hot Metal Mill Return Oxygen

Ferro Alloys Fluxes Argon/ Nitrogen

STEELMAKING
P R O C E S S 2/2

EOF

BAR ROLLING
Bloom & billet Reheating
STEEL MAKING

Ladle Refining

Roughing & Rolling Mill

Vacuum Degassing

Continuous casting

UST / Surface Inspection

Bloom & Billet

Marking / Storage

CUSTOMER & Storage /Dispatch Marking / Bundling / Packing

STOCKYARD

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CERTIFICATIONS
STEELMAKING

ISO 9001 : 2000

ISO 14001 : 2004

ISO/TS 16949 : 2009

OHSAS 18001 : 2007

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WHY KALYANI
 Why Kalyani Steels ?

Because our customers agree we are good at

WHY KALYANI STEELS

what we do

 Four decades of experience in Forging and Engineering Quality Steels.

 Approved by Major International OEMs and Tier-1 ancillaries.

 Global Reach through Bharat Forge (group company).

 Specialized in Steel for Critical Components – Engine, Transmission, Bearings, Boilers.

 Specialized in Micro-Alloyed Grades.

 Capability to manufacture more than 600 different steel grades.

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 Why Kalyani Steels ?

Because we can do a lot more for you

WHY KALYANI STEELS

 Can produce Reliable and Consistent quality of clean steel

— Produced from Iron Ore through Blast Furnace route.
— Low gas elements, Low tramp elements = Superior Steel.
— Advanced Testing Facilities

 Can develop Tailor-Made products for special applications

— In-house R&D facilities – prototyping, simulation, testing.
— In-house value addition facilities – annealing, heat treatment, peeling.
— Cross Functional Teams for new product development.

 Can support custom requirements

— Small quantities (50MT multiples), staggered deliveries, special packaging.
— Adept Logistics partners for overseas deliveries.

 Can produce any grade of steel (low/medium alloy, micro-alloyed) that is produced
commercially anywhere in the world.
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PHILOSOPHY

“ To use our specialized skills and innovative technology to contribute to the

welfare of the society. It is our intention to grow along with our employees and to aid and
encourage them to participate in our Goals in order that they realize their full potential.

Our prosperity is linked to the prosperity of our customers. ”

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CONTACT US

CORPORATE OFFICE
Pune, Maharashtra
India
T : 0091 020 6621 5000
F : 0091 020 2682 1124
W : www.kalyanisteels.com

MANUFACTURING FACILITY
Hospet, Karnataka
India

NORTH
Ajit Yadav
E : ajit.yadav@kalyanisteels.com

WEST
Arvind Sangamnerkar
E : arvind.sangamnerkar@kalyanisteels.com

SOUTH
Kush Jeevan Deep
E : kush.jeevandeep@kalyanisteels.com

EXPORTS
Vilas Patil
E : vilaspatil@kalyanisteels.com
Saikat Sarkar
E : saikat.sarkar@kalyanisteels.com