1.

75 % NICKEL- CHROMIUM- MOLYBDENUM STEEL

FORCINGS FOR CASE HARDENING

FOR INTERNAL USE ONLY

REMOVE THIS PREFACE BEFORE ISSUE TO SUPPLIERS

Comparable Standards:

1. INDIAN : IS::4432-1988
Gr:15Ni7Cr4Mo2

2. BRITISH : BS: 970 Part 1-1996

Gr: 820 M 17

Suggested/Probable Suppliers and Grades:

Refer plant vendors list.

User Plant References:

V

1.BHOPAL : BP 19399
 1.75 % NICKEL- CHROMIUM- MOLYBDENUM STEEL
FORCINGS FOR CASE HARDENING

1.0 GENERAL:

This specification governs the quality requirements of 1.75% Nickel -Chromium- Molybdenum
Steel Forgings for Case Hardening.

NOTE:

The manufacturer MUST confirm in writing at the time of submitting his offer against BHEL
tender of this specification, clearly bringing out deviations, if any. Offers without such
confirmation will NOT be considered.

2.0 APPLICATION:

For the manufacture of gear wheels and pinions for traction machines.

3.0 CONDITION OF DELIVERY:

Forgings shall be homogenized at 900 - 930° C.

Forgings shall be supplied in the normalised and tempered / sub-critical annealed condition.

Proof machining of the forgings shall be carried out unless otherwise specified in BHEL
order / drawing.

4.0 COMPLIANCE WITH NATIONAL STANDARDS:

The material shall comply with the following National standards and also meet the
requirements of this specification.

IS::4432 -1988 : Specification for case hardening steels

Gr 15Ni7Cr4Mo2

BS: 970 Part 1-1996 : Wrought Steel for Mechanical

Gr: 820 M 17
5.0 DIMENSIONS AND TOLERANCES:

Forgings shall be supplied to the dimensions and tolerances stated on BHEL order / drawing.

6.0 MANUFACTURE:

Steel used for ingots shall be fully killed and homogeneous. Ingots shall be adequately
cropped so as to be free from pipe, segregation and other harmful defects.

The discard from top and bottom of the ingot must not be less than 15% of the weight of
balance of ingot. The correct grain size as called for in, clause 14 of this specification, after
forging and heat treatment. The forgings shall not be manufactured from continuously cast
blooms / billets / bars.

The forging ratio shall be 4:1 minimum from ingot to bloom / billet / bar and 4:1 minimum from
bloom billet / bar to blank stage for gear wheel blanks and 2.5 :1 minimum for pinion blanks.

The pinion blanks shall be forged by the method of upset forging.

The gear wheel forgings shall be made by close die forging by process of upset forging,
followed by peripheral forging under a power hammer or press. The forging and rolling process
shall be performed in such a manner that the central axis of the bloom coincides with the axis ol
the gear wheel.

NOTE:
' . - " - , " . • ' - " ' " -v" t '•"•*- - ; " ' '
i) The manufacturer shall give a certificate to the effect that the initial bar stock has been
made from ingot having at least four times cross- sectional area. Also source of
manufacture of bloom / bar stock must be mentioned in the certificate.
!
ji. .•
ii) Details of product analysis, details of manufacture including method of forging with
stage wise sketches, dimensions and forging reduction ratios, stage wise inspection
plans, shall be submitted at the time of his offer for BHEL'S approval.

7.0 FREEDOM FROM DEFECTS:

The forging shall be free from defects, such as cracks'fold .flakes, seams, segregations,
nonmetallic inclusions and other injurious defects which may affect the utility of the forging.
The internal material shall be homogeneous.
8.0 CHEMICAL COMPOSITION:

8.1 The melt analysis of the steel and permissible variation in the composition of the forgings from
the melt analysis shall be as specified below:

Element Composition "Permissible

deviation in melt analysis
% Min % Max.
---••-••-"•••"••"•—•--•••—"•-••"•-•"•"•••«——•-•-—--——-•——•-•.-••-.—-.-••-•---••—•••••••.•-———--——————————»»•————

Carbon 0.14 0.20 ± 0.01

Silicon** 0.15 0.35 ± 0.03
Manganese 0.60 0.90 ± 0.04
Nickel 1.60 2.00 ± 0.05
Chromium 0.80 1.20 ± 0.04
Molybdenum 0.10 0.20 ± 0.02
Sulphur - 0.035 + 0.004
Phosphorus - 0.030 + 0.004

NOTE:

* + or - means that in one cast, the deviation may occur over the upper value OR under the
lower value
specified in the cast analysis but not both at the same time.

** When the steel is silicon killed, the minimum silicon killed content shall not be less than
0.15% and the negative permissible deviation shall not be applicable.

8.2 Elements not specified in the above table shall not be added to the steel except where agreed
to, other than for the purpose of finishing the heat and shall not exceed the following limits:

ELEMENT Max %.

Copper 0.25

Vanadium 0.05

9.0 HEAT TREATMENT:

Forgings shall be homogenised at 900 - 930 ° C.

Forgings shall be normalised at 860 to 880 ° C and air-cooled .

Tempered / sub-critical annealed at 650 to 700 ° C.

Test pieces shall also be heat-treated alongwith forgings they represent.

10.0 TEST SAMPLES (FOR NEW VENDORS ONLY):

10.1 Samples for Approval:

Two numbers of longitudinal test samples (25 mm X 30 mm) machined from duly forged test
bar shall be provided for check test of chemical composition at BHEL.

10.2 Samples with Consignment:

Four separately forged longitudinal test samples, (25 mm dia and 610 mm long ) per batch of
50 numbers or part thereof, machined from duly forged test bar, having similar reduction ratio
and heat treatment as the forging it represents, shall be provided per heat for check testing at
BHEL along with the forgings.

11.0 HARDNESS AS RECEIVED:

The forgings when tested in accordance with IS: 1500 shall show a hardness value of
170-220 HB.

12.0 RESPONSE TO HEAT TREATMENT:

Samples after blank carburizing and single quench heat treatment, as detailed below shall
show the mechanical properties given in clause 13 of this specification.

Blank Carburising : 880-930° C (For I hour, minimum.)

Single Quench Temperature : 820-840° C

Quenching Agent : Oil

Tempering temperature : 180-200°C.

13.0 MECHANICAL PROPERTIES:

Test pieces after heat treatment as detailed in Clause 12 of this specification, shall show the
properties given below:

13.1 • Tensile:

When tested to IS: 1608, test pieces shall show the following values:

Tensile strength : 1160 N/mm2, minimum

Elongation : 8%, minimum

on 5.65 So gauge length
13.2 Charov Impact Value (ISO-V) :

When tested in accordance with IS: 1757, the test pieces shall show an average Charpy impact
value of 22 Joules, minimum over 3 test values while the lowest value of the 3 values being not
less than two third the average value obtained. However, all the three values shall be reported.

14.0 METALLOGRAPHIC EXAMINATION:

14.1 For Bar Stock:

One bar stock shall be cut in the presence of Inspecting Agency and macro tests shall be done
on the same to ensure that sufficient working has been done on the ingot to obtain the bar
stock.

14.2 For Forged Blank:

14.2.1 Microstructure:

The microstructure shall be uniform without any carbon segregation. Banded structure upto 50
microns width is permissible.

The austenitic grain size, when tested in accordance with ASTM E 112 shall be in the range of
5 to 8 or finer at 100 X.

14.2.2. Macroetch Test (New vendors):

The macroetch examination shall be done as per ASTM E 381 (Method of Macroetch Testing
And Inspection of. steel Forgings). The macroetched sections shall reveal satisfactory flow line
pattern right upto the centre of the forged blank.

NOTE: A sketch / photograph of Macrograin flow pattern shall be submitted, alongwith the offer
for BHEL'S approval at the time of establishment of new supplier / component.

14.3 Inclusion Rating:

Inclusion rating of the steel shall be determined in accordance with ASTM E 45. The worst
field of each inclusion from the specimen shall be recorded as a rating for the specification.
The inclusion rating shall not exceed 2.0A, 2.0B, 2.0C and 2.0 D (Both thin and heavy series)
as ASTM E 45.

15.0 ULTRASONIC TEST:

Pinion and gear forgings shall be ultrasonically tested on the rim portion in accordance with
BHEL standard AA 085 01 18, Ultrasonic Testing - Classification and Acceptance Standard for
Steel Forgings, Billets and Bloom , and shall comply with Category - 2 of the acceptance
standards specified therein.
ANNEXURE-I; RECOMMENDED TEST CERTIFICATE FORMAT FOR FORCINGS

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