Defects Atlas For Surface Defects On Cold Rolled Steel

DEFECTS ATLAS FOR SURFACE DEFECTS ON COLD ROLLED STEEL
http://www.iitk.ac.in/robotics/project_lists/sail/atlas.html#RUST
This page is primarily meant to introduce non-experts to some of the types of defects that arise in Cold
Rolling. The images used in these atlas were taken under varying lighting conditions at the very initial
phases of the Surface Defect Inspection Project.
List of Defects
 ANNEAL COLOR
 BLACK PATCH
 COIL BREAK
 HOLE
 INDENT
 IRON PARTICLES
 LAMINATION
 PARALLEL BAND IMPRESSION
 PINCH MARK
 ROLL MARK
 ROLLED IN SCALE
 RUPTURE
 RUST
 SCAB
 SCRATCH
 SLIVER
 SPM_II
 UNDER PICKLING
 WAVINESS
ANNEAL COLOR
Defect Description:
Coloured markings usually found along the coil edges in hood annealed material. The colour can vary from
light brown to deep blue.
Possible Causes:
 High oxygen content in the protective gas for annealing.
 Leakage in sand sealing base.
 Sudden drop of protective gas pressure causing sucking in of air.
Remedial Measures:
 Prevent Leakage during hood annealing.
 Ensure protective gas has low O2 content.
Possibilities of confusion with other defects:
They could be mistaken for prominent oil marks or light grease marks.
Attribute Value
Shop name Shearing Line
Movement and Shape Stationary, Flat
Type of Lighting Sodium
Light Distance infinity
Light Angle Centre/Mid
Camera Distance 5'
Camera Angle Left/Down
Flash Used Yes
Pic Type Color
Attribute Value
Camera Distance 7'
Camera Angle Centre/Down
Flash Used Yes
Pic Type B&W
Attribute Value
Shop name Tandem mill
Movement and Shape Stationary, Coil
Type of Lighting Portable Flourescent
Light Distance 7'
Light Angle Right/Mid
Camera Distance 5'
Camera Angle Centre/Mid
Flash Used No
Pic Type Color
Attribute Value
Shop name Steel Cutter
Type of Lighting Ambient
Light Distance Infinity
Light Angle Ambient Lighting
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Steel Cutter
Light Angle Ambient Lighting
Camera Distance 5'
Flash Used Yes
Pic Type Color
BLACK PATCH
Defect Description:
Dark black stains on the surface distributed either as bands/clusters. They are generally of irregular shape
and can vary from small to reasonably big sizes, can appear on both sides.
Possible Causes:
Oil/emulsion residues on the strip surface which get transformed to carbon residue durind hood annealing
Remedial Measures:
 Emulsion wiping after Tandem Mill air-jets.
 Degreasing of coil surface by Electrolytic cleaning line after Tandem Mill.
Dark and prominent black patches mistaken for grease marks.
Attribute Value
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 4'
Flash Used Yes
Pic Type BW
Attribute Value
Light Angle Ambient
Camera Distance 8'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Slitting Line
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
COIL BREAK
Defect Description:
Creases/Ridges, transverse to the rolling direction. Generally covers total width of the strip. It may also be
found near the edges with regular or irregular spacing. Formed during uncoiling of the strip after annealing.
Possible Causes:
 High yield point elongation particularly with low yield strength values.
 Higher bending stresses induced in strip due to smaller diameter of guide rolls (S-rolls) and greater
strip thickness.
Remedial Measures:
Increase speed of uncoiling at SPM, particularly for thicker guages.

Attribute Value
Camera Distance 5'
Flash Used Yes
Pic Type B&W
Attribute Value
Camera Distance 5'
Flash Used Yes
Pic Type B&W
HOLE
Defect Description:
Holes are discontinuities of the material extending from the top to the bottom. Generally, they have localized
presence on the strip surface and can be present randomly.
Size: Usually varies from 1 to 40 mm, sometimes even bigger.
Shape: Irregular.
Possible Causes:
 Seperation of Rolled in Scab/External Matter.
 Mechanical Damage prior to Colled Rolling leading to localized thinning and subsequent thinning
cold rolling.
 Blowholes/Coarse inclusions.
Remedial Measures:
 Proper scarfing of Slabs.
 Careful Handling of Coils Between hot and cold rolling.
 Improve steel cleanliness.
Attribute Value
Shop name Steel Cutters
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 8'
Camera Angle Right/Mid
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
INDENT
Defect Description:
Indentation (depressions) can be distributed at definite distances apart or irregularly throughout the length
and width of the stock.
Possible Causes:
These are mainly caused by damaged rolls, by proturbences on the rools ar rollers. The distance between
the periodically appearing defects often provides indications of origin and source.
Remedial Measures
 The work rolls should be safeguarded againt foreign matter which may roll in.
 Regular cleaning and inspection of the the work rolls and pinch rolls is required.
Possibilities of confusion:
Indentation can be mistaken for minute blistering and spilliness.
Attribute Value
Camera Distance 8'
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 8'
Camera Angle Down/Mid
Flash Used Yes
Pic Type B&W
Attribute Value
Light Angle Ambient
Camera Distance 5'
Camera Angle Down/Mid
Flash Used No
Pic Type B&W
IRON PARTICLES
Defect Description:
They are patches on the rolled surface, appearing as large number of minute iron particles spread over that
area. They largely occur in bands. the particles are strongly adhered to the surface, and amount to a highly
rough surface.
Possible Causes:
The mechanical wear of the sheet material due to friction results in minute iron particles, which are
transferred from the work rolls to the rolled surface.
Remedial Measures
Regular cleaning of the work rolls, transfer rolls and stretcher rolls.
Prominent iron-particles could be mistaken for fine dents.

Attribute Value
Camera Distance 5'
Flash Used No
Pic Type Color
Attribute Value
Camera Distance 5'
Flash Used Yes
Pic Type B&W
LAMINATION
Attribute Value
Shop name Lab
Movement and Shape Stationary, FLAT
Camera Distance 5'
Flash Used Yes
Pic Type Color
PARALLEL BAND IMPRESSION

Defect Description
Two pairs of continuous parallel lines observed on the strip surface along the rolling direction.
Gap between the lines:70mm
Gap between the bands:750mm(Centre to Centre).
Possible Causes:
Due to the prolonged usage, the back up rolls Tensioning Device which subsequently get transferred to the
strip surfaces.
Remedial Measures:
 Lift up the work rolls of the tensioning device in slitting lines.
 Change all the work rolls of the tensioning device.
Attribute Value
Shop name
Movement and Shape Stationary, FLAT
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name
Light Angle Center/Mid
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name
Camera Distance 5'
Flash Used Yes
Pic Type Color
PINCH MARK
Defect Description
Linear markings of single or periodic occurence diagonal to rolling direction
Possible Causes:
 Single results from lack of flatness causing pinch folding in the roll gap of SPM.
 Periodic roll marks results from transfer of pinch marks from work rolls of SPM
Remedial Measures:
Improve strip flatness at CRM Change SPM work rolls.
Possibilities of confusion with other defects
Although they are of characteristic identification, but they could be mistaken for pitting defects and those
due to rolled in matter.
Attribute Value
Shop name
Light Distance 5'
Light Angle Left/Down
Camera Distance 8'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name
Movement and Shape Stationary, coil
Light Distance 5'
Camera Distance 8'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name
Light Distance 5'
Camera Distance 8'
Flash Used Yes
Pic Type Color
Attribute Value
Camera Distance 5'
Flash Used Yes
Pic Type B&W
ROLL MARK
Defect Description:
Surface markings, generally depressions of various shapes attributable to defective work cell/pinch roll
surface.
Appearance:Smooth shinning patches.

Shape:Irregular
Occurance:Periodic on strip surface.Generally found on one side of the strip.
Possible Causes:
Welding of metallic pieces like detached slivers, scabs etc. on work roll/pinch roll surface.
Remedial Measures:
 Identify the rolls causing the defect by measuring the gap between the marks.
 Clear roll surface.
 Change rolls
They could be mistaken for minute blistering and spilliness
Attribute Value
Light Angle Ambient
Camera Distance 4'
Camera Angle Left/Mid
Flash Used Yes
Pic Type Color
Attribute Value
Type of Lighting portable Flourescent
Light Distance 5'
Camera Distance 3'
Camera Angle Camera/Mid
Flash Used Yes
Pic Type Color
ROLLED IN SCALE
Defect Description:
Other types of rolled in defects are marks in the surface caused by rolled in metallic or non-metallic foreign
bodies of varying shape and size. Largely, they could be identified as scales on the sheet surface
Occurence:
Rolled in defects are caused by foreign bodies imprinted in the stock during rolling.
Possibilities of Confusion:
Rolled in types of defects can be mistaken for identations when the rolled foreign body has been removed
from the defect area. Similar defects can also be caused in the subsequent processing plants by withdrawal
and straightening gear, for example by scale adhering to the rollers.
Attribute Value
Light Distance 5'
Camera Distance 4'
Flash Used Yes
Pic Type Color
Attribute Value
Light Distance 5'
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Distance 4'
Light Angle Centre/up
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Distance 4'
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name RDCIS Lab
Light Distance 10'
Light Angle Diffused Lighting
Camera Distance 5'
Flash Used Yes
Pic Type None
RUPTURE
Attribute Value
Light Distance 4'
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Distance 4'
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
RUST
Defect Description:
Patches of rust or randomly disturbed, normally of irregular shapes observed on both surfaces.
Colour: Reddish brown to black.
Possible causes:
 Presence of aqueous liquid on metal surface.
 Prolonged storage of coils between processing stages at CRM.
 High atmospheric humidity
Remedial Measures:
 Emulsion wiping after Tandem Rolling.
 Reduce coil storage time between processes.
 Arrest acid carry over from picking line by proper squeezing.
Attribute Value
Light Distance Ambient
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
SCAB
Attribute Value
Light Distance 20'
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Distance 20
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Lab
Type of Lighting Flourescent
Light Distance 10'
Camera Distance 5'
Flash Used Yes
Pic Type Color
SCRATCH
Defect Description:
Scratches are mechanical damages in width, depth and length at the surface. They are mostly parallel or at
right angles to the rolling direction. They may be slightly rolled over and seldom contain scale.
Possible Causes:
Primarily caused by friction between the stock and parts of the equipment due to relative movements.
Longitudinal defects occur during transportation of the stock by way of roller tables or during coiling and
decoiling. Transverse defects arise maily during transverse movements of the plates or when hot band coils
are discharged from the coiler. If the stock is damaged when hot, scale forms on the damaged areas and
can be rolled in subsequent passes. When scratch occurs, a sliver can be formed or there may be an
accumulation of the material to the side or at the end of the scratch.
Remedial Measures:
All measures, needed for reducing and limiting the friction between the stock and work rolls, such as
greasing, maintaining the alignment of work rolls etc. should be taken.
Scratch and grooves can be mistaken for seams and less frequently, for light scratches.
Attribute Value
Light Angle Ambient
Camera Distance 5'
Camera Angle Centre/Left
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Lab
Light Angle Left/Mid
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Lab
Light Distance 10'
Camera Distance 5'
Flash Used Yes
Pic Type B&W
Attribute Value
Shop name Lab
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name RDCIS Lab
Light Distance 5'
Camera Distance 5'
Flash Used Yes
Pic Type B&W
Attribute Value
Shop name Lab
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name RDCIS Lab
Type of Lighting Portable Flourescent
Light Distance 4'
Light Angle Centre/Up
Camera Distance 2'
Flash Used Yes
Pic Type Color
SLIVER
Defect Description:
Irregular flaky overlapping material with non-metallic inclusions or scale under it. It is found along the rolling
direction and can appear on both surfaces.Sometimes referred as Shell.
Possible Causes:
Slag or non metallic inclusion entrapment.
Remedial Measurements:
 Prevent slag carry over during tapping
 Use clean ingot moulds
 Proper scarfing of slabs
Attribute Value
Shop name Lab
Light Distance 10'
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Lab
Light Distance 10'
Camera Distance 5'
Flash Used Yes
Pic Type Color
SPM_II
Attribute Value
Light Angle Ambient
Camera Distance 10'
Flash Used No
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 10'
Flash Used No
Pic Type Color
UNDER PICKLING
Defect Description:
This defect is characterized irregular dark patches spread irregularly over the whole surface of the steel
sheet. The patches are finger like and angular in the form.
Possible Causes:
This defect is caused due to the imbalance between the composition of the acid and the time of reaction in
the Pickling Mill.
Remedial Measures:
This defect originates prior to the cold rolling mill, hence it could spoil the final rolled surface, it is important
to inspect the reaction time and the composition of the acidic vehicle in the Prickling Mill.
Attribute Value
Shop name Dispatch
Light Angle Ambient
Camera Distance 4'
Flash Used Yes
Pic Type Color
Attribute Value
Shop name Dispatch
Light Angle Ambient
Camera Distance 5'
Flash Used Yes
Pic Type Color
WAVINESS
Defect Description:
Cross ripples/undulations of varying magnitude appear along the long direction either at the edge or middle
of the strip/sheet. Centre buckles are located at the middle of strip, while edge waves appear at the edges.
Buckle Height: Mostly upto 9mm for precision levelled material.
Possible Causes:
 Mismatch of roll gap with in-comming strip crown leads to differencial elongation along the rolling
direction both at Hot & Cold rolling stage.
 Incorrect profile or positioning of support rollers.
 Contact with edge guides.
Remedial Measures:
 Reduction of waviness through precision leveller/stretch leveller.
 Control of waviness at both HSM and CRM by work roll bending and selective cooling.
Attribute Value
Camera Distance 5'
Flash Used Yes
Pic Type Color
Attribute Value
Light Angle Ambient
Camera Distance 10'
Camera Angle Right/Down
Flash Used Yes
Pic Type Color
Attribute Value
Shop name
Movement and Shape
Type of Lighting
Light Distance
Light Angle
Camera Distance
Camera Angle
Flash Used
Pic Type

Defects Atlas For Surface Defects On Cold Rolled Steel

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Defects Atlas For Surface Defects On Cold Rolled Steel

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DEFECTS ATLAS FOR SURFACE DEFECTS ON COLD ROLLED STEEL

 PARALLEL BAND IMPRESSION

 High oxygen content in the protective gas for annealing.

 Leakage in sand sealing base.

 Sudden drop of protective gas pressure causing sucking in of air.

 Prevent Leakage during hood annealing.

 Ensure protective gas has low O2 content.

Possibilities of confusion with other defects:

 Emulsion wiping after Tandem Mill air-jets.

 Degreasing of coil surface by Electrolytic cleaning line after Tandem Mill.

Possibilities of confusion with other defects:

Dark and prominent black patches mistaken for grease marks.

Increase speed of uncoiling at SPM, particularly for thicker guages.

Size: Usually varies from 1 to 40 mm, sometimes even bigger.

 Seperation of Rolled in Scab/External Matter.

 Proper scarfing of Slabs.

 Careful Handling of Coils Between hot and cold rolling.

 Improve steel cleanliness.

Indentation can be mistaken for minute blistering and spilliness.

Prominent iron-particles could be mistaken for fine dents.

PARALLEL BAND IMPRESSION

 Lift up the work rolls of the tensioning device in slitting lines.

 Change all the work rolls of the tensioning device.

Linear markings of single or periodic occurence diagonal to rolling direction

Improve strip flatness at CRM Change SPM work rolls.

Possibilities of confusion with other defects

Appearance:Smooth shinning patches.

 Clear roll surface.

Possibilities of confusion with other defects:

They could be mistaken for minute blistering and spilliness

 Presence of aqueous liquid on metal surface.

 Prolonged storage of coils between processing stages at CRM.

 High atmospheric humidity

 Emulsion wiping after Tandem Rolling.

 Reduce coil storage time between processes.

 Arrest acid carry over from picking line by proper squeezing.

Slag or non metallic inclusion entrapment.

 Prevent slag carry over during tapping

 Use clean ingot moulds

 Proper scarfing of slabs

 Incorrect profile or positioning of support rollers.

 Contact with edge guides.

 Reduction of waviness through precision leveller/stretch leveller.

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