WCS 15 - Rev 4 Updations-15.02.2016 - Final Uploaded To DMS

Doc. No.
: WCS-015
Rev. : 04
COMPANY STANDARD Date : 15.02.2016
MATERIAL SPECIFICATION
Pages : 1 of 9
1st Issue date : 02.05.1994
Title: Medium Carbon Steel for direct Hardening & Tempering
1. Scope
Section A: This standard covers the acceptance norms for steels designated as 45C8 IS 5517 intended for
hardening and tempering used for manufacturing of piston rods for hydraulic cylinders.
Section B: This standard covers the acceptance norms for steels designated as 45C8 IS 5517 intended for
manufacturing the components (except piston rods) as per WIPRO drawings.
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Other equivalent international standards given below for reference-
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08
Japanese S45C as per JIS G4051 US SAE 1045
ISO C45 as per ISO 683-1 BS 080M46
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EN C45E as per EN 10083-2 DIN CK45
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ASTM 1045 as per ASTM A29 Swedish SS1672
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Note: Refer Clause#6 to know the applicability matrix for the Section A & Section B of the above mentioned scope.
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2. Requirements
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This material shall meet all the requirements of ISO 683-1 or IS 5517 as regards the manufacturing, except as
modified herein to describe the specific acceptance criteria adopted by Wipro.
Note: Words “shall, should, must” in this standard means “to be applied by all means”
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2.1 General
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a. Steel shall be made through, BOS/ EAF - LRF (With Argon purging) - Vacuum degassing - Continuous
casting (with AMLC, EMS) / Ingot route – Rolling.
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b. The steel shall have been fully killed (Aluminum / Aluminum Silicon (AlSi) shall be used as a Grain refiner)
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and must have undergone a minimum reduction ratio 6:1 unless otherwise specified separately.
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c. Calcium is not permitted to use as a de-oxidizing agent in steel making.

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2.2 Chemical Composition

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Section A : Section B : Permissible deviation

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Elements Symbol
Percentage Percentage in the check analysis
Carbon C 0.44 ~ 0.47 0.42 ~ 0.48 0.03 ~ 0.05
Manganese Mn 0.75 ~ 0.90 0.70 ~ 0.90 ± 0.04
Chromium Cr 0.10 ~ 0.20 0.10 ~ 0.20 ± 0.05
Silicon Si 0.15 ~ 0.35 0.15 ~ 0.35 0.02 ~ 0.03
Phosphorous P 0.030 Max 0.030 Max +0.01
Sulphur S 0.035 Max 0.035 Max +0.01
Aluminum Al* 0.015 ~ 0.035 0.040 Max -
Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

Wipro Infrastructure Engineering
Revised by : (A division of Wipro Enterprises (P) Ltd) Reviewed & Approved By:
Praveen Kumar GA/Dharmapal HB Bangalore, India Prasad N / Ganeswara Rao V
Doc. No. : WCS-015
Rev. : 04
Pages : 2 of 9
For the purpose of finishing the heat, unless otherwise specified, the following elements may be added up to a
total (Cr + Ni + Mo + Cu +V) of 0.80%, but individually not exceeding the limit specified below. It is applicable
for Section A & Section B.
Percentage Trace Percentage

Element Symbol Symbol
(%) elements (%)
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Nickel Ni 0.20 max. Zirconium Zr 0.02 max.
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Chromium + Nickel Cr + Ni 0.35 max. Niobium Nb 0.02 max.
Molybdenum Mo 0.05 max. Copper Cu 0.30 max.
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Vanadium V 0.05 max.
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Alternate material approved under the name of S43CR with following chemistry for Section A & Section B.
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Permissible deviation
Element Symbol Percentage
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in the check analysis
Carbon C 0.4 ~ 0.46 0.03 ~ 0.05
Manganese Mn 0.6 ~ 0.8 ± 0.04
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Chromium Cr 0.3 ~ 0.45 ± 0.05
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Silicon Si 0.17 ~ 0.35 0.02 ~ 0.03

Phosphorous P 0.030 max. +0.01
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Sulphur S 0.035 max. +0.01

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Aluminium Al 0.015 ~ 0.035 -

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Percentage Percentage
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Element Symbol Trace elements Symbol

(%) (%)
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Nickel Ni 0.20 max. Zirconium Zr 0.02 max.

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Molybdenum Mo 0.05 max. Niobium Nb 0.02 max.

Copper Cu 0.30 max. Vanadium V 0.05 max.
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Note:
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I. The Carbon equivalent when calculated in accordance with the formula given below shall not exceed 0.70
CE (Carbon Equivalent).
Mn Cr+Mo Ni Cu
C + + + +
6 10 20 40
II. In this, the chemical composition is slightly different as compared to IS:5517 in order to
a) Align the specification with S45C, JIS G4051 and

Doc. No. : WCS-015
Rev. : 04
Pages : 3 of 9
b) Ensure proper hardenability and consistency in hardness in Quenching & Tempering and
Induction hardening process.
III. *Aluminum shall be controlled within this range however the steel shall meet grain size of Minimum of
ASTM 5 and Maximum of ASTM 8 consistently.
2.2.1 Gas content
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Element PPM
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Oxygen (O2) 15 Max
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Hydrogen (H2) 2 Max
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Nitrogen (N2) 90 Max
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2.3 Supply condition
2.3.1
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The material shall be supplied in either “as rolled” (hot) or “normalized” or in “cold drawn” condition
as specified in purchase order. Material also may be supplied in “hardened and tempered (Q&T)”
condition if specifically asked in purchase order.
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2.3.2 All Material to be supplied in straightened condition as specified in 2.7.3.
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2.4 Mechanical Properties

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a) Tensile & Yield Strength

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➢ In “as rolled” (hot) or in “normalized” condition :
Ultimate Tensile Strength (U.T.S.)

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630 MPa
minimum
Yield Strength (Y.S.) minimum 360 MPa
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➢ In hardened and tempered (Q&T) condition :

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Above Ø30 up Above Ø50 up Above Ø70 up

Ruling Section Ø30 and Above
to and to and to and
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(nominal) less Ø90

Including Ø50 Including Ø70 Including Ø90
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U.T.S. (min.)
850 820 780 730 700
MPa
Y.S. (min.)
600 580 550 520 500
MPa
Note:
I. 1% lower value of UTS against specification may be permitted if all other mechanical properties and
metallurgical properties are meeting the specified value.

Doc. No. : WCS-015
Rev. : 04
Pages : 4 of 9
II. It is advised to perform Q&T for components (Section-B) after proof machining (making internal
diameter) if the outer diameter is more than 100mm to make the part tougher. Annular cross section
to be considered as Ruling section for such parts.
b) Elongation: 15% min.
c) Hardness (unless otherwise specified in P.O.)
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- Normalized : 180 to 220 BHN
- Q&T : 227 to 277 BHN
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d) Impact strength (Charpy V-notch):
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5 Kgf-m/cm2 or 49J/cm2, min. at room temp. (+20º ~ 30ºC) (Which is 40 joules for the specimen of 1cm
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x1cm with 2mm V-notch)
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All above tests shall be conducted on samples extracted at D/4 position of the bar diameter. For the sizes
where it is not possible at D/4 due to cross section limitation, sample can be extracted from at least 6mm
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below from the bar diameter refer fig-1 . Refer ISO 6892 / IS 1608 for test piece/specimen preparation.
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Figure 1
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2.5 Metallurgical Properties

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2.5.1 Inclusion rating

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Inclusion rating as per ASTM E45 Method A
Sulphides Alumina Silicates Oxides

(A type) (B type) (C type) (D type)
Thin Heavy Thin Heavy Thin Heavy Thin Heavy
1.5 1.0 1.0 0.5 1.0 0.5 1.5 0.5
The rating shall not exceed the above limits

Doc. No. : WCS-015
Rev. : 04
Pages : 5 of 9
2.5.2 Grain size
The steel must have a fine grained structure. The grain size shall be in the range of ASTM number 5
to 8 as per ASTM E112
2.5.3 Segregation and Banding
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The steel shall be free from Micro and Macro segregation, and shall be free from Harmful banding.
The thickness of the Banding shall be less than 0.030mm (30µm)
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Note: However it is advised to control the banding width as low as possible to have the effective
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hardening properties.
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ED
Figure 2
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2.5.4 Macro Etching

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Shall be better than C2 R2 and S2 As per ASTM E- 381 Plate-1
2.5.5 Decarb depth:

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The depth of decarb, Total (Full + Partial) shall not exceed 1% of nominal diameter or 0.50 mm max
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whichever is less when tested as per SAE J419
2.5.6 Step Down test:
Two samples from the lot of the same heat shall be tested as per JIS G 0556.
Acceptance Norm: No Indications allowed.

Doc. No. : WCS-015
Rev. : 04
Pages : 6 of 9
2.5.7 Microstructure:
For as rolled (Hot) / normalized / annealed / cold drawn steels the microstructure shall reveal ferrite
and pearlite uniformly distributed without any segregation.
For hardened and tempered steels the microstructure shall reveal tempered martensite when tested
on a section at 4 to 6 mm depth from the outer surface. The microstructure shall not reveal presence
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of any un-tempered martensite.
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2.5.8 Mix-up Verification:
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100% Spark test / Mobile spectro shall be carried out to identify the mix up if any and identification of
the test confirmation to be done on the face the bars.
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2.6 Internal and surface defects:
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➢ Steel shall be free from surface cracks, seams, laps, lamination, and shrinkage. However for others,
➢
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depth of the defect shall not exceed 0.5% of the diameter of the bar.
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All bars shall be 100% tested for surface defects by eddy current tester / Magna flux leakage test (MFLT)
/ Magnetic Particle inspection (MPI).
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➢ 100% of the Bars shall be tested by automatic UST (Ultrasonic Test) and bars shall be free from internal
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cracks, porosity, piping, and center looseness. Calibration standard shall be SDH 0.8 X 30mm & FBH
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1.5mm standard notch.

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➢ Identification of the test confirmation to be done on the face the bars.
2.7 Dimensional Requirements:

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2.7.1 Diameter tolerance:

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Sl. no Bar Diameter in mm Tolerance in mm **Out of roundness in mm

1 20 to 25 ± 0.24 within 0.35
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2 > 25 to 28 ± 0.25 within 0.40

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3 > 28 to 31 ± 0.28 within 0.45

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4 > 31 to 34 ± 0.30 within 0.50

5 > 34 to 38 ± 0.36 within 0.60
6 > 38 to 50 ± 0.40 within 0.60
7 > 50 to 64 -0, +0.8 within 0.80
8 > 64 to 89 -0, +1.2 within 0.80
9 > 89 to 114 -0, +1.6 within 1.20
10 > 114 to 139 -0, +2.0 within 1.50
11 > 139 to 180 -0, +3.0 within 2.00

Doc. No. : WCS-015
Rev. : 04
Pages : 7 of 9
Although the tolerances are bilateral for 20 to 50mm diameter, for the purpose of better peeling process
it is advised to maintain OD tolerance at positive (+) side.
Above mentioned tolerances are derived based on references of IS 3739(Grade1)/EN 10060

(precision) specification.
** Out of roundness is measured by micrometer on circumference the deference of value between
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maximum and minimum is considered to be out of roundness and this should fall within in the
permissible tolerance on OD.
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2.7.2 Length Tolerance:
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Length cutting should be done by hot sawing / cold saw cutting / abrasive cut off and ends have to be
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beveled and chamfered properly and the tolerance on length is given below
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Diameter Length in mm Length in mm Length in mm
Sl.no.
range in mm 1500~3000 3000~6000 >6000
1 ≤25 +15irm +20 +35
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2 26 to 50 +15 +25 +40
3 51 to 125 +25 +40 +45
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Above tolerance is applicable for the bars which are ordered on fixed and multiple lengths and not
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applicable for random length.

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Note: Gas cutting is not permitted.

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2.7.3 Straightness:
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Straightness is measured as maximum height of the bend / arc measured from the straight edge as
shown in the figures below. Standard test length is one meter.
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Straightness measurements of bars are generally done by using surface plate and thickness gauge,
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however supplier can use any one of the following method.

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a) Surface plate method: Round bars are measured by placing the bar on horizontal base / surface
plate and the maximum gap between the reference base and arc of the bar is measured by
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thickness gauge.
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Doc. No. : WCS-015
Rev. : 04
Pages : 8 of 9
b) Roller method: Bar is placed on two rollers and rolled for 360 deg. and the Run out (Total indicated
reading) is measured using dial gauge. Measure the run out as above for every 500mm distance
and record. Half of the maximum run out (TIR) amongst these readings is to be considered as
maximum bend.
c) I section block / Parallel Block Method: Precision I section or parallel beam having length of one
meter is placed on the bar surfaces, the gap between bar surface and parallel beam is measured
17
using thickness gauge.
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d) Measurement should be taken for full length placing the block for every 2/3 length of the block (for
every 666mm length considering block length 1000mm) and in two directions at 90deg. in
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circumference and the maximum gap measured is considered as maximum bend.
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e) To avoid bending of bars during transit, storage and handling special care has to be taken in
bundling and stacking methods. Proper strapping at appropriate interval is to be given to facilitate
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firm bundling, and each bundling not to exceed 3 tons Max. For safe and proper handling.
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f) Considering the machining allowance and the subsequent heat treatment, machining process on
the bar, the supply condition should be roller straightened with maximum deviation for straightness
as given below.
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g) Maximum Permissible Bend: 3mm/meter, checked at any point throughout the length of the bar.
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However it is strongly advised to maintain the straightness level less than 1mm/meter to avoid the
material unclear in the bar peeling process.
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3. Identification:
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The heat code no. and vendor identification shall be marked on the Material. Raw material color code shall be
marked when specified in the purchase order.
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4. Certification:
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The test certificate shall contain the actual Process route, Bloom or Billet size, Reduction ratio, Material Grade,
Chemical composition, Metallurgical, Mechanical properties, Heat number, Color code, Quantity and Weight for
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each consignment and each heat.

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5. Material Rejection
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Material which reveals injurious defects subsequent to its acceptance at any stage of manufacture at WIPRO, or
at any stage during functioning of the final product, leading to failure of the equipment shall be rejected and
informed to the suppliers. Necessary countermeasure must be taken immediately to avoid re-occurrence of such
defects in future supplies and same needs to be communicated to Wipro through 8D report. Debits related to the
rejection found will as per the WIPRO debit guidelines standard.

Doc. No. : WCS-015
Rev. : 04
Pages : 9 of 9
6. Applicability Matrix
Below table is referred for the applicability of the clauses numbers for the section A & Section B.
Wherever it is mentioned as “mandatory” specification to be maintained as per the WIPRO standard and wherever
it is mentioned “not mandatory” specification can be followed as national or international standard.
17
Clause No. Section A Section B Clause No. Section A Section B
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2.2 Mandatory Mandatory 2.5.5 Mandatory Not Mandatory
2.2.1 Mandatory Not mandatory 2.5.6 Mandatory Not Mandatory
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2.3.1 Mandatory Mandatory 2.5.7 Mandatory Mandatory
2.3.2 Mandatory Not Mandatory 2.5.8 Mandatory Mandatory
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2.4 Mandatory Mandatory 2.6 Mandatory Not Mandatory
2.5.1 Mandatory Mandatory 2.7.1 Mandatory Not Mandatory
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2.5.2 Mandatory Mandatory 2.7.2 Mandatory Not Mandatory
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2.5.3 Mandatory Not Mandatory 2.7.3 Mandatory Not Mandatory
2.5.4 Mandatory Not Mandatory
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7. References
Latest revisions shall be referred where ever National/International standards indicated in this document .
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IS 5517:1993 : Steels for hardening and tempering

IS 3739:1987 : Dimensional tolerances for carbon & alloy steel products
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ASTM A29-15 : Standard Specification for General Requirements for Steel Bars
ASTM E 381-01 : Marco Etching
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ASTM E112-13 : Grain size

ASTM E45-13 : Inclusion rating
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SAE J 419:1983 : Decarb measurement

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JIS G 4051:2009 : Carbon steels for machine structural use

JIS G 0556:2014 : Step Down test
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ISO 683-1:1987 : Direct hardening unalloyed and low alloyed steels

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ISO 6892:2009/ IS:1608:2005 : Metallic materials - tensile testing at ambient temperature

EN 10083-2:2006 : Steels for quenching and tempering
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EN 10060:2003 : Dimensions and tolerances on shape and dimensions


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Doc. No.

c. Calcium is not permitted to use as a de-oxidizing agent in steel making.

2.2 Chemical Composition

Section A : Section B : Permissible deviation

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

Percentage Trace Percentage

Silicon Si 0.17 ~ 0.35 0.02 ~ 0.03

Sulphur S 0.035 max. +0.01

Aluminium Al 0.015 ~ 0.035 -

Element Symbol Trace elements Symbol

Nickel Ni 0.20 max. Zirconium Zr 0.02 max.

Molybdenum Mo 0.05 max. Niobium Nb 0.02 max.

a) Align the specification with S45C, JIS G4051 and

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

2.2.1 Gas content

2.4 Mechanical Properties

a) Tensile & Yield Strength

➢ In “as rolled” (hot) or in “normalized” condition :

Ultimate Tensile Strength (U.T.S.)

➢ In hardened and tempered (Q&T) condition :

Above Ø30 up Above Ø50 up Above Ø70 up

(nominal) less Ø90

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

b) Elongation: 15% min.

c) Hardness (unless otherwise specified in P.O.)

2.5 Metallurgical Properties

2.5.1 Inclusion rating

Inclusion rating as per ASTM E45 Method A

Sulphides Alumina Silicates Oxides

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

2.5.2 Grain size

2.5.3 Segregation and Banding

2.5.4 Macro Etching

Shall be better than C2 R2 and S2 As per ASTM E- 381 Plate-1

2.5.5 Decarb depth:

whichever is less when tested as per SAE J419

2.5.6 Step Down test:

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

1.5mm standard notch.

➢ Identification of the test confirmation to be done on the face the bars.

2.7 Dimensional Requirements:

2.7.1 Diameter tolerance:

Sl. no Bar Diameter in mm Tolerance in mm **Out of roundness in mm

2 > 25 to 28 ± 0.25 within 0.40

3 > 28 to 31 ± 0.28 within 0.45

4 > 31 to 34 ± 0.30 within 0.50

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

Above mentioned tolerances are derived based on references of IS 3739(Grade1)/EN 10060

** Out of roundness is measured by micrometer on circumference the deference of value between

applicable for random length.

Note: Gas cutting is not permitted.

however supplier can use any one of the following method.

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

each consignment and each heat.

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna

IS 5517:1993 : Steels for hardening and tempering

ASTM E112-13 : Grain size

SAE J 419:1983 : Decarb measurement

JIS G 4051:2009 : Carbon steels for machine structural use

ISO 683-1:1987 : Direct hardening unalloyed and low alloyed steels

ISO 6892:2009/ IS:1608:2005 : Metallic materials - tensile testing at ambient temperature

EN 10060:2003 : Dimensions and tolerances on shape and dimensions

Prepared by: K. Radhakrishna First Approved by: K. Radhakrishna