20 13

2015

Defect Gallery
Defect Gallery _
- Galvanized CRCA
Products
(A Handbook on Defectology )
[Type the document subtitle]

Owner
Unknown Organization
1/1/2013
 Contents
Sl Galvanized Defects Page No
1 Chromate Carry-Over 2-3
2 Chromate drop 4-5
3 Chatter Mark 6-7
4 Cooling line 8-9
5 Dent 10-11
6 Dross 12-13
7 Edge Over- Coating 14-15
8 Fretting Corrosion 16-17
9 Mini Spangle/ Spangle Size - ZS 18-19
10 Pin Prick 20-21
11 Pot Roll Mark 22-23
12 Rolled In Scale 24-25
13 Roll Mark 26-27
14 Sag line 28-29
15 Scratch 30-31
16 Sliver 32-33
17 Unalloyed 34-35
18 Uncoated 36-37
19 Nozzle streak 38-39
20 Unalloyed at Edge 40-41
21 Logo ink Drop 42
22 Norms for Holding @CGL#2 43

N: B – 1.These Defect catalogue has been prepared in view of surface

related concerns at customer's end. 2. Scale used in mm (lowest division)

1|P age
 Galvanized Defect – Chromate Carry-Over
Sev Description
1 Light
2 Light-Medium Detail of Chromate
3 Medium Carryover is given in next
4 Medium-High
5 High page
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on total value of Sheet Chromium on strip*

2|P age
 Chromate Carry-Over

Definition: It is a light to deep brownish surface due to patch observed at strip

surface due to improper chromating after Galvanizing of the strip.

Root Causes: 1. Damage or worn wringer rolls.

2. Loss of passivation tank squeegee rolls pressure. Carryover of

passivation solution due to excessive roll gap. It can also occur
when there is a line change to a different width.

3. Leaks or condensation inside the passivation tank, misdirected

sprays etc that causes drips of passivation solution to fall onto the
strip after the squeegee rolls.

4. Temper fluid carry over.

5. Excessive Chromate concentration.

Process Control: 1. Ensure proper functioning of edge wipers at chromating section.

2. Avoid condense drop falling on the strip.

3. Check whether wringer rolls are rotating.

4. Check the effectiveness of squeezing.

5. Wringer roll rubber hardness to be maintained 55, +/-5 shore

D.

6. Wringer roll should be free from any damage.

7. Air wiper angle and distance from edges should be properly

fixed.

8. Chromate temperature to be maintained around 60 degree C.

9. Chromate drying temperature to be maintained around 100

degree C.

3|P age
 Galvanized Defect – Chromate Drop
Sev Description
1 Light
2 Light -Medium Detail of Chromate Drop is
3 Medium given in next page
4 Medium -High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very-High
*Severity depends on Number of Drops and Diameter of in Drop *

4|P age
 Chromate Drop

Definition: Chromate drop is the surface defect randomly distributed on to

the coated surface post chromating process. This is mainly during
running the strip of oiling campaign there is a drop of condensate
drop on the strip surface.

Root Causes: 1. Chromate condensate drop.

2. Splashing of Chromate on the strip surface.

Process Control: 1. cleaning of condensate chromate on regular basis.

2. Covering chromate section while running oiling campaign to
avoid condensate drop falling on the strip.

3. Avoiding the condition of Chromate splashing.

5|P age
 Galvanized Defect – Chatter Mark
Sev Description
1 Light
2 Light -Medium Detail of Chatter Mark is
3 Medium given in next page
4 Medium-High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very-High

6|P age
 Chatter Mark

Definition: Chatter appears as a series of parallel shallow lines or bands up to

12mm wide running across the full width of the strip transverse to
the rolling direction and is generally continuous throughout a coil .
In its least severe form Chatter is virtually impossible to detect
under normal processing condition.

Root Causes: 1. Poor skin pass mill work profile due to roll grinding practices and
wear and tear.
2. Vibration in the line levellers causing wear and tear in the
mechanical components of the levellers.
3. Skin-pass mill vibration; wear in the mechanical components of
the levelers.
4. Poor leveller roll grinding practice.
5. Poor inter-mesh in the Stab. Rolls.

Process Control: 1. Check the source of the defect first.

2. In case of tension leveller Skin-pass mill vibration; wear in the

mechanical components of the mill can result in a resonance being
set up.

3. Vibration in the line levellers causing wear and tear in the

mechanical components of the levellers.

4. Poor leveller roll grinding practice.

5. Poor inter-mesh in the stab rolls.

7|P age
 Galvanized Defect – Cooling Line
Sev Description
1 Low
2 Light -Medium Detail of Cooling line is given
3 Medium in next page
4 Medium –High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

8|P age
 Cooling line

Definition: Cooling/Air Lines are long lines up to 10mm wide of different

spangle pattern to that of the surrounding Zinc coating. These lines
often appear at 45 degrees to the rolling direction towards the
strip edge. The cooling air above the jet stripping controls the rate
of spangle formation. This cooling air is controlled to chill the
molten Zinc coating to a normal pattern. At times, and at certain
cooling rates some spangles grow along a thermal gradient in a
characteristic pattern in a line at 45 degrees to the rolling
direction.

Root Causes: 1. Air Knife distance too close.

2. Air Knife pressure too low.

3. Tower cooling pressure setting not ok.

4. Elevator height to high.

5. Coating gauge problem.

6. Wrong alloy factor.

Process Control: 1. Check the P4 & the zinc bath temperatures.

2. Reduce the cooling rates in the cooling tower.

9|P age
 Galvanized Defect – Dent
Sev Description
1 Low
Detail of Rolled in Scum is
2 Light -Medium given in next page
3 Medium
4 Medium-High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on projection from surface and Diameter of Dent*

10 | P a g e
 Dent

Definition: Dents is a result of pieces of coating metal or other foreign matter

building up or embedding in the various rolls (i.e. Skin-pass mill /
TL deflector roll/bridle rolls/table rolls/pot rolls etc) on the
Galvanizing line and being forced into the strip surface due to the
resistance of the work roll on the reverse surface once per
revolution of whatever roll is involved.

Root Causes: 1. Deposition or the presence of embedded foreign matter on

various rolls like TCM Rolls, Entry looper rolls, Cleaning section
rolls, Pot rolls, Quench tank rolls, SPM wringler roll, Briddle roll,
Exit looper roll, Idler rolls, Chromate wringler roll, Pinch rolls etc

2. Pick-up inside the furnace.

3. Pick-up during storage.

Process Control: 1. Find out the pitch of dent and get the source and clean it.

2. Check all types of dust or foreign particle sources during

processing.

3. Put the coil on rubber pad / Packing material.

4. Ensure the accurate setting of Docter plate.

5. Ensure perfect air wiping pressure.

6. SPM cleaning of all the rolls on defined frequency as well as

when required.

11 | P a g e
 Galvanized Defect – Dross
Sev Description
1 Low
2 Light -Medium Detail of Dross is given in next
3 Medium page
4 Medium-High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on Number of lines and projection on surface*

12 | P a g e
 Dross

Definition: Dross is a mass of solid impurities floating on a molten Zinc bath or

dispersed in the metal. It forms on the surface of low-melting-
point metals such as tin, lead, zinc or aluminums or alloys by
oxidation of the metal(s). In Zinc coating process, this is the surface
defect and is the oxidized product of Zn, Al & Fe.

Root Causes: 1. Changes in the pot & strip temperature resulting in change in
the bath equilibrium that could result in precipitation (small spots)
of dross.

2. Dross build-up on the Zinc bath surface and not cleaned off at
regular intervals.

3. Changes in Al/Fe concentration in the zinc bath.

Process Control: 1. Zn bath must be kept appropriately clean.

2. The strip and bath temperature control must be on & validated.

3. Check the bath Al results in comparisons with pervious analysis.

13 | P a g e
 Galvanized Defect – Edge Over-Coating
Sev Description
1 Low
2 Light -Medium
3 Medium Detail of Edge Over -Coating
4 Medium-High
5 High is given in next page
6 Very High

Light Light-Medium

NA

Medium Medium-High

NA

High Very High

*Severity depends on Zinc Coating weight & due to EOC deformation material after recoiling*

14 | P a g e
 Edge Over-Coating

Definition: It is build up of extra coating at both the edges.

Root Causes: 1. Uneven coating distribution caused by uneven air knife control.
2. Bad strip shape eg. Edge wave moves sections away from the air
jets resulting in uneven metal coating along the strip edge.
3. Lumps or zinc solidification at the air knife edges.
4. Baffle plate position improper.
5. Zinc pot temperature.

Process Control: 1. Check air knife gap using wedge block.

2. Check for lump/deposits of the air knife edges.
3. Inspect CR shape for heavy edge waviness.
4. Check the strip stability at the zinc pot.

15 | P a g e
 Galvanized Defect – Fretting Corrosion
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Fretting Corrosion is
4 Medium-High given in next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on how Blackish surface is and Diameter of defect*

16 | P a g e
 Fretting Corrosion

Definition: Fretting refers to wear and sometimes corrosion damage at the

asperities of contact surfaces. This damage is induced under load
and in the presence of repeated relative surface motion, as
induced for example by vibration.

Root Causes: 1. Vibration due to relative surface motion within the coil wraps
under load.

2. Poor shadle design.

3. Vibration due to relative surface motion within the coil wraps

under load.

4. Bigger coil mass.

5. Poor road condition.

6. Improper holding of the coil during transit.

Process Control: 1. Avoid relative motion of the surfaces at the contact especially
during transit.

2. Proper amount of RP Oil acts as lubricant can mitigate fretting as

they reduce friction.

3. Jerking during transit to be avoided.

4. Material should be placed at properly designed grooved shadle,

act as shock absorber during transit.

5. Transit a bigger mass coil to long distance especially through

road should be avoided.

17 | P a g e
 Galvanized Defect – Mini Spangles / Spangle size - ZS
Sev Description
1 Low
2 Light -Medium Detail of Mini Spangle /
3 Medium Spangle Size - ZS is given in
4 Medium-High
5 High next page
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

18 | P a g e
 Mini Spangles / Spangle size – ZS

Definition: Most continuous galvanizing lines use air knife, 30-60 cm above
the bath to control the coating thickness. Just below this knife the
strip temperature across the strip width is fairly constant.
However, immediately after air wiping, there is a temperature
variation across the width, which depends upon the coating
weight, strip shape, thermal history and ambient temperature.
Since the strip edges lose heat faster than the centre, areas at the
edges of the strip solidify at a faster rate.

Moreover, if the strip has a centre buckle, this will be further so.
This gives rise to a non-uniform spangle growth rate areas at the
edges of the strip solidify at a faster rate, providing smaller
spangles.

Root Causes: 1. Inclusion/ black surface of the strip before coating.

2. Improper cleaning of the strip surface.

3. Furnace atmosphere not as per specification.

4. Water/Alkali carry over.

5. Air knife setting not ok.

Process Control: 1. Incoming strip for coating should be free from inclusion/black
surface.

2. Furnace atmosphere should be properly maintained.

3. Strip surface should be free from water/alkali carry-over.

4. Air knife setting should be properly done.

19 | P a g e
 Galvanized Defect – Pin Prick
Sev Description
1 Low
2 Light -Medium
3 Medium Detail of Pin Prick is given in
4 Medium-High
5 High next page
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on no of Pinpricks per unit area, Diameter of pinpricks & projection from surface *

20 | P a g e
 Pin Prick

Definition: The cold-rolled feed can be contaminated by a substance that

prevents wetability of the surface during the hot dipping process.
The strip surface becoming oxidized prior to entering the molten
metal coating pot preventing the coating metal adhering to the
strip surface.

Root Causes: 1. CR Surface contaminated.

2. Oxidization of Strip surface prior to zinc coating process.

3. Improper furnace temperature.

4. Improper furnace atmosphere.

Process Control: 1. Check the snout atmosphere for Oxygen content.

2. HNx flow in the snout needs to be controlled to avoid
turbulence.

3. Check for Zinc Oxide build up in the snout.

4. Blast the snout as per standard procedure.

21 | P a g e
 Galvanized Defect – Pot Roll Mark
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Pot Roll Mark is
4 Medium-High given in next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on Area covers on full width and surface appearance*

22 | P a g e
 Pot Roll Mark

Definition: Pot roll mark is the defect originated from a complex steel
formation i.e. dross formation i.e. Zn-Fe alloy crystallites in the
coating. When this dross growth takes place on pot rolls, this
created pot roll marks.

Root Causes: 1. Al transition.

2. Pot roll rotation problem.

3. Sink rolls grove marks.

4. Scratch from Pot rolls.

5. CR shape problem.

6. Pot tension high.

7. Incoming strip is contaminated or blackish in appearance.

Process Control: 1. Zn bath must be kept appropriately clean.

2. The strip and bath temperature control must be on & validated.

3. Check the bath Al results in comparisons with pervious analysis.

4. Control addition in the bath.

23 | P a g e
 Galvanized Defect – Rolled In Scale
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Rolled In Scale is
4 Medium-High given in next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

24 | P a g e
 Rolled In Scale

Definition: During Hot Rolling water with high press. is injected on the slab
surface to remove the scales (iron oxides). It the scale in not
removed properly. It gets rolled during hot rolling and embedded
in to the surface of material. These scales cannot be removed by
pickling. On CR sheet they appear like small needles oriented in
the rolling direction.

Root Causes: 1. Improper Hot rolling parameters.

2. Improper descaling at hot mill.

Process Control: 1. In Secondary Descaler, both headers should be always used.

Water catchers should be in lower position.

2. Laminar Cooling In Front of Finishing Stand #1.

3. Proper Roll bite cooling and Roll bite lubrication.

4. 100 Bar Descaling between Finishing Stand #1 & #2 and

Finishing Stand #3 & #4.

5. Harder grade materials should not be scheduled prior to surface

critical grades.

25 | P a g e
 Galvanized Defect – Roll Mark
Sev Description
1 Low
Detail of Roll Mark is given in
2 Light -Medium next page
3 Medium
4 Medium-High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

26 | P a g e
 Roll Mark

Definition: Roll marks are surface markings, generally depression or

indentation of various shapes attribute to work roll or pinch roll
surface. Its appearance is smooth shining patches. Roll mark
appears with certain pitch i.e. circumference of roll.

While rolling most of the rolls work roll remain in touch

with the sheet. If this work roll has got some mark on its surface it
will transfer it to the sheet at pitch / rolls circumference. The
following diagrammatic representation shows the characteristic
appearance of roll mark.

Root Causes: 1. Welding of metallic pieces (Sliver/Scab/any other) on any roll.

2. Over coating.

3. Uncleaned Air knife cleaning and improper setting.

4. Dross pick-up.

5. High pressure jet not OK.

Process Control: 1. Identify the rolls causing the defect by measuring the pitch /gap
between the marks.

2. Clean roll surface.

3. Change the affected rolls.

4. Ensure the Air Knife in operation is in cleaned condition.

5. All sources of dirt and any foreign particle source to be checked.

6. Over- coating condition to be prevented.

27 | P a g e
 Galvanized Defect – Sag line
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Sag line is given in
4 Medium-High next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

28 | P a g e
 Sag line

Definition: Sag lines are the appearance defect of coated surface. Heavy
coatings produced using a slow line speed may suffer from a line
defect referred to as sag-lines and/or rippled coatings. Reducing
the bath effective aluminum level and adding small amounts of
antimony will generally alleviate the problem.

Root Causes: 1. Low processing line speed.

2. Jet too high above the bath.

3. Wiping medium as air.

4. High coating weight and thicker section.

5. Low jet cooling air flow.

6. Low solidification rate.

Process Control: 1. Improve the line speed.

2. Superior coating weight control.

3. Avoid all sources /condition of scratch during hot rolling.

4. Proper air knife position, angle & pressure setting as per section
and coating amount.

29 | P a g e
 Galvanized Defect – Scratch
Sev Description
1 Low
2 Light -Medium Detail of Scratch is given in
3 Medium next page
4 Medium-High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

30 | P a g e
 Scratch

Definition: Scratches are caused when the strip comes in contact with any
metal coated rolls, tables, plenums etc than in not synchronous
with the line speed. The defect may be in the CR or coated strip.

Root Causes: 1. scoring of sheet by sharp corners / edges of hard objects & M/S
part.

2. Contact of sheet with any stationary part/equipment of the line.

Process Control: 1. Ensure no stationary part / equipment touching the running

strip.

2. Maintain the alignment of rolls.

3. Time to time greasing of roll.

4. Check pass line & improve tension to avoid contact.

31 | P a g e
 Galvanized Defect – Sliver
Sev Description
1 Low
Detail of Sliver is given in
2 Light -Medium next page
3 Medium
4 Medium-High
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

32 | P a g e
 Sliver

Definition: Slivers are surface defect on strip, which has an elongated metal
flap and some entrapped material below it. The metal flap is
oriented in the rolling direction and the flap is tapered at the end.
This defect would split after cold rolling stage, causing hole or
linear defect. A sliver defect on an automotive exposed part would
cause a blemished surface after painting.

Root Causes: 1. Entrapment of mould powder during steel casting.

2. Entrapment of Argon gas bubbles.

3. Complex non-metallic inclusion (CNMI).

4. Entrapment of ladle or tundish slag.

5. Refractory erosion.

6. Nozzle clogging products.

7. Alumina precipitation.

8. Inclusion modification during ladle treatment.

Process Control: 1. Ladle should be hot and clean.

2. Carryover of the slag from LD vessel should be as low as
possible.

3. Casting speed should be constant.

4. Constant tundish level to be maintained.

5. Ratio of Al / Ti in steel to be maintained around 1

6. RH treatment start to end time should be minimum 20

Mintutes.

33 | P a g e
 Galvanized Defect – Unalloyed/Zinc Splash
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Unalloyed is given in
4 Medium-High next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

34 | P a g e
 Unalloyed/Zinc Splash

Definition: This is the defect of GA Material in which alloying of Zn and Fe

phase is hampered as molten zinc bath having higher % Al shows
alloy growth.

Root Causes: 1. Aluminium content of molten Zinc bath too high which inhibits
alloy growth.

2. Line speed too fast.

3. Incorrect GA furnace setting ( P5 temp. too low).

4. Variable coating mass, thicker than "normal" coating takes

longer to form the Zinc/Iron alloy.

Process Control: 1. Zinc Charging guidelines must be followed.

2. Check the Bath Al results in comparison with previous analysis.

3. The strip & bath temperature controls must be on & validated.

4. P5 temperature & the GA furnace set points are to be checked

from previous campaigns.

5. Alloying Power may be increased with the voltage constraints.

35 | P a g e
 Galvanized Defect – Uncoated
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Uncoated is given in
4 Medium-High next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

36 | P a g e
 Uncoated

Definition: This is the defects of galvanized in which few surface areas don't
undergo coating. Appearance of this defect is as blackish spot.

Root Causes: 1. Cold-mill carryover contamination.

2. Any surface contamination (e.g. Grease, oil) that is not fully

removed by the Annealing furnace.

3. Furnace problems e.g. Air/gas ratio, gas contamination, water

leaks, and low furnace pressure resulting in strip surface oxidation.

4. Incompletely removed hot strip mill surface scale on cold-rolled

full hard metal coating feed.

Process Control: 1. Check the furnace atmosphere for Oxygen content.

2. Check the HNx flow in the snout.

3. Check carry over from the cleaning section & also strip
cleanliness.

37 | P a g e
 Galvanized Defect – Nozzle Streak
Sev Description
1 Low
2 Light -Medium
3 Medium
Detail of Nozzle Streak is given
4 Medium-High in next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

NA
NA

High Very High

*Severity depends on projection from surface and width of the area affected *

38 | P a g e
 Galvanized Defect – Nozzle Streak
Definition: This is the defects of galvanized in which Lines of Zinc over-coating
appears as streaks. Appearance of this defect is dull finish from
rest surface.

Root Causes: 1. Nozzle/Knife chocking by Zinc lump or any foreign particle

where defect appears.

Process Control: 1. Check Zinc bath chemistry.

2. Check Knife setting.

3. Check Dross at molten zinc surface near knife.

39 | P a g e
 Galvanized Defect – Unalloyed At Edge
Description
Sev
1 Low
2 Light -Medium Detail of Unalloyed At Edge is
3 Medium
4 Medium-High given in next page
5 High
6 Very High

NA
NA

Light Light-Medium

NA

Medium Medium-High

NA

High Very High

*Severity depends on penetration from edge *

40 | P a g e
 Unalloyed At Edge
Definition: This is the defects of galvanized in which appears at edge.
Appearance of this defect is whitish compare to GA Surface.

Root Causes: 1. Due to low Fe% in coating.

Process Control: 1. Check GA power

2. Check Line Speed

41 | P a g e
 Galvanized Defect – Logo Ink Drop
Sev Description
1 Low
2 Light –Medium
3 Medium
Detail of Logo Ink Drop is
4 Medium-High given in next page
5 High
6 Very High

Light Light-Medium

NA

Medium Medium-High

NA

High Very High

*Severity depends on Number of Drops and Diameter of in Drop *

42 | P a g e
 Galvanized Defect – White Spots
Sev Description
1 Low
2 Light –Medium
3 Medium
Detail of White spots is
4 Medium-High given in next page
5 High
6 Very High

Light Light-Medium

Medium Medium-High

High Very High

*Severity depends on Number of Drops and Diameter of in Drop *
43 | P a g e
44 | P a g e