Module 1: Activity No.

4
Plate No. 1: Steel Manufacturing Processes

Name: Dy, Loyd Benz M.

Student No.: 20171110159

VI. Defects:
Friction scratches may be caused by an encounter with an
abrasive surface.

Figure 6.1 Steel scratches

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Transverse cracks are cracks that extends along the cross-
section of a material or object, usually perpendicular to its
centerline. It is typically the result of axial loading from external
forces or shrinkage due to temperature changes. Cracks not
only reduce the strength of the weld through the reduction in the
cross-section thickness but also can readily propagate through
stress concentration at the tip, especially under impact loading
or during service at low temperature.

Figure 6.2 Chevron cracks

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Internal cracks are local discontinuity produced by a fracture

which can arise from the stresses generated on cooling or
acting on the structure. Internal cracks require ultrasonic or
radiographic examination techniques.

Figure 6.3 Hydrogen cracks in steel

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Built-up edge (BUE) is an accumulation of material against the
rake face, that seizes to the tool tip, separating it from the chip.
The build-up of material changes the geometry of the cutting tool.

Figure 6.4 Built-up Edge

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Seams are longitudinal crevices that are tight or even closed at the
surface, but are not welded shut. They are close to radial in
orientation and can originate in steelmaking, primary rolling, or on
the bar or rod mill.

Figure 6.5 Seam crack

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Porosity occurs when air is trapped into the metal by the die casting machinery, often leaving
gaps at the top of the die or filling a mold too slowly and having some solidification occur too soon.

Figure 6.6 Porosity

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A shrinkage cavity is a depression in a casting which occurs during the solidification process.
Shrinkage porosity appears with angular edges, compared to the round surfaces of gas porosity.
Cavities might also be paired with dendritic fractures or cracks. Pipes are open shrinkage defects
that form at the surface and burrow into the casting. Closed shrinkage defects usually appear at
the top of hot spots, or isolated pools of hot liquid.

Figure 6.7 (a) shrinkage cavity, (b) shrinkage porosity, (c) centerline shrinkage, (d) corner
shrinkage and (e) surface sink
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Slivers are segments of steel that have been torn from the
steel and rolled onto the surface of the metal. This defect
is most common in low strength steel which can easily tear
due to incorrect or high-speed rolling processes. Slivers
can also start from defects that were not previously
removed by conditioning.

Figure 6.8 Slivers on rolled steel

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Inclusion defects of castings are defects such as slag of

oxides and other substances generated in the ladle by the
reaction and sand of molds and the cores that flake away and
are included in molten metal, flowing into products and
appearing on the surfaces of parts as non-metallic inclusions.

Figure 6.9 Oxide inclusions

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 Chemical segregation is a separation of impurities and alloying elements in different regions of
solidified alloy. It develops on three scales. Macrosegregations are the most important ones
since it is the type of segregation that is far more difficult to reduce subsequently by thermo-
mechanical post-treatments. Microsegregation is the pattern of composition variation that
remains in a solidified alloy. Mesosegregations develop on the scale of primary grains.

Figure 6.10 Macrosegregation in ingots Figure 6.11 Oxide inclusions

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