BPSL , SAMBALPUR

Defects in Cold Rolled Products

 PICKLING
Steel pickling refers to a treatment that is used to remove impurities, rust,
and scale from the surface of a material. During hot working processes, an
oxide layer (referred to as scale, due to the scaly nature of its appearance)
develops on the surface of the metal.

Defects :-
1)Over Pickling :- Yellow surface, Pitting surface and lower thickness
2)Under Pickling :- Dull surface, proper scale not removed
3)Patches
4)Coil break lines
 COLD ROLLING
Cold rolling is a process by which metal is passed through rollers at
temperatures below its recrystallization temperatures. The metal is
compressed and squeezed, increasing the yield strength and hardness of
the metal. The primary purpose of cold rolling of steels is to reduce the
thickness of the hot rolled steel strips into thinner thickness.

Defects :-
1)Roll mark :- Soft mark, Skidding mark, Shade mark, Pinch mark
2)Ridge
3)Edge wavy
4)Coolant patches
5)Centre buckling
6)Thickness variation
 ECL AND ANNEALING
ELECTROLYTIC CLEANING (ECL) :- Electrolytic cleaning is a method of
removing soil, scale or corrosion products from a metal surface by
subjecting it as an electrode to an electric current in an electrolytic bath.
Defects :-
1)Dent
2)Scratch
3)Water carry-over
4)Poor cleaning

ANNEALING :- Annealing is a heat treatment process that changes the

physical and sometimes also the chemical properties of a material to
increase ductility and reduce the hardness to make it more workable.
Defects :- High M. Property, Low M. Property, Carbon shoot, Sticky
Defects in steel products are defined as deviations in
appearance, shape, dimension, macro structure/ micro
structure , and /or chemical properties when compared with the
specifications given in the technical standards or any other
normative documents in force.
 Lamination

Laminations are an imperfection in steel , foreign material or scratches on

an ingot or billet that are not repaired during the rolling process.
 Sliver
An undesirable surface defect appears as lines parallel to the rolling
direction. This defect is originated in steelmaking stage.
 Scab

A Scab defect occurs by splash or boiling from casting. Scabs are usually
round or oval shaped and can be seen prior to the rolling process.
 Hole
Hole appears on the inside of a cast and usually isn’t visible until after the
rolling process.
 Scale
Scale defects are common surface defects in hot steel rolling. The reasons
for such defects are not straightforward.
 Rolled-in-Scale
Rolled-in
M scale is the flaky mixture of iron oxides that form on the surface of
hot steel. A rolled-in scale defect occurs when mill scale is rolled into the
metal during the rolling process.
 Blister
Blisters are a unique surface defect because they form between the coating
and substrate and will guarantee no adhesion due to enclosures at the part
surface. This will lead to a complete failure of the finish and possibly
damage the metal surface.
 Roll Mark

Roll mark is periodic bulges and pits on the surface of strips in the shape of
dots, these are developed because of damage work roll or sticking of
foreign particles on the work roll.
 Gouge Line
Gouge defect is a mechanical defect and it is formed when heavy objects
strike the external surface of steel pipes creating a groove which causes
strain hardening at the bottom of the defect as a result of impact.
 Over Pickling
The cause of acid pickling is the continuous operation interruption of the
unit, which leads to the loss of continuity of the pickling or the long
treatment time due to strip breaking.
 Pickling Pits
Pitting may be caused by over pickling, particularly when inhibitors are
used but in less than adequate amounts. Such pitting appears when
materials in the bath much longer than is necessary for complete scale
removal.
 Ridge
Due to the stress concentration in the ridge region during coiling process, it
can result in local material yielding and eventually results in the
development of ridge-buckle defect in cold rolled thin strip when it is
uncoiled.
 Pickling Scratch
Scratches introduced during hot rolling or pickling, as well as pickle its,
both result in line type surface imperfections that persist through
subsequent processing stages.
 Transverse Undulation
Transverse Undulation is a surface defect having no filling it is just a shade
mark imparted from rolls to strip.
 Yellow Patch
The acid washed substrate is directly in contact with the environment so
the surface of the pickled product is very prone to oxidized yellow spot
defect.
 Brown Shade
The acid washed substrate is directly in contact with the environment so the
surface of the pickled product is very prone to oxidized brown spot defect.
 Sticker Mark
Sticky develops between two wraps of coil because of high tension binding,
poor shape or high temperature during heat treatment. During unwinding of
coils sticky surface develops sticker mark.
 Tong Mark
In Batch Annealing Furnace, coils are lifted by the tong, in IF grade material
because of softness of material sometimes tong imparts an impression
mark over the material.
 Pinch Mark/Fold Mark
Pinch mark occurs when strip wrinkles enters in-line rollers. The wrinkles
mainly develops due to poor shape or low tension.
 Stretcher Strain
Stretcher Strain also known as luders bend, are localized bend of plastic
deformation in metals experiencing tensile stresses.This defect can be
remove by skinpassing of matels.
 Feather Mark
Feather mark develops because of uneven extension of strip in roll gap
during skinpass. It can be remove by increasing the tension before and
after.
 Chatter Mark
Chattering is irregular wavy , distributed along the rolling direction on the
whole width of strips. It develops mainly depends on vibration during rolling
or grinding of rolls.
 Coil Break-lines
There are continuous broken lines like the equal sign at edge of strips,
this defects develops because of local yield occurs along the uncoiling
direction during uncoiling.
 Dent
A dent is defined as permanent deformation of strip cross sectional area
as a result of external force.
 Coil Slip Mark
Coil slip mark is a surface defect may have filling , developed because of
rubbing between two wraps because of tension fluctuation.
 Scratch
The mechanical damage looks like a straight line cut parallel to the rolling
direction of the strip. It is caused by a foreign object that is present in the
pass line of a process work centre.
 Rust Patch

Damage caused by oxidation of metal surface in specific environment

such as air and water. It is caused by the concentration of leveling
solution is not consistent or too much leveling solution remains at the
edge.
 Patch
There are black or brown spots of different sizes on the strip surface,
generally with obvious contour lines.
 Brown Patch
Brown patch develops due to improper cleaning of oxide layers during
pickling process.
 Emulsion Patch
Emulsion patch is the residual cracking emulsion on the surface of strip,
randomly distributed on the surface of strip, with irregular shape and dark
color.
 Scum Mark
Scum mark develops because of dropping of emulsion scum during rolling
from mill housing.