BUNGE INDUSTRIAL STEELS PTY.

LIMITED

BISALLOY

TECHNICAL ASSISTANCE MANUAL

THIS MANUAL ALWAYS REMAINS THE PROPERTY OF BUNGE INDUSTRIAL STEELS PTY. LIMITED AND MUST BE RETURNED ON REQUEST.
The information contained in this publication has been prepared as accurately as possible, however, data is given for guidance and the Company will in no way accept liability.
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Page 1

INTRODUCTION
Perhaps once or twice in a generation a product is launched which pioneers a new phase of development in a particular industry. Born out of necessity during World War II, the restricted supply of high alloy armour plate led to the discovery that steels with armour plate properties could be produced with much lower alloy content by quenching and tempering. This original concept was further refined by the U.S. Steel Corporation to produce the weldable grades of Ti steels. The T1 steels are a low carbon multiple alloy boron containing steel with 690 MPa minimum yield strength in the quench and tempered condition. Quench and tempered steels are now used extensively in construction equipment, earth moving equipment, bridges, booms and dipper sticks, cranes, penstocks, shipping, radio and TV towers, road and rail tankers, buildings and pressure vessels. Higher carbon varieties, which are readily welded, are also used extensively in abrasive conditions with hardness up to BHN 525. Until 1980, all quenched and tempered low alloy steels used in Australia were imported. However, the opening of Bunge Industrial Steels' plant at Unanderra in that year meant that this advanced alloying and heat treatment technology was available in Australia.

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Page 2

THE UNANDERRA PLANT

Resolution Drive, UNANDERRA. 2526. New South Wales, Australia.

BUNGE INDUSTRIAL STEELS PTY. LIMITED

P.O. Box 231, UNANDERRA. 2526. NSW. Australia. Telephone: (042) 71-4944 Telex: AA29227

1. Mechanical Properties of Steels

3. Specifications of Bisalloy Steels

5. Welding of Bisalloy Steels

7. Application of Bisalloy Grades 8. Technical Literature

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Page 4

SECTION ONE

MECHANICAL PROPERTIES OF STEELS

1.1 Hardness 1.2 Brinell Hardness Test 1.3 Tensile Test 1.4 Tensile Properties 1.4.1 Elastic Limit 1.4.2 Yield Point 1.4.3 Yield Strength 1.4.4 Tensile Strength 1.4.5 Fracture Strength 1.5 Ductility 1.5.1 Elongation 1.5.2 Reduction in Area 1.6 Charpy Impact Test

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Si: Page 1

MECHANICAL PROPERTIES OF STEELS 1.1 HARDNESS

The property of "hardness" is difficult to define, except in relation to a particular test used to determine its value. Hardness is not a fundamental property of material, but is related to the elastic and plastic properties. The hardness value obtained in a particular test serves only as a comparison between materials or process treatments. Hardness usually implies a resistance to deformation and, for steels, the property is a measure of the resistance to permanent or plastic deformation. The test procedure and sample preparation are usually simple, and the results may be used in estimating other mechanical properties. Hardness testing is widely used for inspection and control, where heat treatment, or working the steel, results in a change of hardness. A hardness value is particularly useful in determining the wear resistant properties of steels. High hardness values result in a higher abrasive resistant material. Most wear resistant steels are ranked in order of hardness. Calculation is unnecessary, due to availability of conversion tables which give hardness values as a function at the measured d.

1.3 TENSILE TEST

The tensile test is widely used to provide basic design information on the strength of materials and as an acceptance test for the specification of materials. Tensile tests are conducted to AS1391-1974. The standard specifies specimen sizes, test conditions and staff requirements. A test specimen is placed under a continually increasing load. Observations are made of the load and extension of the test specimen. Observations are usually taken in the graphic form by a recorder attached to the tensile machine. The graph, load versus extension, can be examined to determine tensile properties such as elastic limit, yield point, yield strength, tensile strength and fracture strength. From the test specimen, ductility properties, such as elongation and reduction in area, can be determined.

1.2 BRINELL HARDNESS TEST

The Brinell hardness test consists of indenting the steel surface with a 10mm diameter steel ball at a load of 3,000kg. The test is conducted under AS1816-1977, which specifies testing conditions. The Brinell hardness number (BHN) is expressed as the load P divided by the surface area of indentation, and is given by: BHN 77-D (D 02 d2 ) 2 where P = load applied, kg D = diameter of ball, mm d = diameter at indentation, mm
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1.4 TENSILE PROPERTIES

The properties which may be determined by a tensile test are as follows:

1.4.1 ELASTIC LIMIT

It is found for many structural materials the early part of the loadelongation graph is a straight line (linear). The load and extension are proportional to each other. Any increase in load results in a proportional increase in elongation of the specimen. If the load is removed, the specimen returns to its original dimensions, thus elastic behaviour has been displayed by the material. If the load is continuously increased, a point will be reached at which permanent elongation will result.
S1: Page 2

The stress of any point is the load divided by the original cross sectional area while strain is the extension of that point divided by the original length. The elastic limit is defined as the minimum stress at which permanent deformation first occurs, as seen in Fig. 1.4a.

1.4.4 TENSILE STRENGTH

The tensile strength is the maximum stress developed by the material point M.

1.4.5

FRACTURE STRENGTH

ELASTIC BEHAVIOUR

PLASTIC BEHAVIOUR

UNIFORM

LOCALISED

Fracture is the separation of a solid body into two or more parts under the action of stress. A ductile fracture is characterised by appreciable plastic deformation, both uniform and localised. After the maximum stress is reached (TS), localised deformation occurs, resulting in the necking of the specimen. The fracture strength is the stress at the point of failure of the specimen. It is always less than the tensile strength. In brittle fractures, little necking occurs. In practical design it is of little consequence.

ELONGATION
Fig. 1.4a. Load versus elongation graph where Y = Yield Point or Elastic Limit M = Tensile Strength F = Fracture Strength X = Proof Stress

1.5 DUCTILITY
The ductility of a material is indicated by the amount of deformation that is possible until fracture. This is determined in a tension test by two measurements.

1.4.2

YIELD

POINT

The stress at Point Y, Fig. 1.4a, is known as the yield point. This phenomenon occurs only in certain ductile materials where there is a sudden discontinuity in the load versus extension curve. If the material is loaded above this limit, permanent deformation will result.

1.5.1 ELONGATION
This is determined by fitting together, after fracture, the parts of the specimen and measuring the distance between the original gauge marks. f Lo x 100 Elongation "'L Lo (per cent) where L = final gauge length f L0 original gauge length (usually 50mm) In reporting per cent elongation, the original gauge length must be specified, since the per cent elongation will vary with gauge length.

1.4.3

YIELD STRENGTH

Most high strength steels do not possess a well-defined yield point. For those materials, the maximum useful strength is the yield strength. The yield strength is the load required to produce a small amount of plastic deformation. The usual definition of this property is the offset yield strength (proof stress), determined by the stress corresponding to the intersection of the curve at an offset value, e.g. 0.2%. The stress at which the steel begins to flow plastically (non-linear section) is an important feature, because it can be used to calculate the load at which permanent deformation results. In engineering design, it is always imperative that components retain their original dimensions. Thus the yield strength is the most important result from tensile tests. 6/84

1.5.2

REDUCTION IN AREA

This is also determined from the broken halves of the tensile specimen by measuring the minimum cross-sectional area and using the following formula: Aci- A f Reduction in Area = (per cent) x 100 A o where A = original cross-sectional area Af= final cross-sectional area S1:Page 3

1.6 CHARPY IMPACT TEST

Structural steel is usually ductile at atmospheric temperatures. However, some of the most disastrous and tragic of engineering failures, such as the complete break-up of ships, bridges and pressure vessels, have been caused by the brittle fracture of steel. Such fractures come without warning and take place very rapidly. A welded steel ship, for example, may break in two in a fraction of a second, due to a brittle crack which runs around its hull and deck at a speed of up to 2000m sec:' Temperature plays a major part in the effect. Except for face centred cubic metals, virtually all solids become brittle at low temperatures. The transition from ductile behaviour to brittle behaviour generally occurs in a narrow range, a few tens of degrees only, so that it is possible to characterise a material by a certain transition temperature. In mild steel, a crack-arrest temperature commonly occurs in the range -23 to 73C. Below the crack-arrest temperature, the metal will allow a crack, once started, to run as a brittle fracture at a stress of the order 69 MPa, which is in the range of ordinary working stresses for steel in structural engineering. Above this temperature, the metal will stop such a crack by extensive plastic deformation at the tip. A number of engineering tests have been devised to evaluate the transition from brittle to ductile fractures in steels. One of these is the Charpy impact test with a V notch specimen. Laboratory environment, condition and procedure are set out by AS1544-1975. Basically, the Charpy specimen has a square cross section (10mm x 10mm) and contains a 45 V notch 2mm deep, with a 0.25mm root radius, as shown in Fig. 1.6a. The specimen is supported

a beam in a horizontal position and loaded behind the notch by the impact of a heavy swinging pendulum. The specimen is forced to bend and fracture at a high strain rate.
as

KNIFE EDGE MOUNTED IN A WEIGHTED PENDULUM HAMMER

Fig. 1.6b. Method of applying the impact load to a Charpy specimen.

The principal measuremennt from the impact test is the energy absorbed in fracturing the specimen. After breaking the test bar, the pendulum rises to a height which decreases as the energy absorbed in fracture increases. The energy absorbed in fracture is read directly from the calibrated dial on the testing machine. The notch bar impact test is most meaningful when conducted over a range of temperatures. By using the test, a change in the mode of fracture of steel as a function of temperature can be observed.

high DUCTILE FRACTURE

cri,
6 mm

IMPACTSTRENGT H

BRITTLE FRACTURE

t
5.5 cm

//icm

low -150 .100 50 TEMPERATURE, "C 50 100

Fig. 1.6a. V-notch Charpy impact test specimen. 6/84

Fig. 1.6c. Representative Charpy impact ductile to brittle fracture transition. S1:Page 4

Impact test results are dependent on a number of factors besides temperature. Rolling direction of the plate, steel chemistry and microstructure are also impact dependent.

ROLLING DIRECTION

high ENERGYABSORBED
LONGITUDINAL (L)

ductile

TRANSVERSE (T)

brittle
low

-100

-00

2 10

+20

+60

+100

TEMPERATUREC

Fig. 1.6d. Effect of specimen orientation of Charpy transition temperature curves.

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Si: Page 5

SEC HON TWO

EA I I ENT HEAT F STEEL

2.1 introduction 2.2 Annealing 2.3 Normalising 2.4 Hardening by Heat Treatment 2.5 Tempering 2.6 Stress-Relieving 2.7 Definition of phases in steel 2.7,1 Carbides 2.7.2 Austenite 2.7.3 Ferrite 2.7.4 Pearlite 2.715 Martensite 2.8 Alloying Elements 2.8.1 Carbon 2.8.2 Boron 2.8.3 Silicon "2.8.4 Manganese 2.8.5 Molybdenum 2.8.6 Chromium 2.8.7 Titanium 2.8.9 Sulphur and Phosphorus

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2. HEAT TREATMENT OF STEEL

2.1 INTRODUCTION
The definition of heat treatment given in the Metals Handbook is "a combination of heating and cooling operations, timed and applied to a metal or alloy in the solid state in a way that will produce desired properties". The mechanical properties of steel are dependent on chemical composition and microstructure. Although chemical composition affects the stability of certain phases in the microstructure, heat treatment generally controls the microstructure in a steel. Thus phases, grain size and distribution can all be influenced and controlled by applying certain heat treatments.

2.2 ANNEALING
Annealing is usually carried out at temperatures above the Ai curve (see FeC Phase Diagram). Annealing consists of the slow cooling of a steel to low temperatures. By annealing a steel, the microstructure tends toward that predicted by the phase diagram, equilibrium conditions. The result of annealing is a uniform composition, stress-free microstructure of ferrite and pearlite. The purpose of annealing may be to refine the grain size, induce softness, improve electrical and magnetic properties and, in some cases, to improve machinability.

1500 ..., 1400 ., 1111 -,

1300

1200
,,.

, Austenite x 1 ,)

1100

1000 to I:C

ANNEALING / 900 AI -,_ -, /

Austenite & Cementite

I 4 to CC800 a. I 700 600

RECRYSTALLISATION

HIGH TEMPERATURE STRESS RELIEF 500 400 LOW TEMPERATURE STRESS RELIEF 300 200 100 ------

Ferrite & Cementite

10

3.0 20 PERCENTAGE CARBON BY WEIGHT

40

50

Fig. 2.1a. The Iron-Carbon Phase Diagram. 6/84

800

EUTECTOID TEMPERATURE 700

AUSTENITE
0.0.*

PEARUTE 600

500

PEARLITE BAINITE

.9 uJ CC

< 400 cc

50%

G.
IIJ

2 AUSTENITE 300 3

BAINITE

200
M50

100

MARTENSITE AND AUSTENITE

BAINITE AND MARTENSITE 4

1

MARTENSITE-0".2 3 fral FINE PEARLITE 0 0.1 1 10 100 TIME, IN SECONDS 103

104

105

Fig. 2.4a. Time Temperature Transition Diagram. Lines 1, 2, 3 & 4 show varying cooling rates to yield the corresponding microstructures. 6/84 S2: Page 3

TEMPERATURE

EFFECT OF BORON

FERRITE 'C' CURVE

Fig. 2.4b. Schematic diagram showing the effect of boron on the isothermal transformation diagram of Bisalloy steels.

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2.3 NORMALISING
Normalising consists of air cooling the steel from the Al temperature (see Fe-C Phase Diagram) to room temperature. Normalising has a faster . cooling rate than that of annealing. The result of normalising is to obtain a finer pearlite structure which yields increased mechanical properties. Hardness and tensile properties would both be increased. Normalising may also be used to improve machinability, modify and refine cast dendritic structures, refine the grain size and homogenise the microstructure in order to improve the response in mechanical properties.

is to relieve residual stresses and to improve the ductility and toughness of the steel. This increase in ductility is usually attained at the sacrifice of some hardness or strength. In general, over the broad range of tempering temperatures, hardness decreases and toughness increases as the tempering temperature is increased. The tempering range of 300-600C is a dividing line between the applications that require high hardness and those requiring high toughness. If the principal desired property is hardness or wear resistance, the part is tempered below 450C; if the primary requirement is toughness, the part is tempered above 4509C.

2.4 HARDENING
Microstructure plays a dominant role in the mechanical properties of steels. By controlling the cooling rate, different microstructures can be obtained, thus different mechanical properties can be produced. Under slow cooling rates (annealed conditions), an equilibrium structure of pearlite and ferrite is obtained from a low alloy steel, such as from the BISALLOY range. This structure has the lowest hardness. Under moderate cooling rates (normalising), a finer grained matrix results. Pearlite, ferrite and bainite would all be present. This finer grained structure has a higher hardness, due to the increase in the amount of bainite present. Under severe cooling rates (quenching), a martensitic microstructure is formed. Martensite is a very hard, brittle metastable phase. A fully martensitic structure is obtained during the production of the BISALLOY range. The formation of martensite leaves high residual stresses in the steel which result in the brittle nature of this phase. By further heat treatment, the brittleness can be removed with only a slight loss of hardness. This is usually done by tempering.

2.6 STRESS RELIEVING

This process, sometimes called subcritical annealing, is useful in removing residual stresses due to fabrication or production. Stress in the metal caused from heavy machining or other working processes, can be removed in a less brittle material. Stress relieving is carried out between 450650C. The higher the temperature, the greater the effect of stress relief.

2.7 DEFINITION OF PHASES IN STEEL

2.7.1 CARBIDES
Iron carbides are present in all steels. One common carbide is cementite (Fe3C). Cementite is a hard brittle interstitial precipitate which increases the hardness of the microstructure.

2.7.2 AUSTENT1TE
Au stenite is an interstitial solid solution of carbon dissolved in faced centred cubic iron. Maximum solubility is two per cent C at 1147C. Average properties are: 830 MPa Tensile strength Elongation 10 per cent in 50mm Hardness BHN 370 (approx.) It is normally not stable at room temperature.
S2: Page 5

2.5 TEMPERING
In the as-quenched martensitic condition, the steel is too brittle for most applications. The purpose of tempering
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2.7.3 FERRITE
Ferrite is an interstitial solid solution of a small amount of carbon dissolved in body centred cubic iron. The maximum solubility is 0.025 per cent C at 723C and it dissolves only 0.008 per cent at room temperature. Average properties are: 300 MPa Tensile strength 40 per cent in 50mm Elongation BHN 170 (approx.) Hardness

2.7.4 PEARLI1
Pearlite is the eutectoid mixture containing 0.80 per cent C and is formed at 723C on very slow cooling. It is a very fine platelike or lamellar mixture of ferrite and cementite. Average properties are: 600 MPa Tensile strength 20 per cent in 50mm Elongaton BHN 270 (approx.) Hardness

mechanical strength and the hardening properties of the steel improve, but its elasticity, forging, welding and cutting properties suffer. The carbon content has no influence on the corrosion resistance of the steel. In addition to carbon, every unalloyed steel contains silicon, manganese, phosphorus and sulphur, which are introduced during manufacture. The addition of further alloy elements to produce specific desired effects and the intentional increase of the contents of manganese and silicon give rise to alloy steel.

2.8.2 BORON
Boron is unique among the alloying elements in that its effect on hardenability is large and the optimum concentration for this effect is small (0.0007%). Reproducibility of this concentration uniformly is so difficult that steelmakers usually aim at the lower hardenability obtained between 0.0015 and 0.0025% boron. In this region, hardenability is less sensitive to concentration. The hardenability of boron-treated steels is attributed to the role boron plays on the pearlite transformation. Boron inhibits the nucleation of pearlite at the grain boundaries. This effect can be seen on the TTT diagram Fig. 2.4b. The effect of adding small amounts of boron is comparable to high alloy steel additions without the drawbacks of availability and price of traditional alloy additions such as molybedenum or chromium. Boron improves the deep hardening of constructional steels.

2.7.5 MARTENSITE
The martensitic structure in steels is a simple phase which marks it from the aggregates of ferrite and carbides. The martensitic crystal structure is body centred tetragonal and can be treated as an intermediate structure between phases. The phase change which occurs in a martensitic transformation is brought about by the movement of the interface of parent and product phases. Martensite is a very hard brittle phase, which produces shape deformation and high internal stresses on formation.

2.8.3 SILICON

2.8 ALLOYING ELEMENTS

Most alloying elements in steels tend to increase the resistance of the steel to softening when it is heated, which means that for a given time and temperature of tempering, an alloy steel will possess a greater hardness after tempering than a plain carbon steel of the same carbon content.

Silicon is present in all steels. It has similar effects to that of carbon, increases hardness (to a lesser degree), however does not promote the welding problems which carbon exhibits.

2.8.4 MANGANESE
Manganese improves the strength and toughness properties of the steel. Furthermore, manganese has a favourable influence on the forging and welding properties.

2.8.5 MOLYBDEMUM
Molybdenum improves the tensile properties of the steel. Improvement in heat resistance is also noted with that corresponding improvement in weldability. Molybdenum has a strong tendency to form carbides and is the alloy element of choice in heat-treating steels as well as heat-resistant steels.
S2: Page 6

2.8.1 CARBON
Carbon is the foremost alloy element of steel and it has the farthest reaching influence on it. The hardenability of a steel is strongly influenced by its carbon content. As the carbon content rises, the
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2.8.6 CHROMIUM
Increases in hardness and strength are notable features when chromium is added to low alloy steels. It also improves the heat resistance and nonscaling properties of the steel.

2.8.7 TITANIUM
The formation of titanium carbide greatly improves the hardness of the steel. Titanium also reduces the grain size, with the corresponding improvement in mechanical properties. It is also used to facilitate uniform and predictable distribution of boron in boron-containing steels.

2.8.8 SULPHUR AND PHOSPHORUS

Both elements are kept to a minimum and are treated as impurities. In particular, low sulphur contents can lead to enhanced ductility properties ( eg elongation, reduction in area and impact properties). It is desirable to keep phosphorus contents low to avoid temper embrittlement during heat treatment.

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SECTION THREE

SPECIFICATION OF BISALLOY STEELS

3.1 Production of Quenched & Tempered Steel Plate 3.1.1 Production Process 3.1.2 Metallurgical Grades of Bisalloy Products 3.2 Bisalloy 80 3.2.1 Chemical Composition 3.2.2 Tensile Properties 3.2.3 Impact & Hardness Properties 3.2.4 Fatigue Properties 3.3 Bisalloy 80 PV 3.3.1 Introduction 3.3.2 Chemical Composition 3.3.3 Tensile Properties 3.3.4 Impact & Hardness Properties 3.4 Bisalloy 320 & Bisalloy 360 3.4.1 Chemical Composition 3.4.2 Tensile Properties 3.4.3 Impact & Hardness Properties 3.4.4 Fatigue Properties 3.5 Bisalloy 500 3.5.1 Chemical Composition 3.5.2 Tensile Properties 3.5.3 Impact & Hardness Properties 3.6 Chromium Molybdenum Steels 3.6.1 Chromium Molybedenum Alloy Grades 3.6.2 Chemical Composition 3.6.3 Tensile Properties 3.6.4 Size & Order Quantities 3.7 HY80 and HY100 3.7.1 Introduction 3.7.2 Chemical Composition 3.7.3 Tensile Properties 3.7.4 Impact Properties 3.8 Special Requirements 3.8.1 Customer Orders 3.8.2 Special Applications of Bisalloy 500 3.8.3 520 MPa Quenched & Tempered Steel 3.8.4 Bisalloy with BHN 400

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53: Page 1

3. SPECIFICATIONS OF BISALLOY STEELS 3.1 PRODUCTION OF QUENCHED AND TEMPERED STEELS

Bunge Industrial Steels Pty Limited is the sole Australian tonnage producer of quenched and tempered steel plate. impact properties, such as Bisalloy 80, are tempered at 600-615C. The versatility of the heat treatment plant permits BIS not only to produce standard high strength and wear resistant grades, but also to quench and temper custom-made grades of steel plates. Enquiries for such grades should be directed to BIS, Unanderra. Note that steels sold in the quenched and tempered condition are normally intended to be used as supplied. However, there may be occasions when parts, such as heads for pressure vessels, require to be hot formed. Because of the significant influence of re-heat temperature on the mechanical properties of quenched and tempered steels, it is desirable that in such cases, specific information as to the correct heat treatment should be obtained for the particular steel in question. Maximum advantage has been taken of the highly efficient quench operation by reducing the alloy content substantially. The strict control of operating conditions for producing a high strength product is maintained by the production process. The result is a weldable, workable, high strength steel product.

3.1.1 PRODUCTION PROCESS

Feed plates for the BIS heat treatment plant are supplied by Broken Hill Proprietary Company in the form of hotrolled plates from Australian Iron and Steel Pty Ltd at Port Kembla. The production of feed for any successful quenching and tempering operation demands the highest technical expertise of the steelmaker as well as the heat treater. In particular, the steel grades involve special steelmaking techniques and plate manufacturing procedures. These have been developed at AWLS, Port Kembla, and incorporated into the total production process. In addition, quality control and assurance of the entire process is maintained through regular, planned liasion between technical and production personnel from both Al&S and BIS. The heat treatment operation, shown schematically below, consists of heating the steel plate in the austenitising furnace to approximately 900C, holding at that temperature for a predetermined time dependent on plate thickness and quenching by water at a sufficiently rapid rate to produce an essentially fully martensitic microstructure. In the BIS plant, quenching water is delivered through high intensity curtain headers and spray pipes at a rate of up to 123,500 litres per minute while the plate is guided between two sets of rolls of the continuous roller quench unit. Quenching is followed by tempering at a temperature chosen to produce the desired combination of strength, hardness and toughness. For example, the highest hardness wear resistant grades are tempered at a temperature between 175C and 450C, depending on the hardness range specified, while the high strength structural grades furnished to guaranteed tensile and
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3.1.2 METALLURGICAL GRADES OF BISALLOY producing the following grades of steel

plates: Bunge Industrial Steels is at present

METALLURGICAL ABBREVIATION GRADE BISALLOY 80 BIS-80

APPLICATION HIGH STRENGTH STEEL MEETING MECHANICAL PROPERTIES OF ASTM A514 HIGH STRENGTH STEEL MEETING PRESSURE VESSEL SPECIFICATION ASTM A517 BHN 320 WEAR RESISTANT STEEL PLATE BHN 360 WEAR RESISTANT STEEL PLATE BHN 500 WEAR RESISTANT STEEL PLATE HIGH TEMPERATURE CREEP RESISTANT STEEL MEETING ASTM A387 HIGH STRENGTH STEEL PLATE MEETING DEFENCE SPECIFICATION MIL-S-16216J

BISALLOY 80 PV

BIS-80PV

BISALLOY 320 BISALLOY 360 BISALLOY 500 CHROMIUM MOLYBDENUM STEEL HY80/HY100

BIS-320 BIS-360 BIS-500 Cr/Mo

HY80/1-1Y100

PRODUCTION PROCESS AT BUNGE INDUSTRIAL STEELS UNANDERRA As rolled plate to BIS specifications from AI&S Port Kembla Plate Inspection at Unanderra by Quality Assurance Metallurgist Charging Table Hardening Furnace Continuous Quenching Unit Tempering Fuinace Cooling Table On line plate hardness testing Plate Inspection (shape/surface) Testpiece Sampling Mechanical Testing Laboratory Approval Certification Despatch 6/84 S3: Page 3

PRODUCTION

ON LINE NATA APPROVED LABORATORY QUALITY ASSURANCE PROGRAM

3.2 BISALLOY 80
3.2.1. CHEMICAL COMPOSITION
Chemical composition data for BIS-80 is shown below. Those elements not shown are present in residual quantities only. The table indicates the very close control achieved during steelmaking over the concentration of individual elements. The carbon equivalent is kept to a minimum by a low alloy content. The tight carbon equivalent range, such as that possessed by all the Bisalloy range of steels, contributes to uniformity of mechanical properties as well as consistency in welding. The ease of other fabrication operations, such as bending and forming, is improved by the low nonmetallic content resulting from the low sulphur and phosphorus content of these steels. Carbon Equivalent = Mn Cr + Mo + V Ni + Cu C+ + 5 15 6 For BIS-80, a typical value of C.E. of 0.53 would be expected. CHEMICAL COMPOSITION OF BISALLOY 80 Element Carbon Manganese Silicon Molybdenum Chromium Boron Titanium Nickel Copper Sulphur Phosphorus Range % Typical %

3.2.2 TENSILE PROPERTIES

It is important to recognise that tensile properties are dimensionally sensitive, thus the thickness of the plate affects the tensile properties. The guaranteed tensile properties of BIS-80 are: BIS-80
Property Thickness mm Minimum Value MPa

Yield Strength 3.25 55 60 100 Tensile Strength Elongation Reduction in Area 3.25 55 60 100 3.25 65 70 100 3.25 16 20 100

690 620 790 720 16% 14% 35% 45%

0.17 0.15 0.21 1.15 0.80 1.30 0.40 0.15 0.50 * 0.40 max. 0.85 0.60 1.20 0.0005 0.006 0.002 0.015 0.050 0.030 0.020 0.30 max 0.020 0.20 max 0.010 0.015 max 0.020 0.025 max

*Molybdenum content is dependent on the thickness of the plate. All data is given as a weight per cent.

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PLATE THICKNESS 5 TO 12 mm

YIELD STRENGTH

TENSILE STRENGTH

30

25

FREQUENCY%

20

15

10

660

700

720

740 MPa

760

780

800

FREQUENCY%

ELONGATION

REDUCTION IN AREA

30

25 FREQUENCY %

FREQUENCY%

20

15

10

18 20 22 24 26 28 30

30 35 40 45 50 55 60 65

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PLATE THICKNESS 12 TO 25 mm

YIELD STRENGTH

TENSILE STRENGTH

30

25

FREQUENCY%

680 700 720 740 760 780 800 MPa.

780 800 820 840

ELONGATION
30

REDUCTION IN AREA

25

20

0 10

20

22

24

26
Ok

28

30

32

35

40

45

50

55

60

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PLATE THICKNESS 25 TO 50 mm

YIELD STRENGTH 25 25 TENSILE STRENGTH

20 20 FREQUENCY % 680 700 720 740 MPa 760 780 800 780 800 820 840 860 MPa 880 900 ELONGATION

15

10

REDUCTION IN AREA

25 FREQUENCY%

20

>LI z iu 15 D 0 Lu cc u. 10

16

18

20

22 %

24

26

28

40

45

50

55

60

65

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PLATE THICKNESS 50 TO 100 mm.

YIELD STRENGTH
25

TENSILE STRENGTH

20 25

>- 20 O 15
CC LL

10

680

700

720

740

760

780

800

780

800

820

840 MPa

860 880

MPa

ELONGATION REDUCTION IN AREA

25

20 FREQUENCY % 16 18 20 22 24 26 28

15

10

35

40

45

50 0/ 0

55

60

65

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TYPICAL TENSILE PROPERTIES FOR BIS-80 Specimen 1 Thickness mm 6 12 20 50 75 Yield Strength MPa 720 760 780 750 740 TS2 MPa 800 835 890 840 830 Elongation % 24 24 24 20 19 Reduction in Area % 35 40 50 60 65

A B C D E

1. These are actual specimens tested during the routine quality assurance programme. 2. Tensile Strength

STRESS (MPa)

The tensile test data for various plate of BIS-80 shown in the graphs clearly indicates that the tensile requirements of such standards as ASTM A514 & A517 can be readily satisfied by the standard grade BIS-80. The graphs also display the variation in tensile properties which may occur. At BIS, the technical staff guarantee a minimum value, however, higher values are always obtained.
High Temperature Tensile Data

BIS-80 HIGH TEMPERATURE TENSILE DATA

1000 800 Y O 600 1 , 41' : 11'

16 ,

TENSILE STRENGTH

'''

Qx...,,,.._..._, a 8 x

o :

1.---, x AN
x \

,x

4 0.2% PROOF STRESS \

400

The application of quench and tempered steel plate such as BIS-80 at elevated temperatures should be approached with caution. Prolonged exposure to excessive heat will lead to substantial loss of mechanical properties, including strength and hardness. This is primarily due to a micro structural change of the plate due to overtempering. Any proposal for the use of Bisalloy 80 at temperatures above 150C should be referred to the manufacturer. The following graphs show the results of high temperature tests performed on BIS-80 in accordance with AS2291-1979. A clear indication of the likely effects of high temperatures on the mechanical properties of BIS-80 is given.

200

100 MALLOY 80 12 mm PLATE 20 mm PLATE X 50 mm PLATE a

200

300

400

500

600

TEST TEMPERATURE (CC)

30 ELONGATION (%)

20

a
ox

, x

10

-x ....i x a o--o x--*"x

' --- x ____ -----4

80 REDUCTION OF AREA ()

. . '4 - . . . . . _. 2 . ...._6x . x

60

.
40

gx K

= _ :

. .

20

100

200

390

400

500

600

TEST TEMPERATURE (DC)

6/84

S3: Page 9

3.2.3 IMPACT & HARDNESS

PROPERTIES
Impact and hardness properties of BIS80 are given below. The notch toughness of BIS-80 steel plates is extremely good. Notch toughness of these plates has been obtained by careful control over chemical composition and heat treatment process. As shown in the graphs, the Charpy V-notch energy values obtained during the routine impact tests at -20C easily exceed the nominated minimum values and, further, extend to exceptionally high energies. Plates of BIS-80 have exceptional notch toughness at low temperatures, as demonstrated by the impact transition curves for tests in both the longitudinal and transverse directions, Fig. 3.2a. The normal measure of notch toughness of quenched and tempered

steels for pressure vessel and similar applications is the lateral expansion of the broken Charpy test piece. The criterion adopted is that the lateral expansion should exceed 0.38mm at the test temperature. Tests have indicated that BIS-80 consistently meet the requirement at temperatures of -20C and below. It is normal practice to Brinell hardness test every plate produced as a matter of routine quality assurance. The range from BHN 235-293 is guaranteed. Unless otherwise specified, one tensile test and one set of three Charpy V-notch tests are taken from each ten tonnes of each batch of plates and the tested plate is certified as having mechanical properties meeting the certification. * A batch is a group of plates of the same thickness and from the same heat.

MINIMUM CHARPY TEST RESULTS FOR BIS-80 Plate mm 3.25 5 68 10 ?1.2 Test Piece
mm

Charpy Impact Value at -20C Joules average of 3 individual 10 13 20 27 7 10 15 20

10 x plate thickness 10 x 5 10 x 7.5 10 x 10

6/84

S3: Page 10

Plate thickness Test Piece Size Longitudinal Transverse (mm) (mm) 6 12 10 x 5

Plate thickness Test Piece Size Longitudinal Transverse (mm) (mm) 25 50 180 10x10 10 x 10 ---

120 160

U)
100 -

140 0

ENERGY VALUE (JOULES)

80 -

w
>

120

100 80

60

cc tu w

60 40 40 20 20
-

-80 -60 -40 -20 0 +20 -80 -60 -40 -20 0 +20

TEST TEMPERATURE(C)

TEST TEMPERATURE (C)

Figure 3.2a Transition Impact Diagram for BIS-80

CHARPY IMPACT NOTCH TOUGHNESS VALUES BISALLOY 80

emm Plate Temperature -20C Specimen Size 10 x 5 mm.

30

26

22

FREQUENCY4'/0

18

15

12 10 8 6 4 2

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110

ABSORBED ENERGY - JOULES 6/84 S3: Page 11

CHARPY IMPACT NOTCH TOUGHNESS VALUES BISALLOY 80 12 mm Plate Temperature -20C Specimen Size 10 x 10 mm.

FR EQUENCY %

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 ABSORBED ENERGY-JOULES

DISTRIBUTION DIAGRAM OF CHARPY V NOTCH VALUES FOR BISALLOY 80 25 mm Plate Temperature - 20C Specimen Size 10 x 10 mm.

14

12

10 >0 9

0 8 CC u- 7 6 5 4 3 2 1

20 25 30 35 40 45 50 65 70 75 80 85 90 95 100 105 110 115 120 125 130 ABSORBED ENERGY-JOULES 6/84

53: Page 12

3.2.4 FATIGUE PROPERTIES

A metal subjected to a repetitive or fluctuating stress will fail at a stress much lower than that required to cause fracture on a single application of load. Failures occurring under conditions of dynamic loading are called fatigue failures. Fatigue has become progressively more prevalent as technology has developed equipment subject to repeated loading and vibration. There are many factors which influence fatigue failures. The most important are maximum tensile stress, variation in applied stress and number of cycles of applied stress. Variables such as stress concentration, temperature, corrosion and others also influence fatigue failures.

Fatigue Results on BIS-80 Fatigue tests were conducted on BIS-80 by Unisearch Ltd, the research division of the University of New South Wales. BIS-80 test pieces oriented parallel to the rolling direction exhibited the highest fatigue limit of 420 MPa, while the transversely oriented test pieces had a fatigue limit of 400 MPa. The fatigue limit for as welded 12mm BIS-80 plate test pieces is 160 MPa. In the case of welded plates with weld reinforcement, fatigue failure invariably initiated at the toe of the reinforcement and propogated through the parent metal. The tests indicated that, if excessive reinforcement is removed from a welded joint, its fatigue limit will approach that of the parent plate. The fatigue tests were conducted up to a run-out condition of 2 x 106 cycles.

800

SN CURVE BISALLOY 80 PARALLEL TO RD G2 R = -a

ALTERNATINGSTRESSMPa

600

400

200

10'
NUMBER OF CYCLES

le

2 X 10'

10'

GOODMAN DIAGRAM ENDURANCE CURVES FOR BISALLOY 80 2. 10 CYCLES FATIGUE STRENGTH R =-1 800

UTS

600

400

200

0 -400 -200

200 STRESS AMIN MPa

400

600

800

6/84

S3: Page 13

3.3 BISALLOY 80 PV
3.3.1 INTRODUCTION
Bisalloy 80 PV is a high strength quenched and tempered low alloy steel plate for pressure vessel applications. Bisalloy 80 PV is intended for use in pressure vessels and every plate is mechanically tested in line with the provisions of ASTM A517. The only difference between Bisalloy 80 and the pressure vessel version is the frequency of mechanical tests conducted on the steel plate. It is therefore possible to convert Bisalloy 80 into Bisalloy 80 PV, provided the appropriate testing is carried out. Upon request, a formal specification approved by the relevant statutory authority in an Australian Standard format is available. Direct contact with BIS at Unanderra is necessary.

3.3.3 TENSILE PROPERTIES

Every plate designated Bisalloy 80 PV is individually tested. One test specimen for tensile testing is taken from each end of the plate, midway between centre and either edge. Tensile tests will be conducted in accordance with AS1391 to establish the tensile properties.

3.3.4 IMPACT AND HARDNESS PROPERTIES

Three Charpy V-notch test pieces are cut from each test specimen parallel to the principal direction of rolling, with the axis of the notch perpendicular to the rolled surface of the plate. Each test piece is tested in accordance with AS1544, Part 2. The test temperature will be -20C, unless otherwise agreed upon between the manufacturer and the purchaser. Lateral expansion measurements will also be conducted in accordance with ASTM A517. An average value for lateral expansion tests will not be below 0.38mm. IMPACT & HARDNESS VALUES FOR BIS-80 PV Hardness BHN Lateral expansion at -20C 235 to 293 0.25mm Minimum 0.38mm Average

3.3.2 CHEMICAL COMPOSITION

The chemical composition of this material is the same as Bisalloy 80. (See Section 3.21)

BIS-SO PV Thickness mm 3.25 16 16 65 65 100 Yield Strength MPa 690 690 620 Tensile Strength MPa 790 790 720 Elongation % 16 16 14 Reduction in Area % 35 45 45

These are minimum requirements for the tensile properties of Bisalloy 80 PV.

6/84

S3: Page 14

3.4 BISALLOY 320 AND 360

3.4.1 CHEMICAL COMPOSITION
Both BIS-320 and BIS-360 have the same chemical composition. The higher hardness of BIS-360 is obtained during the heat treatment of these steels. The chemical composition data is shown below. Those elements not shown are present in residual quantities only. A typical carbon equivalent of these grades would be C.E. = 0.53. The tight carbon equivalent range contributes to uniformity of mechanical properties, as well as consistency in welding.

TYPICAL TENSILE PROPERTIES FOR BIS-320 & BIS-360 PROPERTY Yield Strength Tensile Strength Elongation in 50mm Reduction in Area BIS-320 140,000 psi 98kg/mm2 965 MPa 155,000 psi. 109kg/mm2 1,070 MPa 13% 40 BIS-360 165,000 psi 116kg/mm2 1,135 MPa 180,000 psi 126kg/mm2 1,240 MPa 11% 35

3.4.2 TENSILE PROPERTIES

Unless dictated by special customer requirements, the abrasion resistant grades are seldom tensile tested. In general however, as the hardness and therefore strength of the grades increase, the ductility in terms of elongation and reduction in area decreases. The higher hardness grades are also characterised by a higher yield to tensile strength ratio than that of BIS-80, approaching 0.97 for a typical BIS-360 plate.

CHEMICAL COMPOSITION OF BIS-320 & BIS-360 Element Carbon Manganese Silicon Molybdenum Chromium Boron Titanium Nickel Copper Sulphur Phosphorus Range % 0.15 0.21 0.80 1.30 0.15 0.50 0.40 max 0.60 1.20 0.0005 0.006 0.015 0.050 0.30 max 0.20 max 0.015 max 0.025 max Typical % 0.17 1.15 0.40 * 0.85 0.002 0.030 0.020 0.020 0.010 0.020

It is important to recognise that mechanical properties of Bisalloy products are dimensionally sensitive. Thus, thick plates will have slightly lower tensile properties to that of a thin plate. Also, no two chemical compositions, rolling conditions or heat treatments are identical. Therefore, no two plates will be identical. All plates produced at BIS fall within a small range, however there is a distribution in the mechanical properties of the plates, ie not all BIS-360 has a hardness of exactly BHN 360 (nominally BHN 360-400).
HIGH TEMPERATURE TENSILE DATA

The use of any of the wear resistant grades at elevated temperatures should be avoided at all times. Prolonged exposure to excessive heat will lead to a substantial loss of strength and hardness due to the microstructural changes caused from over-tempering. Softening becomes particularly significant as the operating temperature approaches the tempering temperatures of the steel. Any proposed usage of BIS-320 or BIS360 at temperatures above 100C should be referred to the manufacturer. The following graphs describe the mechanical behaviour of BIS-360 at elevated temperatures. The tests were conducted in accordance with AS22911979. S3: Page 15

*Molybdenum content is dependent on the thickness of the plate. All data is given as a weight per cent.

6/84

HIGH TEMPERATURE TENSILE DATA FOR BISALLOY 360

Yll, ...

30

BISALLOY 360 20 mm PLATE Agamih. 200 TENSI E STRENGTH

ELONGATION (%) REDUCTIONOFAREA ( %) 600

20

10

000

m 0.
U)

800

0.2% PROOF STRESS

80

cc
600 60

400

40

200

20

100

200

300

400

500

100

200

300

409

500

600

TEST TEMPERATURE (C)

TEST TEMPERATURE (C)

TYPICAL IMPACT AND HARDNESS VALUES FOR BIS-320 Plate Thickness mm 6 12 25 50 80 Hardness BHN 320 360 320 360 320 360 320 360 320 360 Charpy Impact Values at +20C in Joules 30 45 40 35 30

TYPICAL IMPACT AND HARDNESS VALUES FOR BIS-360 Plate Thickness mm 6 12 25 50 80 Hardness BHN 360 400 360 400 360 400 360 400 360 400 Charpy Impact Values Joules +20C 0C -20C 25 35 30 25 20 20 25 20 20 15 15 20 15

3.4.3 IMPACT AND HARDNESS PROPERTIES

The impact and hardness values are given below. As the hardness value increases, the impact value decreases. Thus, as a steel becomes harder, it also displays a more brittle nature. The wear resistant grades of steel plate are graded by their hardness value, which is an indication of their wear resistance.

3.4.4 FATIGUE PROPERTIES

Fatigue tests on BIS-320 have been conducted by the research division of the University of New South Wales. It was found that the fatigue limit of BIS-320 is 390 MPa. The test pieces were axially ground in the longitudinal direction and oriented parallel to the rolling direction. Tests were conducted up to the run-out condition of 2 x 106 cycles. This value may be compared with a fatigue limit of 420 MPa for BIS-80. S-N curves and endurance curves are included.
S3: Page 16

6/84

1
1200

800

0. 2 2 400

GOODMAN DIAGRAM BISALLOY 320 2 x 105 CYCLES

400

0
Smay

400 MPa

800

1200

1100

1000

900

IN MPA
-ALTERNATING STRESS

800

S N CURVE BISALLOY 320

700

600

500

400

DNF

104

105
NUMBER OF CYCLES

106

2 x106

107

6/84

S3: Page 17

3.5 BISALLOY 500

3.5.1 CHEMICAL COMPOSITION
Chemical composition data for BIS-500 is shown below. Those elements not shown are present in residual quantites only. To obtain a higher hardness for this grade, the carbon content has been increased. To ensure the correct chemistry balance, the alloy content levels of silicon and chromium have also been increased. A typical carbon equivalent value of BIS-500 would be C.E. = 0.64. CHEMICAL COMPOSITION OF BIS-500

3.5.2 TENSILE PROPERTIES

Unless specifically required by the customer, the abrasion resistant grades are seldom tensile tested. However, if required by the customer, all tests can be conducted. Tensile properties of BIS-500 are given below. BIS-500 TYPICAL TENSILE PROPERTIES Yield Strength 215 000 psi 150 kg/mm2 1 480 MPa 230 000 psi 160kg/mm2 1 585 MPa 8% 30% 0.94

Tensile Strength

Elongation Element Carbon Manganese Silicon Molybdenum Chromium Boron Titanium Nickel Copper Sulphur Phosphorus Range % 0.26 0.32 0.90 1.30 0.40 0.90 0.20 0.30 0.70 1.10 0.0005 0.006 0.015 0.050 0.35 max 0.35 max 0.020 max 0.025 max Typical % 0.27 1.15 0.60 0.25 0.90 0.002 0.030 0.020 0.020 0.010 0.020 Reduction in Area Yield: TS ratio

3.5.3 IMPACT AND HARDNESS PROPERTIES

BIS-500 is the hardest grade produced at Unanderra. Impact and hardness values are given below. As with all wear resistant grades, the hardness value grades the material. IMPACT AND HARDNESS VALUES FOR BIS-500 Hardness BHN Fracture Toughness by Charpy Impact Test at +20C using 10 x 10 specimen cii Guaranteed 460 min. to 525 max.

20 Joules

6/84

S3: Page 18

3.6 CHROMIUM MOLYBDENUM STEELS

3.6.1 CHROMIUM MOLYBDENUM ALLOY GRADES
BIS is also producing a chromium molybdenum steel plate in accordance with the requirements of ASTM A387. The material is used primarily for elevated temperature service, with application in boiler installations, pressure vessel installations, pipework systems and pipe support installations. Through close-co-operation with AI&S producing the steel chemistry requirements, followed by heat treatment at BIS, the following grades are being produced. CHROMIUM MOLYBDENUM ALLOY GRADES ASTM A387 Grade Nominal Chromium Content 0.50 1.00 1.25 2.25 3.00 Nominal Molybdenum Content 0.50 0.50 0.50 1.00 1.00

2 12 11 22 21

NB: British Standards can also be supplied.

3.6.2 CHEMICAL COMPOSITION

The chromium molybdenum alloy grades are based on their chromium and molybdenum content. A more comprehensive range of chemical composition is given as follows: CHROMIUM MOLYBDENUM ALLOY GRADES Element 2 0.21 Carbon .50 .88 Manganese Phosphorus 0.035 Sulphur 0.040 0.13 - 0.45 Silicon 0.46 - 0.85 Chromium Molybdenum 0.40 - 0.65
6/84

11 0.17 0.35 - 0.73 0.035 0.040 0.44 - 0.86 0.94 - 1.56 0.40 - 0.70

12 0.17 0.35 - 0.73 0.035 0.040 0.13 - 0.45 0.74 - 1.21 0.40 - 0.65

21 0.15 0.25 - 0.66 0.035 0.035 0.50 2.63 - 3.37 0.85 - 1.15

22 0.15 0.25 - 0.66 0.035 0.040 0.50 1.88 - 2.62 0.85 - 1.15
93: Page 19

A typical chemical analysis of a Cr-Mo steel Grade 22, Class 2, would be as follows: Element Carbon Phosphorus Manganese Silicon Sulphur Nickel Chromium Molybdenum Copper Aluminium 0.125 0.024 0.50 0.40 0.009 0.060 2.25 1.00 0.025 0.040

3.6.3 TENSILE PROPERTIES

Tensile properties for the Cr-Mo grades are given below. Tensile strengths, yield strengths and elongation for both classes are displayed. It is important to recognise that Cr-Mo steels are a high temperature steel and will retain high strength up to 600C.

The low non-metallic inclusion content of these

steels, as seen by the low sulphur content, contributes to the good mechanical properties exhibited in tensile and impact tests.

Grade 2 iTS in MPa Class 1 Class 2 2 YS in MPa Class 1 Class 2 Elongation in % Class 1 Class 2
1 Tensile Strength 2 Yield Strength

11 415 585 515 690 240 310 22 22

12 380 550 450 585 220 275 22 22

21 415 585 515 690 200 310 18 18

22 415 585 515 690 200 310 22 22

380 520 485 620 220 310 22 22

NOTE: These are tensile property ranges as detailed by ASTM A387

Typical tensile properties of A387, Grade 22, Class 2, are as follows: Property Yield Strength (0.2% Proof Strength) Strength Tensile Elongation Reduction in Area Typical Value* 460 MPa 620 MPa 40% 67%

3.6.4 SIZES AND ORDER QUANTITIES

At the present time, these grades are offered on direct ex-mill basis and so all listed preferred plate from AIS is available, in accordance with minimum order quantities. BIS experience has proven that the most common sizes required are: 2500mm Width 6000mm Length 16, 20, 25, 40, 50mm Thickness These grades are available from the mill, based on the product of an electric furnace heat being 30 tonnes or multiples of 30 tonnes and made up of 5 tonnes per each individual size (minimum).
S3: Page 20

*Mechanical properties of these grades are

dimensionally sensitive. Thus thick plates would have slightly different values.

The standard, ASTM A387, specifies minimum tensile properties for these steels, for each particular grade. Due to the low impurity content of these steels, the tensile properties easily exceed the minimum requirement. The yield strength and tensile strength are on the high end of the range and the minimum elongation is readily achieved.
6/84

3.7 HY-8o AND HY-100

3.7.1 INTRODUCTION
HY-80 and HY-100 are both a military specification. HY-80 and HY-100 are sheared or gas cut alloy steel plates, intended primarily for use in hulls of combatant ships and for other critical structural applications where a notchtoughness, high-strength material is required. The requirements for HY-80 plate apply up to 200mm (8 inches) thick and for HY-100 plate up to 150mm (6 inches) thick. These steels are covered by military specification MIL-S-16216J (SH).

3.7.2 CHEMICAL COMPOSITION

The chemical composition ranges as specified by the military specifications are as follows:

CHEMICAL COMPOSITION RANGE FOR HY-80 AND HY-100 < 32mm Element Carbon Manganese Phosphorus Sulphur Silicon Nickel Chromium Molybdenum Vanadium Titanium Copper Arsenic Tin Antimony HY-80 0.10 - 0.20 0.10 - 0.45 0.020 max 0.020 max 0.12 - 0.38 1.93 - 3.32 0.94 - 1.86 0.17 - 0.63 0.03 max 0.02 max 0.25 max 0.025 max 0.030 max 0.025 max HY-100 0.10 - 0.22 0.10 - 0.45 0.020 max 0.020 max 0.12 - 0.38 2.18 - 3.57 0.94 - 1.86 0.17 - 0.63 0.03 max 0.02 max 0.25 max 0.025 max 0.030 max 0.025 max HY-80 0.10 - 0.20 0.10 - 0.45 0.020 max 0.020 max 0.12 - 0.38 2.43 - 3.32 1.29 - 1.86 0.27 - 0.63 0.03 max 0.02 max 0.25 max 0.025 max 0.030 max 0.025 max > 32mm HY-100 0.10 - 0.22 0.10 - 0.45 0.020 max 0.020 max 0.12 - 0.38 2.67 - 3.57 1.29 - 1.86 0.27 - 0.63 0.03 max 0.02 max 0.25 max 0.025 max 0.030 max 0.025 max

1. All data is given as a weight per cent. 2. As from Military Specification MIL-S-16216J (SH) 3. Product Analysis 6/84 S3: Page 21

3.7.3 TENSILE PROPERTIES

The table below gives the tensile properties by the military specification.

TENSILE PROPERTIES OF HY-80 AND HY-100 Property Yield Strength MPa Elongation % (minimum) Reduction in Area % (minimum) < 20mm thick HY-100 HY-80 550 690 19 690 830 17 > 20mm thick HY-80 HY-100 550 685 20 50 690 795 18 45

Specimen'

TYPICAL TENSILE PROPERTIES OF HY804 TS3 Elongation YS2 Thickness1 mm MPa 630 605 650 MPa 750 725 780 % 38 40 25

Reduction in Area % 65 65 70

A B C
2 3 4

9.5 15.9 50.8

These are actual test results from routine quality assurance program Yield Strength Tensile Strength Test carried out under Section 3.94

3.7.4 IMPACT PROPERTIES

Impact Requirements for a Transverse Charpy Test* Plate Thickness mm Specimen Size mm Average Value of Three Tests Joules HY-80 > 12.7
*As

Test Temperature C

HY-100 40 74 -85 -20

10 x 10

47 81

from Military Specification MILS-16216J (S}1)

The following values obtained by HY-80 produced at BIS. TYPICAL IMPACT PROPERTIES OF,HY-80 Specimens Thickness
mm

Charpy Impact Values at 85C Joules Transverse Longitudinal 160 130 150 120

A B C

9.5 15.9 50.8 the

1 These are actual specimens tested during routine quality assurance program.

6/84

S3: Page 22

3.8 SPECIAL REQUIREMENTS

3.8.1 CUSTOMER ORDERS
Whilst the standard grades shown herein are in regular production, it should be known that Bunge Industrial Steels are producing many other grades of heat-treated high strength and abrasion-resistant steels to meet customers' specific requirements. Thus if an abrasion-resistant grade with a hardness value of BHN 420 is for example, required, BIS can produce a special steel for the particular customer. Enquiries for grades other than those shown will be welcomed by Bunge Industrial Steels.

requirements of Class RI will also comply with the requirements of the "G" category.

3.8.3 520 MPa QUENCHED AND TEMPERED STEEL

A special order in accordance with AS1442 was undertaken. AS1442 only specifies a chemical composition range of a steel. Customer requirement also stated a minimum 0.2% Proof Stress of 520 MPa, and a Charpy Impact Test value at 0C in the longitudinal direction, using a 10 x 5mm specimen of 10 Joules minimum. The following chemical composition was used. Element Carbon Phosphorus Manganese Silicon Sulphur Nickel Chromium Molybdenum Copper Aluminium Heat 1 Weight % 0.15 0.017 1.46 0.28 0.009 0.038 0.083 0.004 0.020 0.040 Heat 2 Weight % 0.16 0.023 1.56 0.26 0.009 0.055 0.126 0.006 0.019 0.032

3.8.2 SPECIAL APPLICATIONS OF BISALLOY 500

BIS-500 is the hardest of the wear resistant plate produced at Unanderra. Besides applying this steel to wear resistance applications. BIS-500 has been tested as a bullet resistant material. Security applications, such as screens can now be produced from a Bisalloy at only a fraction of the weight of a mild steel alternative. Ballistic laboratory tests were conducted on BIS-500 by Olin Australia Limited, Winchester Division. Tests were in accordance with AS2343: Part 2 1984 Bullet Resistant Panels for Interior Use. This standard set out a procedure and equipment for testing bullet resistant materials. BISALLOY 500 Thickness of Plate mm 6 8 10 Actual Hardness BHN 477 477 477 Classification* Class G2 and SO G2 and SO

About sixty tonnes of this product was treated at BIS. A proof stress range of 520550 MPa was attained. Charpy test values on all plates produced (8.0mm) were in the range 60-100 Joules. The production of a tailor-made product for special requirements is a workable proposition here at BIS.

3.8.4 BISALLOY WITH BHN 400

Wear resistant steel plate with a BHN 400 has been produced at BIS. Using the chemical composition of BIS-500 as the starting point, the production process at Unanderra would be modified to obtain a plate with the nominated hardness. This is obtained by varying the tempering conditions tempering temperature and duration. Tensile properties and notch toughness would be similar to those of BIS-500. Any fabrication or welding of this type of steel would need to follow the prescribed conditions set for BIS-500.

*Classification from AS2343

Using a 6mm Bisalloy 500 wear resistant plate, a classification class of G2 and SO were achieved. Class G2 is the highest requirement in the "G" category (hand guns). Class G2 signifies that the material tested was resistant to attack by a 44 magnum hand gun. Class SO signifies that the material tested was resistant to attack by a 12 gauge shotgun (full choke) firing shot. Using a 10mm plate, a classification class of R1 was obtained, proving that this material is resistant to attack by a 5.56mm rifle. A panel complying with the 6/84

S3: Page 23

P-"c'r - .11 -W

4.1 For 4.1.1 Cold f,'orroirig 4.12 tintrming 11.1.a.me Cutting 4.3 Shearing cn d Pune bi n , 4.4 Turning 4.39622>g 4.6 Grinding 4.7 Sawing 4.8 Mining 4.9 Surface Treatment

6/84

S4: Page 1

4. FABRICATION OF BISALLOY
Fabrication of quenched and tempered steels does not require any unusual equipment or procedure, but more care and control is needed than with plain carbon steels. much larger former radii are required to bend about the longitudinal direction, as can be seen in the table of recommended former radii, Fig. 4.1a. For BIS-500, it is recommended that plate exceeding 12mm thickness should not be bent about the longitudinal axis. The minimum recommended former radii were determined at 30C, and, where it is desired to bend these minimum radii, the plate temperature should be at least this value, but not exceeding the tempering temperature. The minimum former radii listed in the table were generally achieved by a "stitching" technique, using a number of adjacent discrete vee bends, each of a few degrees. When it is desired to cold form Bisalloy plate in a single pressing operation, larger radii should generally be used and the supporting vee former should be well lubricated. Also, when forming to minimum radii is required, it is recommended that plate edges should be dressed prior to forming, ensuring that flame hardened edges are removed completely.

4.1 FORMING
4.1.1 COLD FORMING
All Bisalloy grades of quenched and tempered steels may be cold formed. However, the minimum radii of bend increases with the hardness and tensile strength of the steel. BIS-80 can be readily cold formed or angle bent, provided sufficient power is available and suitable forming radii are used. Springback allowances must be greater than for structural plain carbon steel and will depend on the type of forming.* All bending is preferably at right angles to the direction of rolling. Plate edges should be deburred and, in some cases, rounded before forming. With BIS-320, 360 and 500 wear resistant grades, it is recommended, where possible, that the bend axis be transverse to the rolling direction, as

See Springback Test table next page.

Minimum Former Radii in mm for Cold Forming Bisalloy Grades Plate Thickness 3.25mm 5mm emm 8mm 10mm 12mm 16mm 20mm 25mirn 32mm 40mm 50mm Bisalloy-80 T L 8 12 15 20 25 30 45 65 75 100 125 150 8 12 15 20 25 30 45 65 75 110 140 200 Bisalloy-320 T L 8 12 15 20 25 30 45 65 75 110 150 250 10 15 20 30 35 45 60 75 100 140 190 350 Bisalloy-360 T L 8 12 15 20 25 30 45 65 75 110 170 300 13 20 20 35 40 50 75 100 125 175 250 25 40 50 60 85 100 150 250 50 70 90 110 Bisalloy-500 T L

Note: These values are for plate at 30C. Attention is particularly drawn to the text regarding bending in a single operation.

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S4: Page 2

RESULTS OF SPRINGBACK TEST ON BIS-80 Plate Thickness mm 6 10 16 25 6 10 16 25 6 10 16 25 16 25 Former Diameter 2Ro

mm

Ring Diameter After Springing 2Rf

mm

Springback 2 (Rf Ro) mm 48 24 22 15 211 79 67 50 1334 412 554 389 4310 1819

Test Ratio Ro : Rf 0.80 0.89 0.90 0.93 0.65 0.83 0.85 0.89 0.39 0.67 0.60 0.68 0.27 0.47

197 197 197 197 394 394 394 394 834 834 834 834 1626 1626

245 221 219 212 605 473 461 444 2165 1246 1388 1223 5936 3445

4.1.2 HOT FORMING

Hot forming is generally not recommended, because if tempering temperatures are exceeded, the properties of the steel will be impaired. If hot forming is unavoidable, it is essential that the maximum re-heat temperatures be closely controlled and kept below tempering temperature of that particular grade in use. Under these circumstances, it is recommended the manufacturer be consulted.

hardness of the flame cut edge may be as high as BHN 450. Remember that excess heat during cutting may reduce the plate hardness to undesirable levels minimise the heat input as much as possible. Do not stack plates particularly when profile cutting.

4.3 SHEARING AND PUNCHING

Shearing and punching of the softer grades of quenched and tempered steels can be carried out providing a machine of sufficient capacity is available. BIS-80 can normally be cold sheared up to about 25mm in thickness, although the necessary force is about three times that required for mild steel. BIS-320 can be cold sheared to about 10n-im in thickness, but even larger shearing forces will be required. Through hardened wear resistant grades above BHN 360 should not be considered for shearing. Guillotine blades should be sharp and set with a clearance of approximately 0.25-0.40mm (0.010-0.015"). Maximum limiting thicknesses for cold punching are about half the shearing values.
S4: Page 3

4.2 FLAME CUTTING

Flame cutting is widely used for these steels, not only for the heavier sections that cannot be sheared, but also for lighter sections. Conventional techniques are suitable, with the same gas pressures, nozzle size and similar travel speeds being used as for cutting plain carbon structural steels. When stripping plates, the use of parallel torches will help to minimise distortion. In very cold conditions, say 10C or below, care must be taken to prevent edge cracks. Preheating to no more than 175C (100C for BIS-500) and slow cooling after cutting will facilitate subsequent machining as otherwise the
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SHEARING AND PUNCHING MAXIMUM LIMITING THICKNESS GRADE BIS 80 BIS 320 BIS 360 BIS 500 SHEARING 25mm 10mm Not Recommended Not Recommended COLD PUNCHING 12mm 6mm Not Recommended Not Recommended

4.4 TURNING
All Bisalloy grades, including those with hardnesses in excess of BHN 360, can be turned satisfactorily with carbide tooling, provided spindle speeds and speed rates are reduced from those normally employed when carrying out similar machining operations on mild steel. Reductions of 50-70% in spindle speed and up to .50% in feed rate may be necessary, depending on the hardness of the article being machined. High speed tools are generally not recommended. As an example, the following settings have been found to give completely satisfactory results when turning cylindrical workpieces of 25mm diameter from the various Bisalloy grades. With increases in stock diameter, spindle speeds will naturally decrease. TURNING Material Spindle Speed (rpm) 1000 625 625 475 260 Feed Rate (min/rev) 0.15 0.10 0.10 0.075 0.075*

high powered and rigid equipment. Centre drilling is recommended as good practice, particularly for the high hardness grades, as is the use of substantial backing plates to prevent the work "springing", due to the heavy feed pressures required. The following data will provide a guide for setting up drilling operations. Experimentation will be required to determine the optimum conditions for individual machine shops. When Brinell hardness runs 400 and higher, the drills should have a heavy web structure, thinned at the point, and be designed with a slower helix angle. Countersinking presents no problem in any grade, provided an inserted carbide type cutter is used in accordance with supplier's recommended speeds and feeds for the hardness of the material.

Mild Steel BIS 80 BIS 320 BIS 360 BIS 500

Turning Tips: Seco DNMM 150608-37 Grade TP25 * In certain circumstances it may be necessary to increase the feed rate with Bisalloy 500 to avoid "polishing" of the workpiece by the tool.

DRILLING

4.5 DRILLING
Drilling of the various Bisalloy grades becomes more difficult as the hardness of the plate increases. However, the drilling of wear resistant plate up to BHN 400 is routinely carried out on suitable
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Steel Grade BIS-80 BIS-320 BIS-360

Point Angle A 118

125

Lip Angle 10 7.5 5

150

R.P.M. (upper figures) and feed per revolution for given drill size expressed in mm S4: Page 4

Approximate Feeds & Speeds for Drilling Hardened Steels*

Steel Grade Peripheral Speed Metres per minute 3.175mm 2300 Mild Steel 22.86m .050mm 1370 BIS-80 13.716m .038mm 920 BIS-320 9.144m .025mm 460 BIS-360** 4.572mm .025mm .050mm .101mm .152mm .203mm 0.50mm 230 .101mm 115 .152mm 75 .203mm 55 .063mm 460 .127mm 230 .190mm 150 .254mm 115 .101mm 685 .202mm 340 .304mm 230 .406mm 170 6.350mm 1150 12.700mm 575 19.050mm ' 25.400mm 385 285

* This table applies when high speed steel drills are used with a cutting fluid. If no fluid is used the speeds shown above must be reduced. ** Cobalt type high speed steel drills are recommended for this operation.

BLADE MOVEMENT

DRILLING BIS-500 Surface Speed Feed Inserts Grade 60-70m/min .15 - .22mm/rev WCMX R-51 GC015
.F VVVVVVVVVVVVVVV VVVVVVVVVVVVVVVVVVVVVVVVV

FLAME CUT SURFACE

Above information relative to tests done using Sandvik U drill 17.5mm to 58mm. BIS-500 Surface Speed 30-40m/min 0.22 - 0.25mm/rev Feed P25 Grade

CORRECT

Above information relative to test done using Sandvik delta drill 12mm to 20mm.
BLADE MOVEMENT

4.6 GRINDING
All Bisalloy grades can be ground quite successfully.

VVVVVVVVVVVVVVVVVVVVVVVVVVV VVVVVVVV VVVVVVV

FLAME CUT SURFACE

4.7 SAWING
INCORRECT

All Bisalloy grades can be cut with power saws, provided lower blade speeds and up to 50% more blade pressure is used than when cutting mild steel. Because of the high hardnesses associated with flame cut surfaces (up to BHN 400 - 450) sawing directly onto the flame cut surface should be avoided if possible. It has been found to be desirable to use power saw blades normally recommended for cutting stainless steel - 4 or 6 t.p.i. blades have given satisfactory performance.
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4.8 MILLING
Milling operations often entail dressing a flame cut edge or surface, and then subsequently milling bulk material to the desired surface finish and dimensional tolerance. Care must be taken to make a first cut sufficiently deep to remove the heat hardened zone of the flame cut edge. Cutters must be sufficiently robust to take this heavy loading. In such
S4: Page 5

circumstances it is desirable that, due to the high hardnesses adjacent to flame cut surfaces, cutter speeds and feed rates for initial milling should be reduced to 4050% of the speeds normally used when milling mild steel. The importance of adequate preheating prior to flame cutting and slow cooling after cutting to minimise edge hardening is again emphasised. Speeds and feed rates may be increased somewhat for subsequent bulk milling to 50-57% of the settings used for mild steel. (a) Initial milling of flame cut surface Material Cutter Speed (rpm) 1800 700 700 700 600 Feed Rate (mm/min) 125 140 75 75 75 75

Mild Steel BIS-80 BIS-320 BIS-360 BIS-500 (b) Bulk Milling Material

Cutter Speed (rpm) 1800 1400 1300 1000 900

Feed Rate (mm/min) 140 100 100 100 100

Mild Steel BIS-80 BIS-320 BIS-360 BIS-500

3mm deep cut, 60mm dia. cutter equipped with three Seco Titan milling tips SPUN 120312 Grade S25M.

As with all machining operations, machine settings should be adjusted in relation to plate hardness such that milling rates would be proportionately lower for the higher hardness wear resistant grades than for Bisalloy 80.

4.9 SURFACE TREATMENT

All of the Bisalloy range can be surface treated to remove surface scale. Sand blasting, shot blasting or wire brushing are all effective. The Bisalloy range can also be painted with no danger to the product. Storage indoors is advisable to keep the occurence of rust and pitting corrosion to a minimum. Complete water drainage should be provided to any plate stored outside. Identification of plate would be best colour coded.
6/84 S4: Page 6

SECTION FIVE

WELDING OF BISALLOY STEELS

5.1 Introduction 5.2 Manual Metal Arc Welding (MMAW) 5.3 Gas Metal Arc Welding (GMAW) 5.4 Flux Cored Arc Welding (FCAW) 5.5 Submerged Arc Welding (SAW) 5.6 Welding Considerations 5.6.1 Preheating 5.6.2 Electrode Drying 5.6.3 Fluxes 5.6.4 Arc Strikes 5.6.5 Repair Work 5.6.6 Welding Procedures

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S5: Page 1

WELDING OF BISALLOY STEELS

5.1 INTRODUCTION
The Bisalloy grades of quenched and tempered steels are readily weldable by conventional welding processes. It is necessary to provide sufficient preheat and arc energy input to avoid heat affected zone (HAZ) cracking due to hydrogen but at the same time it is desirable that the weld metal and HAZ cool relatively quickly. The preheat and arc energy input should not become excessively high as the strength and fracture toughness of the steels will be impaired. Restrictions on high levels of arc energy input in welding the Bisalloy structural grade are particularly relevant where it is necessary to maintain the high fracture toughness of the parent plate. The maximum values of arc energy input for Bisalloy steel are given in the accompanying table. Particular attention to the cleanliness of the joint preparations and the correct drying and storage of weld consumablees is necessary in the welding of quenched and tempered steels to avoid hydrogen cracking. required for plate 6mm or less in thickness, provided the arc energy input is at least 1.25 kJ/mm. It is necessary to restrict the heat input. Weaving should be avoided. A number of weld runs having an arc energy within the range 1.25 to 2.5 kJ/mm is preferable to heavy single welds deposited at higher arc energy inputs. Suitable consumables recommended by the manufacturer for the MMAW of BIS-80 are: Alloycraft 11018G (CIG) Jetweld LH110-M (Lincoln) Austalloy 11018-TI (WIA) In the case of wear resistant alloy, matching strength is not usually required, as most welding is for attachment purposes and in this regard the conventional basic low hydrogen electrodes to the AWS A5.1-E7018 or AS1552-E4818 classifications are suitable. Care should be taken to ensure the correct welding conditions apply preheating, energy input (see Section 5.6).

5.3 GAS METAL ARC WELDING-GMAW

Solid alloy electrode wires providing matching strength and notch toughness to BIS-80 are available for use with the GMAW process. These wires are to the AWS A5.28-80 specification ER110S-1 and are conventionally used with a gas mixture of Argon 2% Oxygen or Argon-5% CO,. Above the transition current droplet transfer in the GMAW process is by the highly efficient spray transfer mode. For BIS-80 a preheat of up to 170C may be necessary for the most highly restrained weldments but lower temperatures are acceptable for less restrained joints or with high arc energy inputs but these should not exceed the values given in the table. Welds made with these alloy wires

5.2 MANUAL METAL ARC WELDING MMAW

MMAW can be used to weld quenched and tempered plate such as the Bisalloy range. Stick electrodes to the AWSA5.5 E11018-M or AS1586 E7618-M classifications are suitable for the welding of BIS-80 to provide comparable strength and ductility. In the most highly restrained weldments, a preheat of up to 150C may be necessary to avoid cracking in the plate, but for most purposes, a minimum preheat of 100C is sufficient, provided the arc energy input is greater than 1.51d/mm. Preheating is not

Welding Process MMAW FCAW GMAW SAW

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MAXIMUM PERMISSIBLE ARC ENERGY INPUTS FOR BISALLOY STEELS PlateThickness 25 32 mm 40 100 mm 3 10 mm 12 20 min 2.5 kl/ mm 3.5 kJ/ mm 4.5 kJ/ mm 5.0 kJ/ mm

S5: Page 2

may have difficulty achieving the 6.7t joint bend requirement of the structural and pressure vessel codes although the joint tensile requirement is readily achieved. An alloy wire suitable for use with BIS-80 is Autocraft Ni-Cr-Mo (CIG) which is normally used with Argoshield 61 and 52 or similar Argon CO, gas mixtures. Wires for use in the GMAW process which provide matching strength to BIS320 are also available to special order where this grade is used for structural purposes, while the harder grades BIS360 and BIS-500 may also be welded by the GMAW process, providing that matching strength is not required. The conventional wires (eg AWS A5.18 ER705S-4) and shielding gases used for the welding of structural grade steels may be used for the welding of these harder grades.

and impact toughness are available for the welding of BIS-80. Care should be taken to ensure that the arc energy input does not exceed the values shown in the table. Multipass welds should be deposited rather than heavy single pass welds, while interpass temperatures should not exceed 200C. A preheat of 150C may be necessary for plate exceeding 16mm in thickness. It is recommended that root runs in joints to be welded by the SAW process be deposited by the MMAW process using stick electrodes to AWS A5.5 E11018-M class with subsequent backgrinding to sound metal. Welding consumables providing matching properties to BIS-80 are covered by AWS A5.23 and have classifications such as F11A6-ECM2-M2 for a flux cored wire and F11A6-EM2 in the case of a solid wire.
Wire Autocraft Ni-Cr-Mo Lincore M2 Fluxocord 42 Flux BX505 880 Austmatic OP 121 (CIG) (Lincoln) (WIA)

5.4 FLUX CORED ARC WELDING- FCAW

The semi-automatic FCAW process is particularly suitable for the welding of quenched and tempered steels. Owing to low hydrogen content associated with this process, no preheat is normally required for plate up to 12mm in thickness, provided the arc energy is at least 1.0 kJ/mm. Should the arc energy be lower, or for thickness in excess of 12mm a preheat to 100C may be required. Matching strength and ductility to BIS-80 is normally achieved in the weld, while the high Charpy V notch impact values are also maintained, provided the arc energy inputs do not exceed the value given in the preceding table. Suitable consumables are those to AWS A5.29-80 class E 11XT-X such as: Tensi-cor 110T (CIG) Fluxofil 42 (WIA) These wires are normally used with CO2 gas shielding or argon-0O2 mixtures having at least 15% CO2. In the case of wear-resistant grades BIS-320, BIS-360 and BIS-500, where matching strength is not required, the basic flux-cored wires such as Supre-cor 5-11A (CIG), NR-311 or NS-3M (Lincoln) and Fluxofil 31 (WIA) are suitable.

It is particularly important that submerged arc flux be correctly handled in the welding of quenched and tempered steels. Flux should be stored at a temperature in excess of 100C and generally baked at 400C if exposed to the atmosphere for more than 20 minutes. The manufacturers' recommendations for the baking of flux should be followed and, moreover, electrode wire should be kept clean and dry. Wear resistant grades may also be welded by this process but, at present, SAW consumables to provide matching strength are not readily available.

5.6 WELDING CONSIDERATIONS

5.6.1 PREHEATING
Control throughout the preheating process is the most important variable in welding quenched and tempered steels. The purpose of preheating is to prevent cold cracking in the heat affected zone. The preheating temperature of Bisalloy Steels is dependent on grade, thickness and welding process. When a weld cools rapidly, the heat affected zone may harden, causing a resultant decrease in ductility. Preheating prevents this by, retarding the rate of cooling of the weld, especially in the lower temperature region. The
85: Page 3

5.5 SUBMERGED ARC WELDING

Submerged arc welding consumables providing matching strength, ductility
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preheating areas should extend about 75mm on either side of the weld joint. Preheating is also effective in removing hydrogen from a weld (hydrogen promotes cold cracking) especially when it is maintained near the maximum interpass temperature for one or two hours after weld completion. RECOMMENDED PREHEAT TEMPERATURES FOR BISALLOY STEELS Temperature Preheat Maximum Interpass 3-12mm 50-75C 150C Plate Thickness 12-19mm 19-25mm 75-100C 180C 100-120C 200C 25-50mm 120-140C 220C 50-100mm 140-160C 230C

As seen from the table, the preheat temperature is dependent on the thickness of the plate.

5.6.2 ELECTRODE DRYING

It is a requirement of the low alloy steel stick electrode specification AWS A5.5-80 that the mositure content of E11018 electrodes should not exceed 0.2 percent which may be compared with 0.6 percent for lower strength E7018 electrodes. While E11018 electrodes are supplied in hermetically sealed metal containers, they should be stored at a temperature of 120C after opening and rebaked at a temperature of between 370 and 430C if exposed to the atmosphere for more than half an hour, or if there is a doubt as to the moisture content. Only one rebaking is allowed.

have been highly stressed in service and may tend to warp or distort slightly during welding. BIS metallurgists are always available to advise on welding procedures for quenched and tempered steels. Direct contact with BIS at Unanderra will yield the best result.

5.6.6 WELDING PROCEDURES

All flame cut or gouged surfaces must have 1-2mm removed by grinding. Weld preparations and at least 12mm on either side of the weld joint should be free from hydrocarbons (oil, grease, etc) paint, rust, scale to ensure good weld quality. The job or subassemblies should be positioned for downhand welding where possible. This will reduce the risk of weld defects and improve productivity. The use of backing bars facilitates high depostion rate downhand welding with continuous wire processes. In order to prevent excessive heat affected zone hardening, it is important to maintain preheats between specified temperatures and welding heat inputs temperatures should not exceed 220C to prevent heat affected zone embrittlement. Check preheat with a surface thermometer immediately prior to welding. The following MMAW procedures for welding of static and dynamic loaded joints are provided for guidance. An undermatching weld metal is indicated for the dynamically loaded joint but it should be noted that this procedure would not comply with structural or pressure vessel code requirements. Another approach to overcome the hardened HAZ caused by the final surface runs is to use a temper pass deposited within 2mm of the edge of the underlying weld using full strength electrodes. S5: Page 4

5.6.3 FLUXES
Fluxes for SAW should be dry and free of contamination dirt, mill scale or other contaminants. After the container is opened, the flux should be placed in a drying area at a temperature of at least 250C for two hours. The flux should be in thin layers or agitated, so that it maybe uniformly heated and dried. The flux should then be used or placed in a storage oven at a temperature of at least 160C.

5.6.4 ARC STRIKES

Arc strikes outside the welded zone can result in cracks, particularly in dynamically loaded structures. All arc strikes should be made within the joint preparation.

5.6.5 REPAIR WORK

In the repair of equipment where new sections are inserted and welded to original plate sections, it is good practice to repair weld with electrodes of lower tensile strength such as E9018-M. The reason is plate materials and sections 6/84

TYPICAL WELDING PROCEDURE Conditions: Static loading Joint Geometry

1-2 mm

16 mm

0-1 mm

Electrodes Welding Currents Welding Position Bead Types Preheat Interpass Temp. Range Post Heat Butt Welding Sequence

3.2mm E7018 (AWS) 4.0mm E11018-M (AWS) 3.2mm 125 Amps AC 4.0mm 175 Amps AC Flat Stringer 90C 90-180C Nil (a) Root Pass 3.2mm E7018 (AWS) (b) Fill Passes 4.0mm E11018-M (AWS) (c) Grind root pass (e) Cool slowly in still air

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S5: Page 5

TYPICAL WELDING PROCEDURE Condition: Heavy Dynamic Loading Joint Geometry

0-1 mm -1.1 .- '

Electrodes Welding Currents Welding Position Bead Types Preheat Interpass Temp Range Post Heat Butt Welding Sequence

3.2mm E7018 (AWS) 4.0mm E9018-M (AWS) 3.2mm 125 Amps AC 4.0mm 175 Amps AC Flat Stringer 90C 90-180C Nil (a) Root Pass 3.2mm E7018 (AWS) (b) Fill Passes 4.0mm E9018-M (AWS) (c) Grind root pass (d) Root Fill Pass 4.0mm E9019-M (AWS) (e) Cool slowly in still air (f) Buttering Passes 3.2mm E7018-(AWS)

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S5: Page 6

SECTION SIX

QUALITY CONTROL AT BIS

6.1 Quality Assurance at BIS 6.2 Size Capacities of Steel Plate 6.3 Tolerances of Steel Plate 6.4 Tensile Tests at BIS 6.5 Charpy Tests at BIS 6.6 Hardness Tests at BIS 6.7 Identification & Certification of Bisalloy Plate 6.7.1 Identification 6.7.2 Certification 6.8 Services Available

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S6: Page 1

6. QUALITY CONTROL 6.1 QUALITY

ASSURANCE AT BIS
The National Association of Testing Authorities, Australia, (NATA) have registered a mechanical testing laboratory at BIS. The acceptance by the Council of the Association as a Registered Laboratory enables BIS to conduct a comprehensive test program, all which is certified by a NATA approved staff. By being a NATA approved testing laboratory, all tests carried out by the laboratory staff are in accordance with Australian Standards appropriate to the particular test. The Australian Standards set a procedure and report of the test undertaken. NATA approval signifies that the Australian Standards are completely adhered to by the staff. The qualified laboratory staff and the precise testing equipment are also registered under AS1822-1975, Suppliers Quality Control System Level 2. AS1822 establishes requirements for a comprehensive quality control system. It identifies each of the elements of a system to be designed, established and maintained by the supplier for the purpose of ensuring that supplies and services conform to control requirements. If required by the customer, additional mechanical tests, including ultrasonic non-destructive testing, can be conducted at BIS. Of course, extras may apply for any additional testing. Direct contact with the manufacturer will yield the best result. Upon request and approval, the Quality Assurance Manual can be supplied. The Quality Assurance Manual contains information including quality policy statement, operating instructions and all of the controlling parameters in manufacture and quality control of Bisalloy products.

6.2 SIZE CAPACITIES OF STEEL PLATES

BIS-80, BIS-320 and BIS-360 are available in the following sizes: Thickness mm 3.25 5 6-50 55 70 75 80 90 100 Width mm Length m

6.0 1200 6.0 1500 1900, 2500, 3100 6.0, 7.5, 9.0 6.0 1800 6.0 1700 6.0 1500 6.0 1500 6.0 1500

BIS-500 is available in the following sizes: Thickness mm 6 50 Width rnm 1900, 2500 Length 7.5

NOTE: Special thicknesses between 3 100mm, lengths and widths up to 3100mm, can be supplied as required, however extras may apply. Direct contact with BIS is necessary for any non-standard dimension, including imperial.

6.3 TOLERANCE OF STEEL PLATES

The tolerances on steel plates are in accordance with ASTM A20.

FLATNESS TOLERANCES FOR SPECIFIED WIDTHS* THICKNESS mm 6 6.5 6.5 9.5 13.0 19.0 19.0 25.0 25.0 50.0 50.0 100.0 1500-1830 mm 48 35 22 22 21 19 1830-2130
mm

2130-2440
mm

2440-2500
mm

3000-3600
mm

51 44 25 24 22 19

57 48 29 25 24 19

60 51 32 29 25 19

70 60 41 38 25 25

* In accordance with ASTM A20 Table A2.12, 1983. 6/84

S6: Page 2

PERMISSIBLE VARIATION OVER SPECIFIED THICKNESS FOR SPECIFIED WIDTHS* THICKNESS mm 3.0 4.0 5.0 6.0 8.0 10.0 12.0 16.0 20.0 25.0 32.0 40.0 45.0 50.0 5.5.0 60.0 70.0 80.0 90.0 100.00 15004800 mm 0.5 0.5 0.5 0.5 0.6 0.6 0.6 0.7 0.8 1.0 1.3 1.6 1.7 1.8 2.0 2.3 2.5 2.8 3.0 3.3 1800-2100 mm 0.5 0.5 0.5 0.5 0.6 0.7 0.7 0.7 0.8 1.0 1..3 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.3 2100-1400 mm 0.6 0.6 0.6 0.6 0.7 0.7 0.8 0.9 0.9 1.0 1.3 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 3.5 2400-2500 mm 0.7 0.7 0.7 0.7 0.8 0.8 0.9 0.9 1.0 1.2 1.5 1.8 2.0 2.3 2.5 2.8 3.0 3.3 3.5 3.8 3000-3300 mm 0.7 0.7 0.8 1.0 1.0 1.0 1.0 1.1 1.2 1.5 2.0 2.5 2.8 3.0 3.3 3.4 3.5 3.5 3.5 3.8

*In accordance with ASTM A20 Table A2.1, 1983. NOTE: Permissible variation under specified thickness is 0.3mm.

PERMISSIBLE CAMBER OF STEEL PLATES* Edge Condition All All Thickness mm > 50 50 - 100 Width mm All All Camber for Given Thickness & Width Length 500 Length 500

* In accordance with ASTM A20 Table AZ 8. 1983. NOTE: Camber, as it relates to plates, is the horizontal edge curvature in the length, measured over the entire length of the plate in the flat position.

PERMISSIBLE VARIATIONS IN WIDTH & LENGTH FOR STEEL PLATES* Edge Condition Specified Width mm Gas cut or cheared Universal or Mill Edge All 1500 - 1800 1800 - 2700 2700 - 3200 Specified Thickness mm 6 - 50 50 - 100 6 - 100 6 - 100 6 - 100 Variations Over' for all Specified Widths and Thicknesses mm 19 25 40 50 55

* In accordance with ASTM A20, Table A2.9 annd Table A2.10. 1 No under variations allowed.

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S6: Page 3

CALCULATED PLATE WEIGHT (Tonnes) Theoretical Weight + 2.5% (ie 8.04625 tim3)
Length (M) Width (mm) Thickness (mm) 3.25 5 6 8 10 12 16 20 25 32 36 40 45 50 55 60 65 70 75 80 90 100 1200 1500 1700 6 1800 1900 2500 3100 1900 7.5 2500 3100 1900 9 2500 3100

0.188 0.362 0.550 0.734 0.917 1.101 1.468 1.835 2.293 2.935 3.302 3.669 4.128 4.586 4.779. 5.214 5.648 6.083 6.155 5.793 6.517 7.242 0.724 0.966 1.207 1.448 1.931 2.414 3.017 3.862 4.345 4.828 5.431 6.035 0.898 1.197 1.497 1.796 2.395 2.993 3.742 4.789 5.388 5.986 6.735 7.483 0.688 0.917 1.147 1.376 1.835 2.293. 2.866 3.669 4.128 4.586 5.160 5.733 0.905 1.207 1.509 1.810 2.414 3.017 3.772 4.828 5.431 6.035 6.789 7.543 1.122 1.497 1.871 2.245 2.993 3.742 4.677 5.986 6.735 7.483 8.418 9.354 0.826 1.101 1.376 1..651 2.201 2.752 3.440 4.403 4.953 5.504 6.192 6.880 1.086 1.448 1.810 2.172 2.897 3.621 4.526 5.793 6.517 7.242 8.147 9.052 1.347 1.796 2.245 2.694 3.592 4.490 5.612 7.184 8.082 8.980 10.102 11.225

6.4 TENSILE TESTS AT BIS

Tensile tests are an integral part of the quality assurance program at BIS. All tensile tests are conducted and reported by a qualified staff in a systematic format. All test piece sampling procedures are in accordance with AS1227-1980. The AS1227 specifies where the test piece should be obtained from the plate being tested. Tensile properties shall be determined on test pieces taken at right angles to the plate rolling direction (transverse direction). Plate up to and including 16mm thick is normally tested by using a 40mm wide rectangular crosssection test piece specified in Table 2 of AS1391-1974. Percent elongation shall be determined on a 50mm gauge length. If the 40mm wide rectangular cross-section test pieces specified in Table 2 of AS13911974 is used, the percentage elongation shall be determined over the 50mm gauge length, which includes the fracture and shows the greatest elongation. All BIS reports give tensile properties in SI units. Thus yield strength and ultimate tensile strength shall be expressed in MPa. Finally, the strain rate at that part of the test when yield or proof stress is being determined, shall fall within the range specified as Category B in AS1391-1974.
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6.5 CHARPY IMPACT TESTS AT BIS

Charpy impact tests are an integral part of the quality assurance program at BIS. Tests are conducted and reported by a qualified staff. All test piece sampling procedures are in accordance with AS1227-1980. Charpy impact properties shall be determined on test pieces taken in the longitudinal direction. Testing temperature will always be specified, however normally, tests at 20 C are conducted. DimensiOns of test pieces are dependent on plate size. Three tests are always conducted, and the report produced by BIS will state all three values obtained from the tests. Specimen sizes are given below. TESTPIECE SIZES FOR IMPACT TESTS Plate Thickness mm 3-5 6-8 10 12 Specimen Size mm 10 x plate thickness 10 x 5 10 x 7.5 10 x 10

All BIS reports are given in SI units. Therefore Charpy impact results will be given in Joules. By agreement with the customer, reports can include lateral expansion figures in accordance with ASTM A517.
S6: Page 4

6.6 HARDNESS TESTS AT BIS

It is normal practice to Brinell hardness test every plate produced as a matter of routine quality assurance. The abrasion resistant grades are normally certified on the basis of three hardness test results alone, since they establish compliance with the Bisalloy grades hardness range. It should be stressed that the mechanical properties and testing frequency are related to the standard Bisalloy grades produced under normal conditions. If any test requirements are specifically needed, arrangement can be made with direct contact to BIS at Unanderra.

MS: Each plate is metal stamped twice in diagonally opposite corners with a plate number. Stamping is within 20mm of plate edge and end. GCC: All plates are colour coded. The edges at both ends of each plate are painted with the appropriate colour code. The colour code is: BIS-80 BIS-320 BIS-360 BIS-500 Pink Blue Orange Black

6.7 IDENTIFICATION AND CERTIFICATION OF BISALLOY PLATE

6.7.1 FINISHED PLATE IDENTIFICATION
Each Bisalloy plate features the following distinguishing marks:

BIS special grades will be colour coded and the customer advised accordingly. S: All plates are stencilled detailing the following information:

CUSTOMER DESTINATION HEAT NO. PLATE NO. GRADE DIMENSIONS WEIGHT MADE IN AUSTRALIA BY BIS

W
r r
0

I ms

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BISALLOY
S6: Page 5

6.7.2 CERTIFICATION
Every plate which is produced at BIS has a Test Certificate, as follows: The information contained on a Test Certificate includes:
Date of issue of Certificate Year/No. of Certificate Name & Address of Customer Grade of Plate Heat Number from BHP Ladle analysis Weight percent breakdown of elements Heat Treatment: 900/WQ/600QT represents a water quench from 900C, then tempering at 600C. Similarly for other notations. Mechanical Tests: All the mechanical and dimensional data is reported. Every plate produced at BIS is Brinell hardness tested. BIS-80 are tested at each end of the plate, thus two hardness figures are reported. BIS-320, BIS-360 and BIS-500 have three test figures reported, corresponding to the front, centre and back hardness tests. All three are reported. Tensile and impact tests are conducted on every 10 tonne batch of BIS80 on the test certificate has been tested. However, one of the plates, or a representative of the plates would have been tested. The mechanical properties of this plate would be given on the test certificate. Date: Certificate No: Customer: Specification: Chemical Analysis: Analysis: Percent by Mass:

6.8 SERVICES AVAILABLE

A Mechanical Testing: Additional mechanical testing can be conducted at BIS NATA registered laboratory on customer request. B Non-destructive testing: Non-destructive testing such as ultrasonic testing can be arranged. Certified results of plates will be given on request. C Post treatment of Plate: A limited amount of cutting can be arranged at BIS. Surface treatments such as shot blasting are also available upon enquiry. Direct contact with BIS at Unanderra is necessary for arranging these additional services. All enquiries are welcome at BIS.

BUNGE INDUSTRIAL STEELS PTY. LTD.

PG. BOX 991, mNANDERRA NS.W. 2526 TRMLatiommei.rmimemdbythaNdrhoralAmosimionaf AN1 ,66146. WNW NMONd Rll.in M,att.an Oarlonnad .Ion. with Imam rmatallar. Tan 40614awr6 shel lst to mproduad *mane in MI CUSTOMER: OATS CERTIFICATE NO.:

TEST CERTIFICATE
SPECIFICATION:

CHEMICAL ANALYSIS HEAT N6, ANALYSIS

Ma

Si

PERCENTAGE OF ELEMENT BY MASS Me Ni Cr S

Ca

Si

T1

HEAT TREATMENT MAILS 0 SCOIC / WO/ BOOLC OT 0 TPROC / WO / 450C OT MECHANICAL TESTS PLATE SIZE CUSTOMER Ohio. ITEM No. SERIAL No. lf011 . MM 5 III YIELD TENSILE ELONGATION STRESS STRENGTH. GAUGE LENGTH HP. MP. REDS. OF MIA % BIND PASS HARGHESS BIM SPEC SPED DIRECTION CHARPY V.NOTCH IMPACT TEST TEMP Le ENERGY J NBROSITY% 0 900Cf WO 1 400C OT Ell 9.30C t WO I 17VC OT 0 0

NOMINAL STRIKING ENERGY 300.1 NOMINAL IMPACT yELOSITY 0.24 Ws WE CERTIFY THAT THE ABOVE INFORMATION IS IN ACCORDANCE WITH THE RECO DS OF THE COMPANY AND CONFORMS TO THE SPECIFICATION AS STATED. TH ABOVE CHEMICAL ANALYSES ONE REPRODUCED FROM AUSTRALIAN IRON ANO STEEL PTY. LTD. PLATA. ENDORSED TEST CERTIFICATE'S

MANAGER

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SECTION SEVEN

APPLICATIONS OF BISALLOY STEELS

7.1 Introduction 7.2 High Strength Bisalloy Grades 7.3 Abrasion Resistant Bisalloy Grades 7.4 Specific Applications

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7. APPLICATION OF BISALLOY STEELS

7.1 INTRODUCTION:
The preceding information highlights the various characteristics of BISALLOY quenched and tempered steels. By utilising the high strength or high hardness offered by BISALLOY, many applications can now take economic advantage of an Australian made steel. This section attempts to identify the major areas of use or where BISALLOY can be used to economic advantage. While Bunge Industrial Steels make four grades of BISALLOY, the applications can be put into two categories: (i) Structural applications; (ii) Abrasion resistant applications. Often various grades are used in conjunction with each other in the same application, but the following detail is set out under the two distinct areas for ease of identification.

7.2 HIGH STRENGTH BISALLOY GRADES

The high strength Bisalloy grades can be utilised in two ways: 1) decrease the weight of a component without jeopardising its structural integrity; 2) increase the strength of a component without increasing its size or weight. Bisalloy 80 is three times stronger than plain carbon structural steel. This increased strength has provided new fields in engineering design.

HIGH STRENGTH APPLICATIONS FOR BISALLOY 80 fuel, water, grain or feed Storage Tanks Pressure Vessels unfired type Truck Bodies chassis, floor main beams Cranes & Fork Lifts booms, outriggers, uprights Dump Trucks dump vessel Agricultural Equipment plough, main frame Bulldozer chassis, cabin, blade Chutes & Buckets main frame Fans back plate, blades Buildings & Bridges fabricated beams Concrete Equipment barrel, pumping boom Drilling Rigs main structure Where design states that the application of AS1204 material is called for, Bisalloy 80 may be used. ABRASION RESISTANT APPLICATIONS FOR BISALLOY 320, 360 & 500 Dump Truck dump vessel liners Hoppers liners or total construction Chutes liners Concrete Equipment mixer barrel liners Dragline Bucket wear liners Dragline base Rail Trucks body of ore trucks Screens perforated Storage Tanks grain handling wear liners Dozer Blades cutting edge Rippers total construction Shot Blast Units liners Conveyor Buckets liners or total construction Mining Equipment side runners, cutting blades, teeth Crushers liners, hammer Shovel liners, cutting edge Agricultural Equipment rippers, shovels, plough discs, sugar cutting knives Foundries conveyor lines Valves knife gate blade
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HIGH STRENGTH APPLICATIONS FOR BISALLOY 80

1. High strength lifting beam made of BIS 80 2. BIS 80 as used for the arms of this timber picker 3. A submarine plough designed to dig a pipeline trench was made largely of BIS 80 4. Gears cut from BIS 80 5. Construction and quarry sites use rock pickers made from BIS 80 6. Pipelaying equipment using the high strength steel 7. High strength is essential for this type of heavy quarry work 8.Another view of the rock picker at work

7.3 ABRASION RESISTANT BISALLOY GRADES

Hardened abrasion resistant steels have long been imported to assist in the many mining, quarrying, materials handling and transport industries in Australia. In these fields, they have proved their higher costs more than justified in substantial savings, not only in longer wear life, but also in the greatly reduced down-time required for the replacement of worn components. These steels are supplied in hardness from BHN 320 to BHN 525. The lower range of Brinell hardness, ie up to BHN 400, is usually applied where forming, machining or drilling etc is required, or where there is a combination of wear and high impact. Plates up to BHN 525 are generally supplied where no forming, machining or drilling is required, but where wear resistance is of prime importance. However, the grade should be chosen with the greatest hardness consistent with satisfactory impact values and with regard to the work to be done on the plate before it goes into service. When wear plates have to be formed or perhaps drilled, counterbored or countersunk in the field, it may be considered advisable to sacrifice some degree of wear life in favour of easier working.

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,744 ' , 1 6. . g.;?

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ABRASION RESISTANT APPLICATIONS FOR BISALLOY 320, 360 & 500

1. An example of BIS 500 2. BIS 360 as used in tynes on farm equipment 3. Bisalloy pre-cut bars offering hardness right through 4. This quarry dump-truck uses BIS 360 for its tray 5. This large blade utilises both BIS 80 and BIS 360 6. A close view of a tyne made of BIS 500 7. Wear resistance provided by BIS 360 is vital with this sort of heavy work 8. Pre-cut bars are available in a variety of grades and sizes 9. Completing the production of an item made from BIS 360 10. and 11. BIS 500 is used for farm tynes 12. The BIS 500 tynes at work

SECTION EIGHT

TECHNICAL LITERATURE
8.1 Bisalloy Bulletin 8.2 Data Sheets 8.3 Technical Papers

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TECHNICAL LITERATURE
8.1 BISALLOY BULLETIN
The BIS Bulletin will be published three times per year, numbered one, two and three. Each year will be regarded as a volume. It has been designed to give distributors and end-users an insight into Bisalloy applications. It achieves this goal by detailing actual current uses of the steel, that is, specific case studies will be highlighted in each publication. It is therefore apparent that BIS maintains a personal connection between manufacturer, distributor and end-user. Knowledge of how and where Bisalloy products are being applied would be of great benefit to BIS staff. The Bulletin is also designed to keep all users up to date with any new fabrication or welding technique. Details of this type of technical advancements will be a current feature of every Bulletin, situated on the back page.

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BUNGE INDUSTRIAL STEELS PTY LIMITED DISTRIBUTOR LISTING

AUSTRALIA Queensland William Adams Steelmark Ltd. Tubemakers Special Steels Union Steel Company New South Wales Alex Ross Steel William Adams J. Murray-More Steelmark Ltd. Tubemakers Special Steels Union Steel Company Victoria J. Murray-More Steelmark Ltd. Union Steel Company South Australia ANI Austral Steel Tubemakers/William Adams Scarfe Steel Supplies Tasmania Tubemakers/William Adams Western Australia William Adams Steelmark Ltd. Steel Supplies Australia Tubemakers Supply Centre Union Steel Company

NEW ZEALAND Fletcher Steel located at: Auckland Whangarei Hamilton Tauranga Rotorua New Plymouth Wanganui Palmerston North Gisborne Napier Wellington Nelson Christchurch Timaru Dunedin Invercargill

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