Utp5producttech 090311180712 Phpapp01

UT Product Technology
Copyright 2004 WI Ltd
Name
Product Technology
Steel Production Casting
Wrought Production
Extrusion Forging
Welding
Rolling
Defects Inherent
Processing
Service Heat Treatment
Name
Steel Production
2 Stage Process
Iron ore is reduced into pig iron assisted by other materials. Carbon content of Pig Iron is lowered by reacting with oxygen The molten metal is then cast into Ingots or continuously cast Ingots are rolled into Blooms, Billets or Slabs
Name
Steel Production
1st Stage
Iron ore is reduced into pig iron assisted by other materials. Raw materials Hematite (Fe2O3) or Magnetite(Fe3O4) + Coke Limestone Air
Name
Steel Production
1st Stage
Blast furnace reactions Fe2O3 + 3CO = 2Fe + 3CO2 Fe2O3 + 3C = 2Fe + 3CO Lime from limestone combines with impurities (mainly silica) in the ore to form fluid slag SiO2 + 2Cao = 2CaOSiO2
Name
Blast Furnace
Charge Ore Limestone Coke Air
Steel Production
Products Pig Iron Slag Dust Furnace gas
4000 800 1800 8000 14600
2000 1600 200 10800 14600
Name
Steel Production
Blast Furnace
Product of Blast Furnace - Pig iron (>3% carbon)

Name
Steel Production
Pig iron converted to steel by blowing molten metal with oxygen or oxygen rich gases Oxygen reacts with excess carbon
C + 2 O CO2 C + O CO CO + O CO2
Name
Steel Production
Bessemer Open hearth process Basic oxygen process
Name
Steel Production
Basic oxygen process
Solid scrap
Name
Steel Production
Molten Pig Iron
Name
Steel Production
Oxygen lance
Name
Steel Production
Steel
Name
Steel Production
Molten steel poured into large molds (ingots) Ingots are used for further processing
Hot top
Name
Steel Production
Molten steel poured into large molds (ingots) Ingots are used for further processing 2 types of mould - Narrow end up, Wide end up
Name
Steel Production
Metal solidifies from outside inwards 3 types of crystal formed Chill or fine exui-axed Columnar Large equi-axed
Name
Smelting Defects pipe/sink Primary

Pipes Shrinkage
Secondary pipe
Name
Smelting Defects
Non-metallic inclusions
Name
Smelting Defects
Segregation of metals
Name
Steel Production
Alternative to ingots is Continuous casting
Tundish
Mold forming slab
Water spray chamber

Rollers
Name
Steel Production
Name
Steel Production
Advantages of Continuous casting
Faster : 300 tons of steel in 45 mins compared to 12 hours No piping problems Cheaper : No ingot molds, handling
Name
Product Technology
Casting
Name
Casting Process
Liquid metal is caused to fill a cavity and solidify into a useful shape All materials used in metal manufacture cast at some time
Name
Casting Process
Stage 1 : Stage 2 : Stage 3 : A pattern of the finished item slightly over sized Mould constructed from the pattern Liquid metal poured through the channels to fill the mould
Name
Casting
Pouring basin Sprue Riser
Core
Runner
Name
Casting
Chaplets
Chills
Name
Casting
Casting involves the solidification from liquid to solid Solidification proceeds from outside to centre Solidification involves shrinkage
Name
Grain Growth
Name
Casting Methods
Sand casting
Name
Sand Casting
Name
Sand Casting
Name
Sand Casting
Name
Sand Casting
Name
Sand Casting
Name
Sand Casting
Name
Casting Methods
Sand casting Die casting / Injection moulding
Name
Die Casting
Casting cavity
Injection piston
Moving platen
Die
Fixed platen
Name
Casting Methods
Sand casting Die casting / Injection moulding Investment casting / Lost wax process
Name
Investment Casting
Wax Pattern
Name
Investment Casting
Coat with refractory slurry
Name
Investment Casting
Reinforce with plaster backing (Investment)
Name
Investment Casting
Oven dry to liquify or vaporise pattern and dry mould
Name
Investment Casting
Pour metal
Name
Investment Casting
Remove investment material

Name
Choice of Casting Method

Dimensional Accuracy Investment casting Die casting Sand casting Cost Sand casting Die casting Investment casting
Name
Casting Defects pipe/sink Primary

Shrinkage cavities Sinks
Secondary pipe
Name
Casting Defects
Blowholes and porosity
Cross-sectional changes /corners
Name
Casting Defects
Inclusions Scabs Fins
Name
Casting Defects
Shrinkage
Name
Casting Defects
Scabs
Name
Casting Defects
Scabs- part of mould stuck to the casting
Name
Casting Defects
Fins
Gaps
Name
Casting Defects
Fins- excess metal of casting
Fin
Name
Casting Defects
Hot tears
The larger section cools slower than the smaller section The grain are different between the sections
Hot Tears
Name
Hot Tears
Name
Chills are used for:

1. Directional grain growth 2. Uniform cooling rate
Name
Casting Defects
Segregation
Name
Product Technology
Wrought Production Methods
Name
Wrought Production
Forging Extrusion Rolling
Name
Wrought Production
Forging Metal confined under pressure to cause plastic flow Extrusion Metal forced through a die under a large load
Rolling Thickness reduction through compression

Name
Rolling
Ingots, slabs and billets rolled to produce long length products with uniform cross section
PRIMARY ROLLING PROCESS / COGGING
Two-High Reversing Mill

Name
Rolling
PRIMARY ROLLING PROCESS
Secondary piping

Name
Rolling
SECONDARY ROLLING PROCESS
Lamination
Three-High Reversing Mill

Name
Rolling
Non-metallic inclusion

Name
Rolling
Stringers

Name
Rolling
Segregation of metals

Name
Rolling
Banding

Name
Cold Rolling
Initial rolling hot Finishing by cold working
Cluster mill
4 High mill
Name
Rolling
Bloom - Square c/s 150x150mm minimum Slab - Rectangular c/s area greater than 14400 mm2 Billet - Square 50x50 up to 120 x 120mm Primary rolling- ingot to blooms and slabs Secondary rolling - blooms and slabs to plates , sheets etc
Name
Forging
Blacksmith
Hammer
Anvil
Name
Forging
6 basic actions Upsetting Swaging Bending Welding Punching Cutting out
Name
Forging
Blacksmith / Open die forging Hammer (Tup)
Anvil
Name
Forging
Pressure forging
Name
Forging
Closed die
Name
Extrusion
High loads used to shape ferrous and non-ferrous alloys Items produced are of uniform cross section Direct Indirect
Impact
Name
Direct Extrusion
Die
Billet
Ram
Name
Indirect Extrusion
Die
Billet
Extruded item
Name
Impact Extrusion
Punch
Blank
Die
Name
Extrusion Defects
Oxide films (Extrusion defect) Surface cracks Grain structure variation
Name
Impact Extrusion
Name
Wrought Production Defects

Cracks Laps Seams Stringers Slugs Bursts Laminations
Name
Wrought Production Defects

Banding Excessive flash Lack of fill Mismatch Internal cracking Mechanical marks
Name
Other Wrought Processes

Drawing Material is reduced or changed in profile by pulling through a die
Die Wire or rod Force
Name
Other Wrought Processes

Drawing Material is reduced or changed in profile by pulling through a die
Die Tube Mandrel Force
Name
Product Technology
Welding
Name
A Weld : Definitions
A union between pieces of metal at faces rendered plastic or liquid by heat,pressure or both. BS 499 A continuous defect surrounded by parent material NASA
Name
Welds
An ideal weld must give a strong bond between materials with the interfaces disappearing To achieve this Smooth,flat or matching surfaces Surfaces shall be free from contaminants Metals shall be free from impurities Metals shall have identical crystalline structures
Name
Welding
A union between pieces of metal at faces rendered plastic or liquid by heat,pressure or both. BS 499 Possible energy sources Ultrasonics Electron beam Friction Electric resistance Electric arc
Name
Electric Arc Welding

Electrod e
Power supply Work piece

Clamp(Earth)
Name

Electric discharge produced between cathode and anode by a potential difference (40 to 60 volts)
Discharge ionises air and produces -ve electrons and +ve ions
Electrons impact upon anode, ions upon cathode Impact of particles converts kinetic energy to heat (7000o C) and light Amperage controls number of ions and electrons, Voltage controls their velocity
Name

Arc Welding Processes Manual metal arc Tungsten Inert Gas Metal Inert Gas Submerged Arc Differences between them Methods of shielding the arc Consumable or Non-consumable electrode Degree of automation
Name
Zones in Fusion Welds

Fusion Zone
Name

Fusion Zone Heat Affected Zone
Name

Fusion Zone Heat Affected Zone Parent Material or Base Metal
Name
Joint Design
Butt Weld
Name
Joint Design
Butt Weld Lap Joint
Name
Joint Design
Butt Weld Corner Joint Lap Joint
Name
Joint Design
Edge
Weld
Name
Joint Design
Edge
Weld
T Joint
Name
Name
Manual Metal Arc (MMA)

Consumable electrode Flux coating Arc
Evolved gas shield

Slag
Core wire
Weld metal
Parent metal
Name
Manual Metal Arc Welding

Shielding provided by decomposition of flux covering Electrode consumable Manual process Welder controls Arc length Angle of electrode Speed of travel Amperage settings
Name
Tungsten Inert Gas (TIG)

Gas nozzle Filler wire Non-consumable tungsten electrode Gas shield
Weld metal
Arc
Parent metal
Name
Metal Inert Gas (MIG)

Gas nozzle Reel feed
Consumable electrode(filler wire)
Gas shield
Weld metal
Arc
Parent metal
Name
Submerged Arc
Reel feed
Flux retrieval
Consumable electrode
Flux feed
Slag Weld metal Parent metal
Name
Electroslag
Filler wire Water cooled copper shoes
Molten flux Weld metal
Name
Welding Defects
Cracks
4 Crack Types Solidification cracks Hydrogen induced cracks Lamellar tearing Reheat cracks
Name
Welding Defects
Cracks
Classified by Shape Longitudinal Transverse Branched Chevron Classified by Position HAZ Centreline Crater Fusion zone Parent metal
Name
Welding Defects
Cracks
Solidification Occurs during weld solidification process Steels with high sulphur content (low ductility at elevated temperature) Requires high tensile stress Occur longitudinally down centre of weld eg Crater cracking
Name
Welding Defects
Cracks
Hydrogen Induced Requires susceptible grain structure, stress and hydrogen Hydrogen enters via welding arc Hydrogen source - atmosphere or contamination of preparation or electrode Moisture diffuses out into parent metal on cooling Most likely in HAZ
Name
Welding Defects
Cracks
Lamellar Tearing Step like appearance Occurs in parent material or HAZ Only in rolled direction of the parent material Associated with restrained joints subjected to through thickness stresses on corners, tees and fillets Requires high sulphur or non-metallic inclusions
Name
Welding Defects
Cracks
Re-Heat Cracking Occurs mainly in HAZ of low alloy steels during post weld heat treatment or service at elevated temperatures Occurs in areas of high stress and existing defects Prevented by toe grinding, elimination of poor profile material selection and controlled post weld heat treatment
Name
Welding Defects
Incomplete root penetration
Causes Too large or small a root gap Arc too long Wrong polarity Electrode too large for joint preparation Incorrect electrode angle Too fast a speed of travel for current Copyright 2004 WI Ltd
Name
Welding Defects
Root concavity
Causes Root gap too large Insufficient arc energy Excessive back purge (TIG)
Name
Welding Defects
Lack of fusion
Causes Contaminated weld preparation Amperage too low Amperage too high (welder increases speed of travel)
Name
Welding Defects
Undercut
Causes Excessive welding current Welding speed too high Incorrect electrode angle Excessive weave Electrode too large Copyright 2004 WI Ltd
Name
Welding Defects
Incompletely Filled Groove
Causes Insufficient weld metal deposited Improper welding technique
Name
Welding Defects
Gas pores / Porosity
Causes Excessive moisture in flux or preparation Contaminated preparation Low welding current Arc length too long Damaged electrode flux Removal of gas shield Copyright 2004 WI Ltd
Name
Welding Defects
Inclusions - Slag
Causes Insufficient cleaning between passes Contaminated weld preparation Welding over irregular profile Incorrect welding speed Arc length too long
Name
Welding Defects
Inclusions - Tungsten
Causes Contamination of weld during TIG welding process
Name
Welding Defects
Burn Through
Causes Excessive amperage during welding of root Excessive root grinding Improper welding technique
Name
Welding Defects
Arc Strikes
Causes Electrode straying onto parent metal Electrode holder with poor insulation Poor contact of earth clamp
Spatter
Causes Excessive arc energy Excessive arc length Damp electrodes Arc blow
Name
Steel Metallurgy
Steel- Iron and carbon alloyed with other elements Carbon- Strength, hardness, toughness, ductility Manganese- Strength, hardenability Silicon - Toughness Molybdenum- Creep resistance, temper embrittlement Chromium- Hardness, wear resistance, corrosion Nickel - Ductility, strength, toughness
Name
Steel Metallurgy
Steel- Iron and carbon alloyed with other elements
BCC
FCC
Name
Steel Metallurgy
Low Stress
Elastic Deformation
Increased Stress
Plastic Deformation
Name
Heat Treatment
Post heat treatment performed to improve specific metallurgical or mechanical properties or stress relief
Softening Hardening Tempering Stress Relief
Controlled by Heating rate Temperature attained Time at the elevated temperature Cooling rate
Name
Heat Treatment
900
850
800 Ac2 750 Ac1
Ac3 Ar3
Ar2
700
1
Ar1 2
Name
Minutes to raise temperature by 10 C
Iron Carbide Diagram

1000 900 Ac3
800
700 600 .2 .4 .6 .8 1 1.2 1.4 1.6 1.8 2
Ac1
Carbon %
Name
Iron Carbide Diagram

1000 900 Ac3
Austenite Austenite and Ferrite
800
700
Austenite and Fe3 C Ac1 Pearlite and Cementite
Ferrite and Pearlite 600
.2 .4 .6 .8 1 1.2 1.4 1.6 1.8 2

Carbon %
Name
Heat Treatment
Hardening Produce hard but brittle material Heat to above transformation range Cool very quickly ( quench ) in oil, water or brine
Name
Heat Treatment
Stress Relief Relax stresses without significant changes in the metallurgical structure Heat to 550-650 degrees C Hold for 1 hour per 25mm thickness Cool in air
Name
Heat Treatment
Full Annealing Produces very soft low hardness material for machining or cold work Heat to above 910 degrees C Hold Cool very slowly in furnace Once reached 680 C , Copyright cool Ltd 2004 WI in air
Name
Heat Treatment
Sub Critical Annealing Spheroidizing produces soft low hardness material cheaper than full anneal Heat must not rise above 700 degrees C Hold for recrystallisation to occur Cool in air
Name
Heat Treatment
Normalising Maintains and improves mechanical properties and modifies grain structure Heat to above 910 degrees C Hold Cool in air
Name
Nature and Origin of Defects

Inherent Processing In Service
Name
Heat Induced Defects

Heat treatment cracks Grinding cracks Friction induced cracks
Name
In Service Cracks
Cyclic stress
Fatigue cracks Stress corrosion cracks Hydrogen induced cracks
Fatique crack
Hydrogen
Name

Utp5producttech 090311180712 Phpapp01

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Utp5producttech 090311180712 Phpapp01

Uploaded by

Copyright:

Available Formats

UT Product Technology

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

4000 800 1800 8000 14600

2000 1600 200 10800 14600

Copyright 2004 WI Ltd

Product of Blast Furnace - Pig iron (>3% carbon)

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Smelting Defects pipe/sink Primary

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Water spray chamber

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Reinforce with plaster backing (Investment)

Copyright 2004 WI Ltd

Oven dry to liquify or vaporise pattern and dry mould

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Remove investment material

Choice of Casting Method

Copyright 2004 WI Ltd

Casting Defects pipe/sink Primary

Copyright 2004 WI Ltd

Cross-sectional changes /corners

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd

Copyright 2004 WI Ltd