Scribd
Upload
79 views12 pages

Bar Defects

The document outlines various defects that can occur in steel bars during the rolling mill process and billet casting, categorizing them into mill-induced and casting-related defects. It details specific defects such as laps, cracks, overfills, and surface issues, along with their causes and implications. Additionally, it discusses defects related to steel quality and compliance with specifications, including issues like inclusions, segregation, and incorrect documentation.

Uploaded by

kuldeepsrj12
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
79 views12 pages

Bar Defects

The document outlines various defects that can occur in steel bars during the rolling mill process and billet casting, categorizing them into mill-induced and casting-related defects. It details specific defects such as laps, cracks, overfills, and surface issues, along with their causes and implications. Additionally, it discusses defects related to steel quality and compliance with specifications, including issues like inclusions, segregation, and incorrect documentation.

Uploaded by

kuldeepsrj12
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 12

Bars Defects

Introduction
In Rolling mill we have 2 kinds of
defects
1- Due to mill and operation way
2- Due to Billet Casting
MILL INDUCED DEFECTS
LAP A mechanically induced defect when a fin, or overfilling, rolls in at
subsequent stands leaving a lap or crease on the surface of the product.
Would be at an acute angle to the bar surface. Is seen on rounds, but more
prevalent on square and hexagon shapes, on the corners.

CRACKS Rapid heating/cooling giving thermal expansion/contraction of the


steel leading to crack(s), especially on higher alloy steels. Would be at 90 ° to
the bar surface.

OVERFILL (1) Miss-alignment of the roller guide to the finishing pass. (The
opposite side of the bar would be empty).

OVERFILL (2) Stock size going into the finishing pass too big.
UNDERFILL Stock size going into the finishing pass too small, this condition
may also give rise to twist, scratching, gouging.

DULL CORNERS Generally refers to two opposing corners being dull or


rounded, this the result of stock into the finishing pass being too small to fill
out the corner. If only one corner dull, then the alignment of the guide to
the groove is suspect.

OVERSIZE The size of the bar is greater than quoted in the specification or
agreement of supply.

UNDERSIZE Size of the bar is smaller than quoted in the specification or


agreement of supply.

OVALITY A bar where the largest and smallest dimensions around the
circumference of the bar are outside the specification or agreement of
supply.
TWIST Most common is axial miss-alignment of the groove, causing a
twist in the finishing, can also be caused by entry guide of finishing groove
set too large.

SCRATCH An open scratch on the bar surface without loss of metal, from
mechanical equipment after the last rolling stand.

GOUGE Much deeper than the scratch, can easily see the gouge associated
with the removal of metal, leaving either a hollow or depression where the
metal has been removed, or a section of bar with deep lap type defects.

GUIDE MARKS These marks exhibit a shallow depression on the bar, may
be wrongly thought to be scale marks, but normally caused when the
rollers are too tight causing rolling marks these will be full length of the bar
and always in the same place.
POOR SURFACE The bar exhibits an orange peel or even worse type of
surface caused through over rolling of the finishing group of stands.

ROLLER MARKS A depression when something adhering to a roll or roller


makes a hole or depression in the bar, or when a hole or depression in a work
roll leaves a high mark on the rolled bar.

ROLLED IN SCALE Scale not fully removed prior to rolling can be rolled
into the surface of the bar, leaving irregularities in the general smoothness
of the steel, once this scale is removed the bar size is generally within
tolerance.

PITTING As above but in a much pronounced condition, the bar being


grossly undersize after descaling. This condition is associated with alloy steels,
heating in a reducing atmosphere and poor descaling.
BURNT Carbon physically burnt out of the steel leaving a metal that
resembles sponge iron, due to overheating. Normally only a localized
condition maybe one furnace burner is out of balance and too strong.

DECARBURISED Carbon reduced to the atmosphere during heating.


Holding at elevated temperatures for long periods will aggravate the
condition. The acceptable levels of decarburisation will be in the
specification or agreement of supply.

MIXED A supply of steel bundles/coils, quoted on the packaging as


being a particular grade, is found to contain other material in the
consignment.

WRONG QUALITY A supply of steel bundles/coils, quoted on the


packaging as being a particular grade, is found to be an entirely different
material.
EXCESS The excess amount of material dispatched to a particular order
considered as over-delivered. Normally an order will be considered ‘as
complete when +/- 5% has been received.

OVERLENGTH Where the bar length exceeds the agreed length plus
tolerance
UNDERLENGTH Where the bar length shorter than the agreed length
minus tolerance

SHORTS Short bars delivered without an agreement to supply or in


excess of such an agreement.

POOR BAR END When the bar end is sheared through poor shear knives
giving gross distortion or heavy fash to the bar end from sawing.
BENT Bent bars outside of the specification or agreement of supply.

POOR COIL SHAPE The shape of the coil is poor being either an oval
shape or grossly entwined.

DISCOLORED Steel which has been rolled for some weeks/months


(according to local and atmospheric conditions) will begin to deteriorate on
the surface, as in a powdery substance of iron oxides. Not detrimental.

RUSTY Steel which has been rolled for some months/years (according
to local and atmospheric conditions) will deteriorate on the surface to
rust, leaving the bar undersize.

WRONG PAPERWORK Of all the complaints held against a rolling mill


this has to be the very worst. When the packaging information does not
match the material. Imagine in the supermarket if the outside of the can
shows carrots but when opened it is found to contain fruit! This type of
complaint has no excuse
DEFECTS OF STEELMAKE AND/OR CASTING

CRACKS Certain types of steel grade must be pit cooled after casting. This
group of steels, if allowed to cool too quickly will crack.

SEAMS A defect of short crack type defects are visible on the product
surface, the usual origin of seams is gaseous steel or blow-holes which
elongate on rolling.

BLOW-HOLES This seen in the as-cast product, once rolling is carried out
these blow holes can form the above seam type defect. More commonly
found on ‘rimming’ and ‘balanced’ steel and steels with low silicon and
aluminum.
POROSITY Steel with high gas content, in severe cases resembles a spongy
type material.
INCLUSIONS Inclusions of foreign material in the steel, the most common
being refractory materials from furnaces or ladles.
SHELL/SCABS More commonly associated with the ingot route where
splashes of steel inside the ingot mould form part of the ingot surface.

SEGREGATION Local enrichment of steel components like phosphorous,


sulphur, carbon, manganese.

PIPE Central cavities in the steel, more common to the ingot route.
Contraction of hot metal creates a void or cavity.

OUT OF SPEC 1 Elements of the chemical analysis found to be outside of


the permitted range of the specification or agreement of supply.

2 Physical properties found to be outside of the permitted range of the


specification or agreement of supply.
Typical continuous cast defects

Depression
Longitudinal Restart
face cracks
Hook cracks Transverse Mould mark Torch scar
corner cracks

Pipe

Gouge Bleed
Longitudinal &
Porosity Oscillation Transverse off corner cracks
laps face cracks

You might also like