Steel process flow_lines
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About This Presentation
STEEL PROCESS COMPLETE FLOW CHART USE IN STEEL INDUSTRY
Slide Content
STEEL
PROCESSING
FLOW
LINES
PROCESSING
FLOW
LINES
The lowlines in this booklet are designed to give viewers a graphic
Impression of now steal is processed. The drawings are nat lo scale or al
Inclusive, bu they offer leachers, students and others 2 simplified view of the
or most useful metal
Published by
Communications and Education Services Department
American Iron and Steel Institute
1000 Jh Street, NM Washington, D.C. 20036
a
y)
Stool Processing Flowlines was produced in cooperation with
“American Iron and Steel institute's Educator Consulting Panel
Members are
Dr. Richard Wilson, Chairman
Coordinator of Social Studies
Montgomery County, Maryland Schools, Rockville, MD
Ruth Naumott
Teacher, Washington High School, East Chicago, IND
Marily DeWalt
Editorial Consultant, National Science Teachers Association, Washington, D.C.
David Chase
‘Teacher, Seven Locks Elementary School, Bethesda, MO
Impression of now steal is processed. The drawings are nat lo scale or al
Inclusive, bu they offer leachers, students and others 2 simplified view of the
or most useful metal
Published by
Communications and Education Services Department
American Iron and Steel Institute
1000 Jh Street, NM Washington, D.C. 20036
a
y)
Stool Processing Flowlines was produced in cooperation with
“American Iron and Steel institute's Educator Consulting Panel
Members are
Dr. Richard Wilson, Chairman
Coordinator of Social Studies
Montgomery County, Maryland Schools, Rockville, MD
Ruth Naumott
Teacher, Washington High School, East Chicago, IND
Marily DeWalt
Editorial Consultant, National Science Teachers Association, Washington, D.C.
David Chase
‘Teacher, Seven Locks Elementary School, Bethesda, MO
STEEL
PROCESSING
FLOWLINES
One way or another, steel figures into all of our lives. Day in
and day out we take it for granted and yet it is the very
basis of so much we see and do. Few people are aware of
the full extent of human effort that is required. Steelmaking
is a complicated procedure that requires an in-depth study
before one can obtain a full understanding; however, a
working knowledge of the basic steps can be acquired in a
relatively short time.
This booklet of flowlines traces many of the steps involved
in steel processing. An earlier published booklet entitled
“Steelmaking Flowlines” is available which follows the
steps to produce steel in its first solid forms.
PROCESSING
FLOWLINES
One way or another, steel figures into all of our lives. Day in
and day out we take it for granted and yet it is the very
basis of so much we see and do. Few people are aware of
the full extent of human effort that is required. Steelmaking
is a complicated procedure that requires an in-depth study
before one can obtain a full understanding; however, a
working knowledge of the basic steps can be acquired in a
relatively short time.
This booklet of flowlines traces many of the steps involved
in steel processing. An earlier published booklet entitled
“Steelmaking Flowlines” is available which follows the
steps to produce steel in its first solid forms.
a flowline of steelmakin From iron ore, limestone and coal in the earth's crust
to space-age steels — this fundamental flowline shows
only major steps in an intricate progression of pro-
cesses with their many options.
MOLTEN STEEL
MOLTEN STEEL
MOLTEN STEEL
COKE OVENS
some environmental
systems parallel
to steelmaking
de in
Land reclamation restores mines and quarris to natural state, Stack cleaners capture dust — Venturl scrubbers spi
‘Tree-planting is one method. from numerous steelmaking — 1er nto dustiaden
processes, Keeping tout of Recovered solid particles
fhe atmosphere. may often be recycled
to space-age steels — this fundamental flowline shows
only major steps in an intricate progression of pro-
cesses with their many options.
MOLTEN STEEL
MOLTEN STEEL
MOLTEN STEEL
COKE OVENS
some environmental
systems parallel
to steelmaking
de in
Land reclamation restores mines and quarris to natural state, Stack cleaners capture dust — Venturl scrubbers spi
‘Tree-planting is one method. from numerous steelmaking — 1er nto dustiaden
processes, Keeping tout of Recovered solid particles
fhe atmosphere. may often be recycled
iy before it can be mage into fin-
lo variety, considering chem-
{sy properties, sizes and shapes. Mar
‘SLING
‘COLD STRIP
WELDED
Pipe
CONTINUOUS CASTING GALVANIZED OTHER ¿INMI
COATED FLAT ROLLED PRODUCTS.
PRODUCTS
Fiat rolled products commonly are
folted from slabs by mils using sets of
CONVENTIONAL cylindrical rot.
INGOT TEEMING
Grooved rolls cquoeze bits into
diferent cross-sections (round,
‘angles, ete) in a sequence of
ores wine operations
PRODUCTS
Piercing is the process used to make
‘seamless pipe and tubing trom a
‘Semiinished product called tube
founds
SEAMLESS PIPE
‘BLOOM
ercnner so ses
PIG IRON pl Aaah vet ello. STRUCTURAL SHAPES used to roll blooms into.
CASTING oe ie ie haw bane or
see te añ tre sate
onstruction or for rails
Bag houses uso cloth bags Electrostatic precipltators
like big vacuum cleaners 10 use electricity 10 remove plantlsescontialto know the steal plant water by letting
capture dust EXA Etectveness of pollution solids setle out
‘Acid Neutralization isan im- Cooling towers reduce tem
tant pat of Weating water porature of cooling water so
Esedin cleanngotsie’. can be used again and
Some measures again
Claritiors are used to ciean
lo variety, considering chem-
{sy properties, sizes and shapes. Mar
‘SLING
‘COLD STRIP
WELDED
Pipe
CONTINUOUS CASTING GALVANIZED OTHER ¿INMI
COATED FLAT ROLLED PRODUCTS.
PRODUCTS
Fiat rolled products commonly are
folted from slabs by mils using sets of
CONVENTIONAL cylindrical rot.
INGOT TEEMING
Grooved rolls cquoeze bits into
diferent cross-sections (round,
‘angles, ete) in a sequence of
ores wine operations
PRODUCTS
Piercing is the process used to make
‘seamless pipe and tubing trom a
‘Semiinished product called tube
founds
SEAMLESS PIPE
‘BLOOM
ercnner so ses
PIG IRON pl Aaah vet ello. STRUCTURAL SHAPES used to roll blooms into.
CASTING oe ie ie haw bane or
see te añ tre sate
onstruction or for rails
Bag houses uso cloth bags Electrostatic precipltators
like big vacuum cleaners 10 use electricity 10 remove plantlsescontialto know the steal plant water by letting
capture dust EXA Etectveness of pollution solids setle out
‘Acid Neutralization isan im- Cooling towers reduce tem
tant pat of Weating water porature of cooling water so
Esedin cleanngotsie’. can be used again and
Some measures again
Claritiors are used to ciean
REHEATING
A FURNACE,
ROUGHING STANDS
SCALE BREAKER
SOMVEYOR! 1. Highlight of continuous hot rolling are shown above. Gags in the
raving roprosent conveyor sections, so, in realty, the full ent of
mii val Yous fee, Surface aca Yet removed trom the WATER ANSE
a cone eb ln tan Boren ne anger or sare Tae
In a few minutes the contin- zonal ote al each mil usualy cal roughing stands. Vera
‘iste edges nlp contol win Teste not eerste ei
uous hot strip mill dia- Sande lor final reduction, raveing at speeds up 10 50 mis per Nout a
grammed here can turn a arms th cooing tale and eee
glowing slab of steel into a
Coil of thin sheet more than a
quarter of a mile long. That Per
coil may be shipped to cus- SIDE SUTTER ©
tomers, or it may be cleaned, recouer
as shown in the second dia-
gram, and cold rolled (lower
left) to make products. More
than one-third of all steel
shipped annually is the prod-
uct of sheet mills and is fg
it i 14S OF PICKLED very
fade Into. ia ol TROLLED SHEET D RES Sn system
other products.
4. Coll ol cleaned, hot-tlled sheet may be cold roles so make a
product thinner and smoother This process gives steel a
Figher strengin-to-weight rato than can bs made on a hot mil
A modern Verstand tandem cold roducing mil may recone. <=
shoot about 1/10:nch thick and % of à mia long; Ivo minutes
that sheet wil have been rolled to 03-inch thick and be
More than two mils long.
A FURNACE,
ROUGHING STANDS
SCALE BREAKER
SOMVEYOR! 1. Highlight of continuous hot rolling are shown above. Gags in the
raving roprosent conveyor sections, so, in realty, the full ent of
mii val Yous fee, Surface aca Yet removed trom the WATER ANSE
a cone eb ln tan Boren ne anger or sare Tae
In a few minutes the contin- zonal ote al each mil usualy cal roughing stands. Vera
‘iste edges nlp contol win Teste not eerste ei
uous hot strip mill dia- Sande lor final reduction, raveing at speeds up 10 50 mis per Nout a
grammed here can turn a arms th cooing tale and eee
glowing slab of steel into a
Coil of thin sheet more than a
quarter of a mile long. That Per
coil may be shipped to cus- SIDE SUTTER ©
tomers, or it may be cleaned, recouer
as shown in the second dia-
gram, and cold rolled (lower
left) to make products. More
than one-third of all steel
shipped annually is the prod-
uct of sheet mills and is fg
it i 14S OF PICKLED very
fade Into. ia ol TROLLED SHEET D RES Sn system
other products.
4. Coll ol cleaned, hot-tlled sheet may be cold roles so make a
product thinner and smoother This process gives steel a
Figher strengin-to-weight rato than can bs made on a hot mil
A modern Verstand tandem cold roducing mil may recone. <=
shoot about 1/10:nch thick and % of à mia long; Ivo minutes
that sheet wil have been rolled to 03-inch thick and be
More than two mils long.
2. Hot rod sheet ste! is normaly loaned i asa of supruio
. Or nyerochione acta to remove surface oxide (scale) formed
sii ‘during hor roling. A modern picker, shown below, operates
continuously When one col of shest is almost cleaned, ts end
fs sheared square and seslded tothe star of a new col inthis
Dicker, a tempor ml alas break up tne scale before the sheet
ners to plekling” or “cleaning” section o Ihe Ine
PICKLING TANKS
B cous or
col HOFROLLED
ELEVATOR ‘SHEET
the rubberaineg pickling
tanks, th ringers and the dryers. Tne sheet accumulated 1 is
Sysier feeds Into the picking tanks when the entry-end of the line
1 stopped to ward on a new coll Thus iis possible to clean à
sheet continuously at Iho rate of 1200 feet per minute. À smaller
looping systom atthe deivery-en ofthe ina permits continuous.
ENTRENO {ine operation during interruptions for el.
ACOUMULATOR SYSTEM
6. After the steel has been softened in the annealing process, a
tome mi at y gv trl he dee en,
metalurgicalproperies, and, surtace fa rod m
e shipped to consumers as cols or thor ae timed or
sheared into ul lengths
BATCH (OR BOX)
process narcens TEMPER MILL
Sane, Covers are paced over the
Stacks to contol ne amonio
Stmogphere and Ihen the furnace is
fomento oe’ cora lia
o heating and 1eegaing of
may take five or six days. =
. Or nyerochione acta to remove surface oxide (scale) formed
sii ‘during hor roling. A modern picker, shown below, operates
continuously When one col of shest is almost cleaned, ts end
fs sheared square and seslded tothe star of a new col inthis
Dicker, a tempor ml alas break up tne scale before the sheet
ners to plekling” or “cleaning” section o Ihe Ine
PICKLING TANKS
B cous or
col HOFROLLED
ELEVATOR ‘SHEET
the rubberaineg pickling
tanks, th ringers and the dryers. Tne sheet accumulated 1 is
Sysier feeds Into the picking tanks when the entry-end of the line
1 stopped to ward on a new coll Thus iis possible to clean à
sheet continuously at Iho rate of 1200 feet per minute. À smaller
looping systom atthe deivery-en ofthe ina permits continuous.
ENTRENO {ine operation during interruptions for el.
ACOUMULATOR SYSTEM
6. After the steel has been softened in the annealing process, a
tome mi at y gv trl he dee en,
metalurgicalproperies, and, surtace fa rod m
e shipped to consumers as cols or thor ae timed or
sheared into ul lengths
BATCH (OR BOX)
process narcens TEMPER MILL
Sane, Covers are paced over the
Stacks to contol ne amonio
Stmogphere and Ihen the furnace is
fomento oe’ cora lia
o heating and 1eegaing of
may take five or six days. =
coated sheet steel products
galvanizing
The huge, complicated facility
shown at the right is used to coat
sheet steel with zinc, continuously,
1. Inthe continuous hot-dip gaivanizing ne
dlagrammad here, tool maves through the
process generally rom
{he welder and accumu
Suriaces are cleaned to make
Better in the continuous annealing furnace,
‘the steel strip (8 raciant-heated in à controles
yn Once past
Soon
ne stick
at the rate of several hundred feet
per minute. Once coated, this gal-
vanized product is highly versatile.
For example, it is used in the un-
derbody parts of automobiles, and
in making air ducts, garbage cans,
culverts, storage tanks, and wher-
ever corrosion resistance is re-
quired. A large amount of the gal-
vanized sheet and strip made each
year is painted. This adds to the
corrosion resistance and gives the
product a pleasing, colorful appear-
ance. Painted galvanized sheets
are frequently used for roofing and
siding for industrial buildings, gut-
ters, downspouts, or for interior
cabinets, appliances and many
other eye-catching applications.
atmosphere at temperatures wnien cevelop.
{he desrec meraiurgical properties the
steel
‘ACCUMULATOR
ELECTROLYTIC CLEANING
AND BRUSH SCRUBBING
Painting
In the continuous paint coating line
shown at the right, steel strip
moves from a pay-off reel into an
entry accumulator, or looping tow-
er, and then into a cleaning and
pre-treatment section where the
surface is prepared for painting.
The strip then moves to the first
paint coater where a primer is ap-
plied to the top and bottom sur-
faces with reverse roller coaters.
The primer-coated strip passes into
a baking oven to cure the primer
and then into a cooling zone. The
strip is then conveyed to the sec-
ond paint coater where the finish
a 3
(e)
coating is applied to both surfaces IN | WELDER
with reverse roller coaters. The
strip then enters another oven for
curing and cooling.
galvanizing
The huge, complicated facility
shown at the right is used to coat
sheet steel with zinc, continuously,
1. Inthe continuous hot-dip gaivanizing ne
dlagrammad here, tool maves through the
process generally rom
{he welder and accumu
Suriaces are cleaned to make
Better in the continuous annealing furnace,
‘the steel strip (8 raciant-heated in à controles
yn Once past
Soon
ne stick
at the rate of several hundred feet
per minute. Once coated, this gal-
vanized product is highly versatile.
For example, it is used in the un-
derbody parts of automobiles, and
in making air ducts, garbage cans,
culverts, storage tanks, and wher-
ever corrosion resistance is re-
quired. A large amount of the gal-
vanized sheet and strip made each
year is painted. This adds to the
corrosion resistance and gives the
product a pleasing, colorful appear-
ance. Painted galvanized sheets
are frequently used for roofing and
siding for industrial buildings, gut-
ters, downspouts, or for interior
cabinets, appliances and many
other eye-catching applications.
atmosphere at temperatures wnien cevelop.
{he desrec meraiurgical properties the
steel
‘ACCUMULATOR
ELECTROLYTIC CLEANING
AND BRUSH SCRUBBING
Painting
In the continuous paint coating line
shown at the right, steel strip
moves from a pay-off reel into an
entry accumulator, or looping tow-
er, and then into a cleaning and
pre-treatment section where the
surface is prepared for painting.
The strip then moves to the first
paint coater where a primer is ap-
plied to the top and bottom sur-
faces with reverse roller coaters.
The primer-coated strip passes into
a baking oven to cure the primer
and then into a cooling zone. The
strip is then conveyed to the sec-
ond paint coater where the finish
a 3
(e)
coating is applied to both surfaces IN | WELDER
with reverse roller coaters. The
strip then enters another oven for
curing and cooling.
2. From the furnace, he stip enters the molten zinc coating bath
‘which fs contained in a se! or retractoryined pot As the nb
‘omorges from the molten air, an air (or sloam) mp0 ls used to
ontra ne zine coating thickness. The sin then continues.
Spward info a cooling tower where the zing costing solis.
reálmont can be applied 10 the zinc-coated
si then passes through anole" accumulator before iis
siotenfattoned. Finally, colled and removed from te line
for shipping
Le
WU
AAN
‘CONTINUOUS ANNEALING FURNACE
FINISH COATER RVING OVENS. EXIT LOOPING TOWER. ‘WINDING REEL
‘which fs contained in a se! or retractoryined pot As the nb
‘omorges from the molten air, an air (or sloam) mp0 ls used to
ontra ne zine coating thickness. The sin then continues.
Spward info a cooling tower where the zing costing solis.
reálmont can be applied 10 the zinc-coated
si then passes through anole" accumulator before iis
siotenfattoned. Finally, colled and removed from te line
for shipping
Le
WU
AAN
‘CONTINUOUS ANNEALING FURNACE
FINISH COATER RVING OVENS. EXIT LOOPING TOWER. ‘WINDING REEL
tin mill products
Tin plate and chromium-coated steels are primarily
used to make cans and other containers. Today,
there are three types of continuous tin plating pro-
cesses — alkaline, halogen and acid. The halogen
tin plating line has been diagrammed here (top
right). A chrome-plating line is shown below.
4. At the start ofthe Ine, the front ond
‘of one call of steel, referred to as
Blackplate s welded to the back end
‘of the coll ahead to ma
Sontinuous operations. The see!
‘vanhed and cleaned in a dite acia.
then enters a plating solution where
{tie eloctroplates. in the platino
Section in leaves the positively
charged tin anodes and s deposied
fon the negatively charged steel, Tne
‘ating may be as thir as 0.000008,
iron on a side
1. Much of the steel for making in mi
products gees om a cold reduction mil,
Through a continuous annealing faciiy. As
the sip uncale and passes through tne
‘annealing furnace, ts subjected to heat
mien sohene fin preparation for turnor
Processing
2. Coils from continuous ennealing go sitter
Esa lempar sit antro the resol
ist enough to gve proper hercness an
Alriace ptoperden orinoy goto double
ols reduction mil which can furthor
‘eguce the thickness up to 80 percent.
6. “Tindtee stools” aro a chromium-coated
produei. Caromium plating processes use
soluble anodes In a platng solution rom,
which enromium is electrodeposited onto the
negatively charges sheet moving Ihrougn the
Plating tank
Reading from lel to ight on the diagram below,
the steel sheot Is cleaned, pickied in allute acts,
Fined, chromium plates. In some proce
second chemical post treatment complet
comino. After this, to shoot ls rinsed,
lied.
3. The double cold reduced product has
greater strength than material that
as boon tomper role, ard 1
thinner Einer single or double
say for coating
(ihe product at
red 10 a8 Diack
chrome plating line
Tin plate and chromium-coated steels are primarily
used to make cans and other containers. Today,
there are three types of continuous tin plating pro-
cesses — alkaline, halogen and acid. The halogen
tin plating line has been diagrammed here (top
right). A chrome-plating line is shown below.
4. At the start ofthe Ine, the front ond
‘of one call of steel, referred to as
Blackplate s welded to the back end
‘of the coll ahead to ma
Sontinuous operations. The see!
‘vanhed and cleaned in a dite acia.
then enters a plating solution where
{tie eloctroplates. in the platino
Section in leaves the positively
charged tin anodes and s deposied
fon the negatively charged steel, Tne
‘ating may be as thir as 0.000008,
iron on a side
1. Much of the steel for making in mi
products gees om a cold reduction mil,
Through a continuous annealing faciiy. As
the sip uncale and passes through tne
‘annealing furnace, ts subjected to heat
mien sohene fin preparation for turnor
Processing
2. Coils from continuous ennealing go sitter
Esa lempar sit antro the resol
ist enough to gve proper hercness an
Alriace ptoperden orinoy goto double
ols reduction mil which can furthor
‘eguce the thickness up to 80 percent.
6. “Tindtee stools” aro a chromium-coated
produei. Caromium plating processes use
soluble anodes In a platng solution rom,
which enromium is electrodeposited onto the
negatively charges sheet moving Ihrougn the
Plating tank
Reading from lel to ight on the diagram below,
the steel sheot Is cleaned, pickied in allute acts,
Fined, chromium plates. In some proce
second chemical post treatment complet
comino. After this, to shoot ls rinsed,
lied.
3. The double cold reduced product has
greater strength than material that
as boon tomper role, ard 1
thinner Einer single or double
say for coating
(ihe product at
red 10 a8 Diack
chrome plating line
RINSE TANK
$5. Once the steel is coated with tn itis
Sometimes passed through a high
tinplate 1 elecirostaloaly coated with
ke Tinplate 6 carofuly Inspected and
may be shipped as cols oF sheared
Into cut lengths.
WELDER
AR
WATER
QUENCH
ELECTROCHEMICAL
TREATING
A
Tal
\
INES | Ue
DIA | dan obama! reatmant
~ CLEANING «STEERING PICKLE RINSE: y POSTTREAT WASHE
TANK ROLLS “TANK TANK Tan
$5. Once the steel is coated with tn itis
Sometimes passed through a high
tinplate 1 elecirostaloaly coated with
ke Tinplate 6 carofuly Inspected and
may be shipped as cols oF sheared
Into cut lengths.
WELDER
AR
WATER
QUENCH
ELECTROCHEMICAL
TREATING
A
Tal
\
INES | Ue
DIA | dan obama! reatmant
~ CLEANING «STEERING PICKLE RINSE: y POSTTREAT WASHE
TANK ROLLS “TANK TANK Tan
structurals & bars
Buildings and bridges require struc-
tural and other shapes rolled by mills
similar to those shown at right. Among
the most familiar products are the
beams and angles shown being rolled
in the top sketch. Many other shapes
are available, largely for the construc-
tion industry. Smaller shaped sections
are also produced on the bar mill
shown in the bottom sketch,
REHEATING FURNACES
ROUGHING’ ea
Stand GENE
structural & shape mill rt
1
dy fr rolling are brought
Temperature In à Fehoatng furnace. Then
‘breakdown stand where grooved,
horizontal rolls squeeze the steel In
Sequences designed to produce varlous end
Products, The inset drawings show now the steel is
Shaped at each roling Star. A change of rolls m the
same sland produces numerous shapes ranging from
Hosarıs to shoot ping.
2. From elevated pulpits, operators control the
passes ofthe Hot steel through the stands. The
Product may de passed back and forth severa!
mes (except atthe finishing stand) reducing It to
‘smaller cross sections, Egg stand alls aro
ratracted fro when not in use,
bar mill me a
4.A bird's-eye schemall of a bar mil is shown at the
ul
bottom ofthese pages. Two perapactive drawings aro Horizontal and veriealy to produce
Presented separately clong wth a diagram showing Y ARES
Bow grooved role shape the Pol bins Ino one ype
of bat
STEEL BILLETS
RADIANT FURNACES \
5. Bikes are stocked in special yares
Inspection devices can detect possible
intemal laws and external
Imperfections In the bar mil, rohoet
furnaces bring the Pile to rolling
temperature at individually controled
rates
‘OVERHEAD DIAGRAM OF BAR MILL.
Buildings and bridges require struc-
tural and other shapes rolled by mills
similar to those shown at right. Among
the most familiar products are the
beams and angles shown being rolled
in the top sketch. Many other shapes
are available, largely for the construc-
tion industry. Smaller shaped sections
are also produced on the bar mill
shown in the bottom sketch,
REHEATING FURNACES
ROUGHING’ ea
Stand GENE
structural & shape mill rt
1
dy fr rolling are brought
Temperature In à Fehoatng furnace. Then
‘breakdown stand where grooved,
horizontal rolls squeeze the steel In
Sequences designed to produce varlous end
Products, The inset drawings show now the steel is
Shaped at each roling Star. A change of rolls m the
same sland produces numerous shapes ranging from
Hosarıs to shoot ping.
2. From elevated pulpits, operators control the
passes ofthe Hot steel through the stands. The
Product may de passed back and forth severa!
mes (except atthe finishing stand) reducing It to
‘smaller cross sections, Egg stand alls aro
ratracted fro when not in use,
bar mill me a
4.A bird's-eye schemall of a bar mil is shown at the
ul
bottom ofthese pages. Two perapactive drawings aro Horizontal and veriealy to produce
Presented separately clong wth a diagram showing Y ARES
Bow grooved role shape the Pol bins Ino one ype
of bat
STEEL BILLETS
RADIANT FURNACES \
5. Bikes are stocked in special yares
Inspection devices can detect possible
intemal laws and external
Imperfections In the bar mil, rohoet
furnaces bring the Pile to rolling
temperature at individually controled
rates
‘OVERHEAD DIAGRAM OF BAR MILL.
WADE FLANGE
omen
SHAPES
CHANNEL
LA AA
BULB ANGLE STANDARD ANGLE
BEAN SECTION
Pue
INTERMEDIATE por
STAND Srano
ROLL CHANGING
IG
coouns
ENSHING
STAND
LI 7 rique to this
IN" raie mt are
re dual outet
Iinshing stands,
ile one eet of
stands ls working,
Ihe rolls can be
changed in the
ther to make a
Siren size or
Shape of
DUAL GUTLET
FINSHING STANDS
ROTARY
But not always, Tor
Successive sections ara moved along the cooling
bed. When tney reach eltnor out
fare processes
3. Products leaving the fishing stand are generally
Ind cropped by a hol sav.
xtreme, they
à rotary straightener and cut to the
th speatiod by customers. The products are then
for shipment.
STRAIGHTENER
ROUND CORNERED
SQUARE BAR.
COOLING BED
FOR STRAIGHT PRODUCTS:
8. Stoo! bars that are hot rllod into the many kinds of
Founded er latidos cross sections, suen as oval or
hexagonal, are ordered In azes ranging Irom à
fon of an Inch to several inches in dameter Many of
the amal dlameter bare aro colled. The colle may weigh
Up to two tons. Large-diametor bars aro pusnad OU
‘nto cooling Dada and eut fo lengih in eraight sections,
Standard shapes and special sections (or example,
‘all channels or U-bars) rolled on these mils aro water
Sprayed and moved onto the cooing beds. Many hot
{led bare regure additonal processing within tne
‘luo! plant before being chipped to customers
Al bars are mepecıec, Special veaimen such as
‘izing, loning and eonterless grinding ara required
For many appleatons. Cold drawing 9 bare tough
Special ies produces bars for applications wher
real strengin and precise dimensions are necessary.
omen
SHAPES
CHANNEL
LA AA
BULB ANGLE STANDARD ANGLE
BEAN SECTION
Pue
INTERMEDIATE por
STAND Srano
ROLL CHANGING
IG
coouns
ENSHING
STAND
LI 7 rique to this
IN" raie mt are
re dual outet
Iinshing stands,
ile one eet of
stands ls working,
Ihe rolls can be
changed in the
ther to make a
Siren size or
Shape of
DUAL GUTLET
FINSHING STANDS
ROTARY
But not always, Tor
Successive sections ara moved along the cooling
bed. When tney reach eltnor out
fare processes
3. Products leaving the fishing stand are generally
Ind cropped by a hol sav.
xtreme, they
à rotary straightener and cut to the
th speatiod by customers. The products are then
for shipment.
STRAIGHTENER
ROUND CORNERED
SQUARE BAR.
COOLING BED
FOR STRAIGHT PRODUCTS:
8. Stoo! bars that are hot rllod into the many kinds of
Founded er latidos cross sections, suen as oval or
hexagonal, are ordered In azes ranging Irom à
fon of an Inch to several inches in dameter Many of
the amal dlameter bare aro colled. The colle may weigh
Up to two tons. Large-diametor bars aro pusnad OU
‘nto cooling Dada and eut fo lengih in eraight sections,
Standard shapes and special sections (or example,
‘all channels or U-bars) rolled on these mils aro water
Sprayed and moved onto the cooing beds. Many hot
{led bare regure additonal processing within tne
‘luo! plant before being chipped to customers
Al bars are mepecıec, Special veaimen such as
‘izing, loning and eonterless grinding ara required
For many appleatons. Cold drawing 9 bare tough
Special ies produces bars for applications wher
real strengin and precise dimensions are necessary.
steel plate & large diameter pipe
A flat-rolled product that may range in
thickness from less than one-quarter of an
inch to more than one foot. steel plate
serves the public in many essential ways. It
is fabricated, both by platemakers and their
customers, for various uses such as build-
ings, bridges, nuclear reactor vessels, in-
dustrial equipment, ships, machines and
railroads, to name only a few. As a single
example of a steel company plate-forming
operation, the manufacturer of large O.D.
(outside diameter) pipe is shown here. Weld-
ed girders or circles formed into en
“heads” for pressure vessels are al
other plate product processes that might
have been shown had space permitted.
Most plates are rolled from slabs. The mil
stands shown at the right reduce the thick-
ness of the steel without controlling the
straightness of the edges, which can be
trimmed by shears or cutting torches.
EDGE & END PLANNING
3. The manutacture of large diameter
piso for such usos as water mains
Sa and gas pipelines begins
nen the ends ofthe toe! piste 4, The crimped plate is then sant to
tho Using press wnoro a U-shaped
‘ie torcee the steal down between
are cut square and the sages
Bevelec and made parallel, The
‘edges are then shaped or bent rockar r
“er with ros (above) or with a
uned dle I as
nd forms half the
is. Ta
{ong as the plate
Pydraule press. Pipe ercumierence,
HIGH REVERSING
ROUGHING STAND
FURNACE
are individually passed irom tha heating furnace
processes to lis finished form. A conveyor table
Stee through high pressure water Sprays 10 remove
‘Seale and Into the 2-ngh reverting roughing stand, There tis
Passod back and for in the diminishing spaco Beleioen two ros to
luge its thickness. Then tho steel goes on to the nigh reversing
fining stand. Hore the two rolls that squeeze tho steel thinner on
pass are supported by backup rolls. Automatic gage controls help ensure
Lnitorm thickness and fatness.
large diam seal mil 6. The ‚of the plate
Tun
Bruch eine
Setar Bs na
Ei
ER ee
Selig te
Sed can bra
Enoc
Serna lane
Soom wel m
‘nied on
Cele rn arte
may seat
Eonar anne
wong apart
5. The O-ing press taxes a plate
whieh nas Boen shaped by the U-
yindrical form.
A flat-rolled product that may range in
thickness from less than one-quarter of an
inch to more than one foot. steel plate
serves the public in many essential ways. It
is fabricated, both by platemakers and their
customers, for various uses such as build-
ings, bridges, nuclear reactor vessels, in-
dustrial equipment, ships, machines and
railroads, to name only a few. As a single
example of a steel company plate-forming
operation, the manufacturer of large O.D.
(outside diameter) pipe is shown here. Weld-
ed girders or circles formed into en
“heads” for pressure vessels are al
other plate product processes that might
have been shown had space permitted.
Most plates are rolled from slabs. The mil
stands shown at the right reduce the thick-
ness of the steel without controlling the
straightness of the edges, which can be
trimmed by shears or cutting torches.
EDGE & END PLANNING
3. The manutacture of large diameter
piso for such usos as water mains
Sa and gas pipelines begins
nen the ends ofthe toe! piste 4, The crimped plate is then sant to
tho Using press wnoro a U-shaped
‘ie torcee the steal down between
are cut square and the sages
Bevelec and made parallel, The
‘edges are then shaped or bent rockar r
“er with ros (above) or with a
uned dle I as
nd forms half the
is. Ta
{ong as the plate
Pydraule press. Pipe ercumierence,
HIGH REVERSING
ROUGHING STAND
FURNACE
are individually passed irom tha heating furnace
processes to lis finished form. A conveyor table
Stee through high pressure water Sprays 10 remove
‘Seale and Into the 2-ngh reverting roughing stand, There tis
Passod back and for in the diminishing spaco Beleioen two ros to
luge its thickness. Then tho steel goes on to the nigh reversing
fining stand. Hore the two rolls that squeeze tho steel thinner on
pass are supported by backup rolls. Automatic gage controls help ensure
Lnitorm thickness and fatness.
large diam seal mil 6. The ‚of the plate
Tun
Bruch eine
Setar Bs na
Ei
ER ee
Selig te
Sed can bra
Enoc
Serna lane
Soom wel m
‘nied on
Cele rn arte
may seat
Eonar anne
wong apart
5. The O-ing press taxes a plate
whieh nas Boen shaped by the U-
yindrical form.
HIGH REVERSING FINISHING STAND
3 re 8 2
purr y )
Heil r
2, Aleveler Is commonly used to improve fitness of the
Plate. aie Grawing below shows a
drawn through the ppo. In the weld
{he notch a leg with molan metal pr
‘covered with ai
Used to produce a wold
‘Seam on the outside.
>
bes = f TESTING 8 SHIPPING
QUTSIDE
SEAM WELOING. y D TESTING & SHPPING
77] 7. Expanding steel pipe to give it adational
Sirengin and Improved dimensions requires
‘The welded pipe
‘of tne
GOLD EXPANSION AND imped in una the
HYDROSTANG TESTING fau pressure expanes tre pipe (as much
ne restrain of tho dls.
23 one percent)
3 re 8 2
purr y )
Heil r
2, Aleveler Is commonly used to improve fitness of the
Plate. aie Grawing below shows a
drawn through the ppo. In the weld
{he notch a leg with molan metal pr
‘covered with ai
Used to produce a wold
‘Seam on the outside.
>
bes = f TESTING 8 SHIPPING
QUTSIDE
SEAM WELOING. y D TESTING & SHPPING
77] 7. Expanding steel pipe to give it adational
Sirengin and Improved dimensions requires
‘The welded pipe
‘of tne
GOLD EXPANSION AND imped in una the
HYDROSTANG TESTING fau pressure expanes tre pipe (as much
ne restrain of tho dls.
23 one percent)
other pipe & tubing continuous butt-weld pipe mill
Three ways by which steelworkers make
most of their pipe and tubing are illus-
trated here. They are different from each
other and from the method of forming UNCOILER LEVELER
large diameter pipe described earlier in WELDER
this series. Each process has advantages COILS OF SKELP
for producing certain kinds of end prod-
ucts. For example, the continuous butt-
weld pipe mill (right) makes much of the
standard pipe used in plumbing. The elec-
tric-resistance welded tubing mill (below)
is often employed to make products of rel-
atively high diameter/wall thickness ra-
tios. Seamless tubing is made by the man-
drel type mill (at bottom). Seamless prod-
ucts are used by the oil, gas and chemical
industries and also for boiler tubing.
ENTRY CONVEYOR
SKELP HEATING
FURNACE
welded tubing mill forme nous
OIL OF
Kar
2. The second process, the eleciicresitance
welded tubing mil, begins when rotary shears
{im the edges of skolp parallel. Tho contour
‘af te forming oli forms tubing step by ste.
Barotuly guided by role. the tube eüges are
slecisicaly welded together by pressure
the heat caused by sieurs resistance to
4. Once the mandret mil, tho
Soamlose tubing ls rohoatod in eth
Feneat uraace Oran induction hes
lengths aro tnen rolled 10 very precie
SE eter on a song mil ot ón Sich
Ê iucing mil In tna later, cach palr of
E SAI he (soles later han Dr receding
TRE ROBE 4 ‘the tubes’ diameter and weil thickness:
ROTARY HEARTH ‘simultancoushy.
FURNAGE
tec and pores. Th eat MES
enter and pcrce. Then a eyindrica ML
fed lo a uniorm rolirg. anal bar lingerie info Me percod
Temporaturo, À plereing mi rotar to. she The desire diameter welfinickness
Sig undor nom preseure, whieh” ane length ar obtained asthe anal vn
£ausas Ihe meal to pan up in ne center the bar ale progress through MANDREL
Stine round: pormiting the mandrel to. Succercho stands of he mance mil BAR
3. Round steel bet,
rounds. are fest
MANDREL,
EN
Three ways by which steelworkers make
most of their pipe and tubing are illus-
trated here. They are different from each
other and from the method of forming UNCOILER LEVELER
large diameter pipe described earlier in WELDER
this series. Each process has advantages COILS OF SKELP
for producing certain kinds of end prod-
ucts. For example, the continuous butt-
weld pipe mill (right) makes much of the
standard pipe used in plumbing. The elec-
tric-resistance welded tubing mill (below)
is often employed to make products of rel-
atively high diameter/wall thickness ra-
tios. Seamless tubing is made by the man-
drel type mill (at bottom). Seamless prod-
ucts are used by the oil, gas and chemical
industries and also for boiler tubing.
ENTRY CONVEYOR
SKELP HEATING
FURNACE
welded tubing mill forme nous
OIL OF
Kar
2. The second process, the eleciicresitance
welded tubing mil, begins when rotary shears
{im the edges of skolp parallel. Tho contour
‘af te forming oli forms tubing step by ste.
Barotuly guided by role. the tube eüges are
slecisicaly welded together by pressure
the heat caused by sieurs resistance to
4. Once the mandret mil, tho
Soamlose tubing ls rohoatod in eth
Feneat uraace Oran induction hes
lengths aro tnen rolled 10 very precie
SE eter on a song mil ot ón Sich
Ê iucing mil In tna later, cach palr of
E SAI he (soles later han Dr receding
TRE ROBE 4 ‘the tubes’ diameter and weil thickness:
ROTARY HEARTH ‘simultancoushy.
FURNAGE
tec and pores. Th eat MES
enter and pcrce. Then a eyindrica ML
fed lo a uniorm rolirg. anal bar lingerie info Me percod
Temporaturo, À plereing mi rotar to. she The desire diameter welfinickness
Sig undor nom preseure, whieh” ane length ar obtained asthe anal vn
£ausas Ihe meal to pan up in ne center the bar ale progress through MANDREL
Stine round: pormiting the mandrel to. Succercho stands of he mance mil BAR
3. Round steel bet,
rounds. are fest
MANDREL,
EN
butt weld pipe mil ett) a col of Mato steel
ls À long loop of sel is created
je while the taling end of one col i
leading end of a now one. The skelp is heated 1 forming temperature
the steal winds through a long turtace. afte exiting the furnace, the skelp ecges.
Aro heated 10 welding temperature, goneraly with an oxy-acetylene burner. The
‘kelp I then passed through welding rolls which form the tubs and squeeze the hot
20986 together lo make a Sold weld: Seing rol correct pipe dia
Sul to engin
MAGNET ROLLS SKELP LOOPING FLOOR
COOLING BED.
TESTING.
a SHIPPING
FORMS, weLons, yT SAW SANGMEL
AND REGUCING MEL Mora OT
TESTING.
ecc, The welder wel has wo copper =: - ¡IU 8 SHIPPING
Charge. ln Continuous operation, provision fs MELDEN PRESSURE ROLLS FLYING CUT-OFF
made lo weld tho equare-croppes end of Ihe
ol to ne leading end of ne rent without
Stopping the progress of forming and
ing
REHEAT FURNACE SIZING MILL
TESTING
SHIPPING
INDUCTION HEATER
STRETCH REDUCING MILL
ls À long loop of sel is created
je while the taling end of one col i
leading end of a now one. The skelp is heated 1 forming temperature
the steal winds through a long turtace. afte exiting the furnace, the skelp ecges.
Aro heated 10 welding temperature, goneraly with an oxy-acetylene burner. The
‘kelp I then passed through welding rolls which form the tubs and squeeze the hot
20986 together lo make a Sold weld: Seing rol correct pipe dia
Sul to engin
MAGNET ROLLS SKELP LOOPING FLOOR
COOLING BED.
TESTING.
a SHIPPING
FORMS, weLons, yT SAW SANGMEL
AND REGUCING MEL Mora OT
TESTING.
ecc, The welder wel has wo copper =: - ¡IU 8 SHIPPING
Charge. ln Continuous operation, provision fs MELDEN PRESSURE ROLLS FLYING CUT-OFF
made lo weld tho equare-croppes end of Ihe
ol to ne leading end of ne rent without
Stopping the progress of forming and
ing
REHEAT FURNACE SIZING MILL
TESTING
SHIPPING
INDUCTION HEATER
STRETCH REDUCING MILL
specialty steel tubing
Specialty tubing is more economically suited to
the tasks required of it than any other form of
steel or other material
The products range from boiler tubes to air-
craft hydraulic lines and hypodermic needles. In
all cases, the chemistry, metallurgy, size and
shape of specialty tubing are controlled with ex-
tra care. Most of the product is made by the
seamless tube mills or the electric welded tubing
mills as shown in the flow chart “Pipe and
Tubing.”
Other methods of making specialty tubing are
sometimes used for special products which re-
quire precision. Four of these methods are briefly
diagrammed here. All are suited to making small
quantities of very high quality tubing
FURNACE
hot extrusion
‘inthis process a it or ound)
Mas a prot has ried song te
Duis of plecad na vertical
Piercing ares. Wen renested, me
Bic rappedin glass wecl
nica mel become a rent.
an lacada me contamer of
Fusion press stm
Zhvough which runs à aso"
trapped mange new comes into
Bay The mandre extends through
{ne holow Bat ang out through
th canter of à le hat Lubrbaiec
vith sronglyremotead glass
Burg extusion the sten forces
the sie cut beteven to de walls
CN
ANS
is lso called "piercing and
raving.” Is a process that
fins some features In common,
‘ath hot extrusion, But ie
less commony used. The
plercing mandrel ls not
forced entreiy through the
het bitet and thus forme à
thickewalied cup. This cup
's placed on the end of a
org mangrel Mat forces
the tel rough a
progresalvay smal
‘his ation orcos
back over the advancing
mandrel, forming a tube
in one closed end which
‘Slater sawed of
ang the mandrel, forming a tube in
{Wo or three seconds,
The drawing atte i
adds operational tos
Perspective o e
Seen diagramed
cold drawing
3. Cold drawing Involves puling tubing through a die, but much
preparation 3 he steel pracsdes that operation. Tubing trom a
hot mil or weld ls caraluly inspected, clennod, srnealed
and lubricated. One ena s swaged, or pointed, to fit easy
through the die so thatthe jaws on the draw.haad (carriage)
an glo I. A hook trom the carriage engages a ink in tno chan
five or the craw bench (ar righ) and the tubing 8 Col drawn
{rough tne die. When thera ls no mandrel (slug) inside the
tubing bong drawn, te diameter ls reduced, but the wall
"ickess fs unaffected, Wh luge or
‘ouside diameter and wall thickness of D
DAVE GHAIN
4. Tube reducing involves a machino that uses matened tapered
groaves, or des, mounted in lacing ros to reduce the ting
vor a siationary tapered mandrel. Large reductions are
possible. The "saddle" formed by the 7018 works the outside of
fhe tubing, ana the mangrel works the Inside, as In result of
the compressive force. The tapered grooves rock
th aver ne tube surface,
PICKLING (CLEANING) TUBES
Specialty tubing is more economically suited to
the tasks required of it than any other form of
steel or other material
The products range from boiler tubes to air-
craft hydraulic lines and hypodermic needles. In
all cases, the chemistry, metallurgy, size and
shape of specialty tubing are controlled with ex-
tra care. Most of the product is made by the
seamless tube mills or the electric welded tubing
mills as shown in the flow chart “Pipe and
Tubing.”
Other methods of making specialty tubing are
sometimes used for special products which re-
quire precision. Four of these methods are briefly
diagrammed here. All are suited to making small
quantities of very high quality tubing
FURNACE
hot extrusion
‘inthis process a it or ound)
Mas a prot has ried song te
Duis of plecad na vertical
Piercing ares. Wen renested, me
Bic rappedin glass wecl
nica mel become a rent.
an lacada me contamer of
Fusion press stm
Zhvough which runs à aso"
trapped mange new comes into
Bay The mandre extends through
{ne holow Bat ang out through
th canter of à le hat Lubrbaiec
vith sronglyremotead glass
Burg extusion the sten forces
the sie cut beteven to de walls
CN
ANS
is lso called "piercing and
raving.” Is a process that
fins some features In common,
‘ath hot extrusion, But ie
less commony used. The
plercing mandrel ls not
forced entreiy through the
het bitet and thus forme à
thickewalied cup. This cup
's placed on the end of a
org mangrel Mat forces
the tel rough a
progresalvay smal
‘his ation orcos
back over the advancing
mandrel, forming a tube
in one closed end which
‘Slater sawed of
ang the mandrel, forming a tube in
{Wo or three seconds,
The drawing atte i
adds operational tos
Perspective o e
Seen diagramed
cold drawing
3. Cold drawing Involves puling tubing through a die, but much
preparation 3 he steel pracsdes that operation. Tubing trom a
hot mil or weld ls caraluly inspected, clennod, srnealed
and lubricated. One ena s swaged, or pointed, to fit easy
through the die so thatthe jaws on the draw.haad (carriage)
an glo I. A hook trom the carriage engages a ink in tno chan
five or the craw bench (ar righ) and the tubing 8 Col drawn
{rough tne die. When thera ls no mandrel (slug) inside the
tubing bong drawn, te diameter ls reduced, but the wall
"ickess fs unaffected, Wh luge or
‘ouside diameter and wall thickness of D
DAVE GHAIN
4. Tube reducing involves a machino that uses matened tapered
groaves, or des, mounted in lacing ros to reduce the ting
vor a siationary tapered mandrel. Large reductions are
possible. The "saddle" formed by the 7018 works the outside of
fhe tubing, ana the mangrel works the Inside, as In result of
the compressive force. The tapered grooves rock
th aver ne tube surface,
PICKLING (CLEANING) TUBES
MANDREL, MANDREL
PIERCED yy
STEEL BILLET
HOT EXTRUDED TUBING
CONTAINER
"Tra drag at ne indian now a
HAR Mae inborn lee
BGC land
a ey ae et way ¡pues!
AS al
MANDREL (START
dh u DL = —)
FU.
©
THICK WALLED,
(CUP (PIERCED BILLET)
MANDREL (FINISH)
TESTING.
a SHIPPING
SINGING WITH A FLOATING PLUG -
+ PLUG MITH A ROD.
‘TUBE DRAWING PROCESS
ROTARY TYPE
STRAIGHTENER,
INA
TUBE
TOBE
5. Cold drawing and tube reducing usually produce a
Brodit rearing a sagten opera. Te
Tolar type machine fs shown at fight along wih a
lagram ilustrating now rolls are shaped and set at
gles Lo each eer in order fo sragnie no lubina
without erushing R. Same lubing 1 59 delicate tht
Ishand-straightened.
‘The action within the
{ube reducing machine
diagrammeg here,
PIERCED yy
STEEL BILLET
HOT EXTRUDED TUBING
CONTAINER
"Tra drag at ne indian now a
HAR Mae inborn lee
BGC land
a ey ae et way ¡pues!
AS al
MANDREL (START
dh u DL = —)
FU.
©
THICK WALLED,
(CUP (PIERCED BILLET)
MANDREL (FINISH)
TESTING.
a SHIPPING
SINGING WITH A FLOATING PLUG -
+ PLUG MITH A ROD.
‘TUBE DRAWING PROCESS
ROTARY TYPE
STRAIGHTENER,
INA
TUBE
TOBE
5. Cold drawing and tube reducing usually produce a
Brodit rearing a sagten opera. Te
Tolar type machine fs shown at fight along wih a
lagram ilustrating now rolls are shaped and set at
gles Lo each eer in order fo sragnie no lubina
without erushing R. Same lubing 1 59 delicate tht
Ishand-straightened.
‘The action within the
{ube reducing machine
diagrammeg here,
steel rods & wire
Billets, rolled into steel rods, are the
semi-finished products from which wire
is made. Rods are much like small di
ameter bars, and are produced in coils.
These coils are then unwound as the
rods are drawn through one or more dies
which reduce their diameter to make
wire. It has been estimated that there
are more than 100,000 uses for wire.
3. The frst set of intermediate
stands lence the steal to à
EMiding point.
EU
STEEL BILLETS INTERMEDIATE STANDS
ROUGHING STANDS
4. The perspective drawing
below shows the area.
where Ine billets leave the
furnace and enter the
roughing Stands
2. Inthe picture above, four bata enter tn roughing stands aer they
nave been brought to uniform roling temperature era
à mail furnace’ ln roughing stands and ne siccdng memos
ro stands Ih diameter of the sise may ba reduced ram four inches to
as is asi inch. This roduetion great incroases ie length ai he
See! Thus, the grooved pol In ech ml stand must uty taster
tle na he rer eto hale coa eth. Each eo
Fall to a cross section oly sighty lagar than 116 opening In tha
frst o hat wi D dran tought Make ui dl
Tee
158 etre arca wae es
SE aeutra ar or any recia ga, eee
Gescaling cap abo be used. To be good arte ora wiremaking
can the ime coning ont toed man
‘horoghiy cried a air À phosphate Coming also
User the casted ana baked See ae has al a
‘raving machine. Once 2106 dra troughs get
cain Ure ro nie nis che
‘hie propery prepared and LEE goose a ,
ris of sien’ Shoave aol control 1 anal spa
Beten blocks They Jos cove ie de Dec
Siccoesig motor te MORT et Soe E
proven lack nthe lohan ie
8. Schamatic cross section (not o
scale) o a single-nole ra drawing
BAKER feempoynganis al eros
(250-400°F) EEE
~ HOT OF Le do
OR PHOSPHATE ‘Steel holder
HOT DILUTE SULPHURIC ACID LUBRICATING DE BOX DRAW BLOCK
Billets, rolled into steel rods, are the
semi-finished products from which wire
is made. Rods are much like small di
ameter bars, and are produced in coils.
These coils are then unwound as the
rods are drawn through one or more dies
which reduce their diameter to make
wire. It has been estimated that there
are more than 100,000 uses for wire.
3. The frst set of intermediate
stands lence the steal to à
EMiding point.
EU
STEEL BILLETS INTERMEDIATE STANDS
ROUGHING STANDS
4. The perspective drawing
below shows the area.
where Ine billets leave the
furnace and enter the
roughing Stands
2. Inthe picture above, four bata enter tn roughing stands aer they
nave been brought to uniform roling temperature era
à mail furnace’ ln roughing stands and ne siccdng memos
ro stands Ih diameter of the sise may ba reduced ram four inches to
as is asi inch. This roduetion great incroases ie length ai he
See! Thus, the grooved pol In ech ml stand must uty taster
tle na he rer eto hale coa eth. Each eo
Fall to a cross section oly sighty lagar than 116 opening In tha
frst o hat wi D dran tought Make ui dl
Tee
158 etre arca wae es
SE aeutra ar or any recia ga, eee
Gescaling cap abo be used. To be good arte ora wiremaking
can the ime coning ont toed man
‘horoghiy cried a air À phosphate Coming also
User the casted ana baked See ae has al a
‘raving machine. Once 2106 dra troughs get
cain Ure ro nie nis che
‘hie propery prepared and LEE goose a ,
ris of sien’ Shoave aol control 1 anal spa
Beten blocks They Jos cove ie de Dec
Siccoesig motor te MORT et Soe E
proven lack nthe lohan ie
8. Schamatic cross section (not o
scale) o a single-nole ra drawing
BAKER feempoynganis al eros
(250-400°F) EEE
~ HOT OF Le do
OR PHOSPHATE ‘Steel holder
HOT DILUTE SULPHURIC ACID LUBRICATING DE BOX DRAW BLOCK
4. The looping section ofthe rod
mil offers various economies in
Power usage and speed for
Eertaln kinds of rode. The
Äniening mis ol navigue,
‘which prevents the steel trom
using In Inp ml shown here,
tods sighty less than % Inch In
Slameter ate dalvered o no
faying cones tor eailng at the
tate of about 8500 feet per
LOOPING SECTION minuto; larger sizes aro rolled
ä more siowy
(CONS OF WIRE RODS
6) x
NO TMST. ‘CONVEYORS
LOOPING SECTION FINISHING MILLS
©
© D
TAYING
‘Cones
7. Once the rod Is drawn to wie, its
treatment may ter great,
Coating Process desendngon ne niended vse. Haat
ofall see! wire is coated
of zinc, The wire is water-cooled,
leaned wen acid. hot water rinses
{ne then fluxes with à solution of
¿late zine ammonlum chioido. The
ire noxt goes through molten zine
ich molalurg.cally roacle with the,
‘Heel Surface, producing a tight bond,
‘The comes vito fe then vip and
reeled or shipment Wire 18 also
galvanized electroveally
FURNACE
‘QUENCH WATER: re a
HOT OTE / y s SHIPPING
HYDROCHLORIDE ACID 1
HOT WATER
DILUTE ZINC
ÄNMONIUM CHLORIDE,
WIRE CARRIERS
mil offers various economies in
Power usage and speed for
Eertaln kinds of rode. The
Äniening mis ol navigue,
‘which prevents the steel trom
using In Inp ml shown here,
tods sighty less than % Inch In
Slameter ate dalvered o no
faying cones tor eailng at the
tate of about 8500 feet per
LOOPING SECTION minuto; larger sizes aro rolled
ä more siowy
(CONS OF WIRE RODS
6) x
NO TMST. ‘CONVEYORS
LOOPING SECTION FINISHING MILLS
©
© D
TAYING
‘Cones
7. Once the rod Is drawn to wie, its
treatment may ter great,
Coating Process desendngon ne niended vse. Haat
ofall see! wire is coated
of zinc, The wire is water-cooled,
leaned wen acid. hot water rinses
{ne then fluxes with à solution of
¿late zine ammonlum chioido. The
ire noxt goes through molten zine
ich molalurg.cally roacle with the,
‘Heel Surface, producing a tight bond,
‘The comes vito fe then vip and
reeled or shipment Wire 18 also
galvanized electroveally
FURNACE
‘QUENCH WATER: re a
HOT OTE / y s SHIPPING
HYDROCHLORIDE ACID 1
HOT WATER
DILUTE ZINC
ÄNMONIUM CHLORIDE,
WIRE CARRIERS
forging hot steel
Whenever a steel part is to be subjected to
high stresses in service, designers consider
a forging process to make it stronger.
Whether the part is a turbine shaft of well
over 100 tons, or a conveyor roller weighing
a few pounds, forging it is likely to squeeze
or hammer more strength for less bulk into
the product than if one of the higher-ton-
nage-making processes were used. Steel
for forging can be made in any steelmaking
furnace, and it may also be degassed or
vacuum melted. In addition to the important
forging processes shown here, others can
weil claim advantages in making certain
Products. All methods, including extrusion,
mechanical forging, upsetting and roll forg-
ing, “knead” the original steel into a denser
structure and bring it so close to its finished
shape that it requires minimal cutting with
machine tools so that very little metal is lost
as scrap.
‘Compared with the amount of steel rolled
by mills into useful shape, forging accounts
for a small tonnage — but the products of
the forging processes are indispensable
Some steel plants operate forge shops and
many more sell billets and bars of forging
quality steel to an independent forging in-
dustry that has sales exceeding a billion
dollars annually.
open die forging
OEGASSING CHAMBER,
vacuum
2. Many hot forgings are made from billets, which are the
product of einer roling mils or strand eásters. In the
Example shown hore. a section of round-comered, 45-inch
square billet s cut by the saw. Special dios, win the nal
Shape of Ihe desiod product machined Into each. aro set for
tise in à steam hammer
BILLET MILL
closed die forging
3. Tho steel ls placed between the two dies which are hammered
CUT-OFF SAW
togetner. Tho hot metal inside the closed dies flows 10 MI
both halves. Then, machine tools provide
ishing touches 10 a
ew conveyor roi
Whenever a steel part is to be subjected to
high stresses in service, designers consider
a forging process to make it stronger.
Whether the part is a turbine shaft of well
over 100 tons, or a conveyor roller weighing
a few pounds, forging it is likely to squeeze
or hammer more strength for less bulk into
the product than if one of the higher-ton-
nage-making processes were used. Steel
for forging can be made in any steelmaking
furnace, and it may also be degassed or
vacuum melted. In addition to the important
forging processes shown here, others can
weil claim advantages in making certain
Products. All methods, including extrusion,
mechanical forging, upsetting and roll forg-
ing, “knead” the original steel into a denser
structure and bring it so close to its finished
shape that it requires minimal cutting with
machine tools so that very little metal is lost
as scrap.
‘Compared with the amount of steel rolled
by mills into useful shape, forging accounts
for a small tonnage — but the products of
the forging processes are indispensable
Some steel plants operate forge shops and
many more sell billets and bars of forging
quality steel to an independent forging in-
dustry that has sales exceeding a billion
dollars annually.
open die forging
OEGASSING CHAMBER,
vacuum
2. Many hot forgings are made from billets, which are the
product of einer roling mils or strand eásters. In the
Example shown hore. a section of round-comered, 45-inch
square billet s cut by the saw. Special dios, win the nal
Shape of Ihe desiod product machined Into each. aro set for
tise in à steam hammer
BILLET MILL
closed die forging
3. Tho steel ls placed between the two dies which are hammered
CUT-OFF SAW
togetner. Tho hot metal inside the closed dies flows 10 MI
both halves. Then, machine tools provide
ishing touches 10 a
ew conveyor roi
An ingot (below of alloy stew = vaeum
Broceanu 17 puriy ar unter estos
frroughout = forged in an hyerauie press
make a huge trtane sha A pstan den, 1
Most forgings
been
impact, plies hyéraulle press forging
products are nishes by mechine tools and
Subjected to norough inspection.
= = stem
” HAMNER,
1. As spectacular example of open dle hol forging, although vacuum processing of ses
Ke atom 30% Comman, hs nt necessary or al soptatcrs
ied into seminishe form. in the case
how below, a section of Bet 's made into &
‘conveyor roller by Me closed die process using a
‘Steam hammer.
x forging ls
"ade Tom stool that nas fret
HEATING FURNACE
MACHINED PRODUCT
HYDRAULIC PRESS
TESTING & SHIPPING.
Broceanu 17 puriy ar unter estos
frroughout = forged in an hyerauie press
make a huge trtane sha A pstan den, 1
Most forgings
been
impact, plies hyéraulle press forging
products are nishes by mechine tools and
Subjected to norough inspection.
= = stem
” HAMNER,
1. As spectacular example of open dle hol forging, although vacuum processing of ses
Ke atom 30% Comman, hs nt necessary or al soptatcrs
ied into seminishe form. in the case
how below, a section of Bet 's made into &
‘conveyor roller by Me closed die process using a
‘Steam hammer.
x forging ls
"ade Tom stool that nas fret
HEATING FURNACE
MACHINED PRODUCT
HYDRAULIC PRESS
TESTING & SHIPPING.
stainless steels
Because its resistance to corrosion is supe-
rior to that of carbon steels and other alloy
steels, the family of stainless steels is im-
portant for food handling equipment,
energy conversion equipment, hospital and
laboratory facilities and other applications
which must be cleaned with solutions. Cor-
rosion resistance generally increases with
increased chromium content. Steels con-
taining 10 percent or more of chromium
with at least 50 percent iron are designated
as stainless rather than alloy steels. One of
the most common grades contains 18 per-
cent chromium. A wide range of mill prod-
ucts is produced from stainless steels, and
many of the making, shaping and treating
practices resemble those for carbon and al-
loy steels. This steel processing flowline
emphasizes some of the procedures char-
acteristic of stainless steel plants.
Fefined in electric furnaces seh
Coss control of ho chemical analysis
I mainlained. ‘the major
materials cha
Carefully selec
ARGON OXYGEN.
DECARBURZANON
2. Stainless steels are often further 3. An altomate way of pumping gaseous
Impuries trom molten metal contaned
ime stamens laclodumaco 1 10 use
‘Tho metal bhgeled and sired by an
Seay ae
EEE Eine
Seen ae ere
secre RS
pe
SRI SR in
bici
inde!
is introduced through a water"
‘cooled lance ano sold additions
are made through a hopper.
je into the furnace are
rap, luorspar and
limestone. Alloy actions are 5. Another way o produce slabs is
pouring, which 1 a grocess Inat ullzes ar
pressure 1 fore
improv
VACUUM OXYGEN
DECARSONIZATION
jen dacarouri
rica current
ET]
smooth, carbon
an inort gas. The results à smooth slab of
surface quality.
4. Most tainiesn steel is
cast into ingot mos.
‘ho rosuling ingots are
heated to a unorm
omperature and then
roll by a roughing mit
Imo blooms, abs or
lets suitable for further
processing nto tnished
Products
LOOWING m
OR SUABBING WiLL
PRESSURE POURING
pressure y
6. Strand casting may be used as an
atternate tothe Ingo! process for
Slainiees or olher steels. Molton metal
tors the machine atthe top ana e
‘Cooled rom the outside towards the
form to lots and slabs. There is
‘generally an energy savings 28
Sompared to the got process.
enter staring la a ol that gives nie
Because its resistance to corrosion is supe-
rior to that of carbon steels and other alloy
steels, the family of stainless steels is im-
portant for food handling equipment,
energy conversion equipment, hospital and
laboratory facilities and other applications
which must be cleaned with solutions. Cor-
rosion resistance generally increases with
increased chromium content. Steels con-
taining 10 percent or more of chromium
with at least 50 percent iron are designated
as stainless rather than alloy steels. One of
the most common grades contains 18 per-
cent chromium. A wide range of mill prod-
ucts is produced from stainless steels, and
many of the making, shaping and treating
practices resemble those for carbon and al-
loy steels. This steel processing flowline
emphasizes some of the procedures char-
acteristic of stainless steel plants.
Fefined in electric furnaces seh
Coss control of ho chemical analysis
I mainlained. ‘the major
materials cha
Carefully selec
ARGON OXYGEN.
DECARBURZANON
2. Stainless steels are often further 3. An altomate way of pumping gaseous
Impuries trom molten metal contaned
ime stamens laclodumaco 1 10 use
‘Tho metal bhgeled and sired by an
Seay ae
EEE Eine
Seen ae ere
secre RS
pe
SRI SR in
bici
inde!
is introduced through a water"
‘cooled lance ano sold additions
are made through a hopper.
je into the furnace are
rap, luorspar and
limestone. Alloy actions are 5. Another way o produce slabs is
pouring, which 1 a grocess Inat ullzes ar
pressure 1 fore
improv
VACUUM OXYGEN
DECARSONIZATION
jen dacarouri
rica current
ET]
smooth, carbon
an inort gas. The results à smooth slab of
surface quality.
4. Most tainiesn steel is
cast into ingot mos.
‘ho rosuling ingots are
heated to a unorm
omperature and then
roll by a roughing mit
Imo blooms, abs or
lets suitable for further
processing nto tnished
Products
LOOWING m
OR SUABBING WiLL
PRESSURE POURING
pressure y
6. Strand casting may be used as an
atternate tothe Ingo! process for
Slainiees or olher steels. Molton metal
tors the machine atthe top ana e
‘Cooled rom the outside towards the
form to lots and slabs. There is
‘generally an energy savings 28
Sompared to the got process.
enter staring la a ol that gives nie
‘ANNEALING FURNACE: (CONDITIONING GRINDING
7. Surface quality on sami-inished stanioss is particulary
Important in succeeding slop towards finished products
‘Tho grnger snown above fs one melbod at sod to
remove Imperfections beiore they can bo roled Into the
Steet Conditioning is done after annealing.
PICKLING $ ANNEALING LINE
TAKE UP REELS
SHEAR ORYER PICKLING TANKS
TESTING & SHIPPING
2 HIGH REVERSING MILL SENDZIMIR MILL,
Cold-roed stainless stip is made Irom the hotroled_ 10. Another way lo cold-reduce stantoss
‘and pickled product, general on arourhigh reversing "steels wih a Sendaimir mil Here
mil. The cele unwind rom one reel and are moves Small Work role neaviy reintoroes by
{Through the work rol unicn reduce the Ilckness and Cluster of back-up ols, enat
Increase the longin of the shaot before ll recoled. Sondaimi mil to conte! gage Better
‘Thon the process is reverses un the required than anotner type of mi
{hiokness'end/or strengtn I achieves. carla equipment cost
thinner spe.
Bs. About 60 percent of all stainless
ls shippod in the form of hot. anc
Colg-folad ghost and stip. Many
Salniess stas requre groator
ther cross sections are reduced
mare gradual, than most othe
Silo
Great care I taxon to preserve a
9908 surface during the heating,
Gieaning and raling ‘processes
$0 the firal-surtace ‘wil have
‘990d sains qual
ass” between highly polished roils produc: TESTING,
Ehe of the more frequently used rolles a SHIPPING
Suriaces Such surfaces aro often polished SHEETS, COLS
with fine abrasives and buffers to mal ES
Bdremeiy ine or decorativo surface
7. Surface quality on sami-inished stanioss is particulary
Important in succeeding slop towards finished products
‘Tho grnger snown above fs one melbod at sod to
remove Imperfections beiore they can bo roled Into the
Steet Conditioning is done after annealing.
PICKLING $ ANNEALING LINE
TAKE UP REELS
SHEAR ORYER PICKLING TANKS
TESTING & SHIPPING
2 HIGH REVERSING MILL SENDZIMIR MILL,
Cold-roed stainless stip is made Irom the hotroled_ 10. Another way lo cold-reduce stantoss
‘and pickled product, general on arourhigh reversing "steels wih a Sendaimir mil Here
mil. The cele unwind rom one reel and are moves Small Work role neaviy reintoroes by
{Through the work rol unicn reduce the Ilckness and Cluster of back-up ols, enat
Increase the longin of the shaot before ll recoled. Sondaimi mil to conte! gage Better
‘Thon the process is reverses un the required than anotner type of mi
{hiokness'end/or strengtn I achieves. carla equipment cost
thinner spe.
Bs. About 60 percent of all stainless
ls shippod in the form of hot. anc
Colg-folad ghost and stip. Many
Salniess stas requre groator
ther cross sections are reduced
mare gradual, than most othe
Silo
Great care I taxon to preserve a
9908 surface during the heating,
Gieaning and raling ‘processes
$0 the firal-surtace ‘wil have
‘990d sains qual
ass” between highly polished roils produc: TESTING,
Ehe of the more frequently used rolles a SHIPPING
Suriaces Such surfaces aro often polished SHEETS, COLS
with fine abrasives and buffers to mal ES
Bdremeiy ine or decorativo surface
tool steels
Tool steels are highly sophisticated high carbon and
alloy materials which get their name from the fact that
they are used mostly for cutting, shaping, forming and
blanking steels and other materials. They have addi-
tional applications in which strength, toughness, re-
sistance to wear and other special properties are re-
quired. An outstanding characteristic of American tool
steel manufacture is the extreme care taken at each
step to meet very high metallurgical specifications.
1. Tool steel ingots are cast from electric are furnace or
induction ace ses. Ht inge are rough rol HYDRAULIC
or forged to shape the ¡metal and improve ie pi
properties, Tho caro used o Oblain high surface FORGING
Eualiy and uniformly sound steel cannot be shown in
‘tai in ws smpified Nowehart, Out kw a val part
INDUCTION
2. Eloeti are furnaces, malting
‘carefully graded sorzo and.
‘alloying adations, are the
Principal sources of mailen metal
fr lool steels. Most of thelr
tipa Is east into ingols as are
‘Smaller batones melted and
feted m electric induction
Turnaces, The ingots trom born
processes are then hot rolled or
forged (above). specie cases.
‘ler matting and remelin
processes come into play (ght).
STEAM
Haven
FORGING,
[ANNEALING
FURNACE
ELECTROSTATIC
MELTING
Vaguum
INDUCTION
MELTING
In vacuum induction melting, the crucible filed
either with selected scrap, whichis melted and
Surred as above, or win mon steel The vacuum
Femoves impurtios from the metal, ln vacuum are
Femetting, a eyindor is melted (or consumed) and
redeposited like a welding elctrode, The sico!'s
‘degassed by vacuum as tbe metal mets into a mota
Etectrosiag remoting also usos electichy for malting
à cylindrical electrodo, but the impurities a
captured ina slag oaling on the molten meta.
Etther ease produces a finer grain size than an ingot
product
VACUUM ARC OR
‘CONSUMABLE
ELECTRODE
REMELTING
Tool steels are highly sophisticated high carbon and
alloy materials which get their name from the fact that
they are used mostly for cutting, shaping, forming and
blanking steels and other materials. They have addi-
tional applications in which strength, toughness, re-
sistance to wear and other special properties are re-
quired. An outstanding characteristic of American tool
steel manufacture is the extreme care taken at each
step to meet very high metallurgical specifications.
1. Tool steel ingots are cast from electric are furnace or
induction ace ses. Ht inge are rough rol HYDRAULIC
or forged to shape the ¡metal and improve ie pi
properties, Tho caro used o Oblain high surface FORGING
Eualiy and uniformly sound steel cannot be shown in
‘tai in ws smpified Nowehart, Out kw a val part
INDUCTION
2. Eloeti are furnaces, malting
‘carefully graded sorzo and.
‘alloying adations, are the
Principal sources of mailen metal
fr lool steels. Most of thelr
tipa Is east into ingols as are
‘Smaller batones melted and
feted m electric induction
Turnaces, The ingots trom born
processes are then hot rolled or
forged (above). specie cases.
‘ler matting and remelin
processes come into play (ght).
STEAM
Haven
FORGING,
[ANNEALING
FURNACE
ELECTROSTATIC
MELTING
Vaguum
INDUCTION
MELTING
In vacuum induction melting, the crucible filed
either with selected scrap, whichis melted and
Surred as above, or win mon steel The vacuum
Femoves impurtios from the metal, ln vacuum are
Femetting, a eyindor is melted (or consumed) and
redeposited like a welding elctrode, The sico!'s
‘degassed by vacuum as tbe metal mets into a mota
Etectrosiag remoting also usos electichy for malting
à cylindrical electrodo, but the impurities a
captured ina slag oaling on the molten meta.
Etther ease produces a finer grain size than an ingot
product
VACUUM ARC OR
‘CONSUMABLE
ELECTRODE
REMELTING
id steel from the remelting processos is reheated
ingots af electric tumace
Important factors in toot steel product manufaclure.
HOT-ROLLED BARS
CONDITIONING
GRINDER
ng
finished (ool steel ls caretul and
time-consuming work. About 80
percent of foo! steal products
[eave the mite as bars and rose,
‘mostly In the hot rolled form. A
{ool Sieg! bar mil reduces the
rose Section of bills gredualy
Temperature ot the stedi
Controlled at cortaln levels to
bring out various proparties in the
steel Plates, sheets, ino, wire
{and forgings are aso shped by
{ool steel manufacturers. Further
finishing of some mil products ls
often required and four major
methods are skelchod at ght
Numerous machining ang heat
eating operators maybe used
products.
6. Contertess grinding
‘the entire,
of round
2 011001
Steels uch as dri
ods. Tris process
produces an
Sccuvete fish.
7. Machining or plains
Yan zulacen provides
shen avait
8. Cota tnishing bars
Stat red ane
sed ber rat
ran tog
at are amaier
El
in diameler than the
tolled cross section,
‘thus etrotening tho
steel throughout and
providing à smooth
9. Straightening
involves 2 machine
with specially
ositaned rol to
Femave possible
ends in certain
products —
principally bars.
TESTING & SHIPPING >
ingots af electric tumace
Important factors in toot steel product manufaclure.
HOT-ROLLED BARS
CONDITIONING
GRINDER
ng
finished (ool steel ls caretul and
time-consuming work. About 80
percent of foo! steal products
[eave the mite as bars and rose,
‘mostly In the hot rolled form. A
{ool Sieg! bar mil reduces the
rose Section of bills gredualy
Temperature ot the stedi
Controlled at cortaln levels to
bring out various proparties in the
steel Plates, sheets, ino, wire
{and forgings are aso shped by
{ool steel manufacturers. Further
finishing of some mil products ls
often required and four major
methods are skelchod at ght
Numerous machining ang heat
eating operators maybe used
products.
6. Contertess grinding
‘the entire,
of round
2 011001
Steels uch as dri
ods. Tris process
produces an
Sccuvete fish.
7. Machining or plains
Yan zulacen provides
shen avait
8. Cota tnishing bars
Stat red ane
sed ber rat
ran tog
at are amaier
El
in diameler than the
tolled cross section,
‘thus etrotening tho
steel throughout and
providing à smooth
9. Straightening
involves 2 machine
with specially
ositaned rol to
Femave possible
ends in certain
products —
principally bars.
TESTING & SHIPPING >
environmental systems
Environmental control systems within the
steel industry involve a variety of operations
from cleaning water to covering conveyor
belts. Illustrated here are some of the major
processes used to clean air and water in
the steelmaking process.
arios Rerining ole
een o cra sms om Its o
oils ar seling basins are used to remove ening Scat
id materials and ol! from the waler used on =
foling mils, These solids aro most ¡es are devices which function on the same
flakes and partos of ron oxide nat e aci cent cn In
ing heslo. EE principle as a vacuum cloanor Exhaust al ls pales through
ino tt neo ae dp Eee Ses tn tne pb oc
Feng In he next. This recuces tho effuonts end reduces me feoyeing’ ON eter e aos E OF and the wat Di raveralng tho air flow, the bags are empti
Birnen ee ane oben ping 10 ino surface ofthe basi ind the dus! colectas or posa
testing & research Aion born anal a mens uses
current testing is
rane nae
fonda uct est. À I percentage of 8
Sent le induced ho HET
Brice being tested £tcated rom tne
Break are found In that Stop in ntenty of tne
Many types of testing including those
shown here are used by the steel industry
to improve product quality and uniformity.
Brief descriptions of each type of testing
caren toy are sno igre
shown are provided although the tech: freneured'é Grate the er Rime’ nat eH ome,
nology involved is very complex fies indias Mo Date utters"
electrical flow. Slgificant drop inthe
ensured tot pressure
car indicate lene,
‘Magnetic partici testing works by means o the
propone of magnets: Fooly es magne
Bares concentra
Environmental control systems within the
steel industry involve a variety of operations
from cleaning water to covering conveyor
belts. Illustrated here are some of the major
processes used to clean air and water in
the steelmaking process.
arios Rerining ole
een o cra sms om Its o
oils ar seling basins are used to remove ening Scat
id materials and ol! from the waler used on =
foling mils, These solids aro most ¡es are devices which function on the same
flakes and partos of ron oxide nat e aci cent cn In
ing heslo. EE principle as a vacuum cloanor Exhaust al ls pales through
ino tt neo ae dp Eee Ses tn tne pb oc
Feng In he next. This recuces tho effuonts end reduces me feoyeing’ ON eter e aos E OF and the wat Di raveralng tho air flow, the bags are empti
Birnen ee ane oben ping 10 ino surface ofthe basi ind the dus! colectas or posa
testing & research Aion born anal a mens uses
current testing is
rane nae
fonda uct est. À I percentage of 8
Sent le induced ho HET
Brice being tested £tcated rom tne
Break are found In that Stop in ntenty of tne
Many types of testing including those
shown here are used by the steel industry
to improve product quality and uniformity.
Brief descriptions of each type of testing
caren toy are sno igre
shown are provided although the tech: freneured'é Grate the er Rime’ nat eH ome,
nology involved is very complex fies indias Mo Date utters"
electrical flow. Slgificant drop inthe
ensured tot pressure
car indicate lene,
‘Magnetic partici testing works by means o the
propone of magnets: Fooly es magne
Bares concentra
Cooling towers are huge
fiches win reduce the
inertia ter by
contacting in tho alo
Electrostatic preciptatore are air cleaning devices in which dus ° Cater by pacsng
abate are passed through chambers equlpped with hig ou of gerd or Simian Ing
ge wires strung equidistant between parallel plates. The a Teen de materia.
slactrica! dicharge ‘rom the wires produces an electrical fold that Fin reine eras de " a
Du a charge onto cust parles and causes trem 10 bo at rt, ood and fans to
Fo arounded plates where they adhere Te platos are struck with Capture fumes generated in
rappers and the dust fails into bins for disposal. —— iaa
‘Sompounds from solution
ee © unein u sa erm paco sai u
RE Set a
products as well as the Ihickn waves through the steol Imperfections reflect the Industry for rapie Chemica!
em mes En ily babe oe
pr rectas oe See ie a
cas, EP ice, Pileta
electrons take the place of ne calbrated intensity are directed. von burned in an ar.
more conventional beam of ito steel. The intensiy of re mis racition of
Tight Images are formed on a faye passing through the stee is charactoriste wave lengths
{iuorescent scrcon or on a treasures. dhe amount of rays ‘The intensity of ins
photographic te eorzed by the slog fe a on res
1.000.000 times are possible SE an nd ol
displayod or
fiches win reduce the
inertia ter by
contacting in tho alo
Electrostatic preciptatore are air cleaning devices in which dus ° Cater by pacsng
abate are passed through chambers equlpped with hig ou of gerd or Simian Ing
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rappers and the dust fails into bins for disposal. —— iaa
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steel processing glossary
Acid neutralization — Chemical treatment of water to eliminate
aciaity.
Annealing — The process of heating steel and then cooling it slowly
to induce softness.
Baghouse — An air pollution control device used to trap particles by
filtering gas streams through large cloth or fiberglass bags.
Basle oxygen furnace (BOF) — The chief method of producing steel.
The furnace is charged with molten iron from a blast furnace and
steel scrap. Oxygen is blown into the furnace at high velocity to
speed combustion and refine the iron and scrap.
Billet — Semi-finished product that has been rolled or forged from
an ingot or strand cast. Usually has a square cross section less than
36 square inches.
Black plate — Steel plate of 12 to 32 inches wide produced in a tin
mill by cold reduction, prior to any cleaning operation.
Blast fumace — The furnace used to produce iron. A blast of hot air
is blown through the charge of iron ore, coke and limestone. The
coke burns, emitting gases that reduce the ore to metallic iron. The
limestone combines with impurities and forms slag.
Bloom — Semi-finished product that has been rolled or forged from
an ingot or strand cast. Usually has a square cross section
exceeding 36 square inches.
Claritier — A settling tank where solids are mechanically removed
from waste water.
Cold drawing — Process of reducing the cross-sectional diameter of
tubes or wire by drawing them through dies without previously
heating the material
Cupping — Process of forming tubular or closed cylindrical products
from a flat plate. The plate is heated prior to forming
Electric arc furnace — A method of producing steel to exacting
specifications. The furnace is charged with selected steel scrap,
limestone and other additives. Heat supplied by an electric arc melts
and refines the charge.
Hot extrusion — The forming of material of continuous cross section
by forcing it through a die in a press.
Ingot — Metal cast into a mold. it has to be rolled or forged to be
usable. Can weigh as much as 30 tons.
Mandrel — Shaft on which work already bored is mounted for
turning, milling, etc. Also a rod used to retain the cavity in hollow
metal products during their processing.
O-ing press — A press that takes a plate that has been shaped by
the U-ing press, and, using much greater force, completes the
bending to cylindrical form.
Pickling — Process of chemically removing scale or oxide from metal
objects to obtain a clean surface.
Planishing — Production of a superior finish on a previously rolled or
forged product, accomplished by passing the bar or other product
through chill cast or hardened steel rolls or by hammering with a
smooth-faced hammer.
Reversing mill — Rolling mill designed so the direction the rolls are
turning can be reversed following each pass of material. This
rotation can be repeated until the desired reduction is attained.
Roughing stand — Mill used for preliminary rolling.
Sendzimir mill — Named after its inventor, Thaddeus Sendzimir. It is
a cold reduction mill
Skelp — Steel sheet or plate from which welded tubing or
pipe is made.
Slab — A rectangular semi-finished product hot-rolled down from an
ingot or strand cast.
Tube reducer — Machine that uses a pair of rolls for cold rolling
tubing and rod
U-ing press — Press where a U-shaped die forces the steel down
between rocker rolls.
Acid neutralization — Chemical treatment of water to eliminate
aciaity.
Annealing — The process of heating steel and then cooling it slowly
to induce softness.
Baghouse — An air pollution control device used to trap particles by
filtering gas streams through large cloth or fiberglass bags.
Basle oxygen furnace (BOF) — The chief method of producing steel.
The furnace is charged with molten iron from a blast furnace and
steel scrap. Oxygen is blown into the furnace at high velocity to
speed combustion and refine the iron and scrap.
Billet — Semi-finished product that has been rolled or forged from
an ingot or strand cast. Usually has a square cross section less than
36 square inches.
Black plate — Steel plate of 12 to 32 inches wide produced in a tin
mill by cold reduction, prior to any cleaning operation.
Blast fumace — The furnace used to produce iron. A blast of hot air
is blown through the charge of iron ore, coke and limestone. The
coke burns, emitting gases that reduce the ore to metallic iron. The
limestone combines with impurities and forms slag.
Bloom — Semi-finished product that has been rolled or forged from
an ingot or strand cast. Usually has a square cross section
exceeding 36 square inches.
Claritier — A settling tank where solids are mechanically removed
from waste water.
Cold drawing — Process of reducing the cross-sectional diameter of
tubes or wire by drawing them through dies without previously
heating the material
Cupping — Process of forming tubular or closed cylindrical products
from a flat plate. The plate is heated prior to forming
Electric arc furnace — A method of producing steel to exacting
specifications. The furnace is charged with selected steel scrap,
limestone and other additives. Heat supplied by an electric arc melts
and refines the charge.
Hot extrusion — The forming of material of continuous cross section
by forcing it through a die in a press.
Ingot — Metal cast into a mold. it has to be rolled or forged to be
usable. Can weigh as much as 30 tons.
Mandrel — Shaft on which work already bored is mounted for
turning, milling, etc. Also a rod used to retain the cavity in hollow
metal products during their processing.
O-ing press — A press that takes a plate that has been shaped by
the U-ing press, and, using much greater force, completes the
bending to cylindrical form.
Pickling — Process of chemically removing scale or oxide from metal
objects to obtain a clean surface.
Planishing — Production of a superior finish on a previously rolled or
forged product, accomplished by passing the bar or other product
through chill cast or hardened steel rolls or by hammering with a
smooth-faced hammer.
Reversing mill — Rolling mill designed so the direction the rolls are
turning can be reversed following each pass of material. This
rotation can be repeated until the desired reduction is attained.
Roughing stand — Mill used for preliminary rolling.
Sendzimir mill — Named after its inventor, Thaddeus Sendzimir. It is
a cold reduction mill
Skelp — Steel sheet or plate from which welded tubing or
pipe is made.
Slab — A rectangular semi-finished product hot-rolled down from an
ingot or strand cast.
Tube reducer — Machine that uses a pair of rolls for cold rolling
tubing and rod
U-ing press — Press where a U-shaped die forces the steel down
between rocker rolls.
American Iron and Steel Institute
1000 16 Stee, NA, Washingtun, D.C 20086
1000 16 Stee, NA, Washingtun, D.C 20086
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