Indian Stainless Steel Development Association ISSDA Conference. Venue: Hotel Grand, New Delhi
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1 Indian Stainless Steel Development Association ISSDA Conference Date: 7 th November 2014 Venue: Hotel Grand, New Delhi 1
2 Challenges in Manufacture of Making of Heavy Stainless Steel Forgings dual certified (SS304/304L) from 92MT stainless steel ingots- The heaviest SS ingot produced in India R.G. Kulkarni, Arun Kumar, T. Venkatramana, Neeraj Borwankar* 2
3 L&T Special Steels and Heavy Forgings Private Limited 3
4 Joint Venture of L&T and NPCIL, India. India s heaviest & fully integrated Steel Making, Forge and Machining facility. Capable of making steel ingot of up to 300MT single piece weight( in conventional ingots) & 200MT( in hollow ingots). Top poured ingot casting using stream degassing can be done in VIC up to 500MT. One of its kind facility in India to produce Nuclear-Grade Heavy Forgings. 4
5 LTSSHF Business Sectors L&T SSHF Refinery & Hydrocarbon Steel Sector LTSSHF Power Sector Assured Supply Nuclear No Foreign dependence Price & Delivery Advantage 5
6 Process Flow L&T SSHF 6
7 Electric Arc Furnace L&T SSHF Features Transformer capacity 80MVA Process Raw Materials used : Low P Fe-Cr, MS Scrap & 304 scrap. 7
8 Ladle Refining Furnace L&T SSHF Features Transformer capacity 18MVA Automatic sampling and temperature measurement system Auto feeding system Addition of alloys & Fluxes. Process Slag Drain before VOD. Chemistry adjustment. Temperature adjustment C. 8
9 VD/ VOD L&T SSHF Pump down time 5.5 minutes ( Vacuum <0.67mbar) Provision of addition of ferroalloys under vacuum. 9
10 VD/ VOD Monitoring of CO/CO 2 ratio. L&T SSHF Exhaust Gas Temperature monitoring. Chemistry attainment Finish chemistry after VOD and further fine tuning in Ladle refining was targeted in range of : C : %; Mn: % ; Si :0.45 to 0.60 % ; P <0.030 %; S < 0.015%; Cr: %; Ni : %; Co:0.10% Max. N :850 to 950 ppm. 10
11 Ingot Casting L&T SSHF Corrugated mold with wide end up used for casting. Ingot molds and runner bricks are preheated before ingot teeming. Ingot teeming is done with Argon shrouding over trumpet. 11
12 Ingot Casting L&T SSHF Critical Parameters: Teeming rate Teeming temperature. Mold Flux Exothermic Powder 12
13 Ingot Casting L&T SSHF - 92T ingot with conventional bottom pouring method was having following dimensions: - Body Mean Diameter: 2100mm - Body Height: 2900mm - Hot top Height: 560mm 13
14 Forging ( 1 st Route) - Hot charging of ingots. - Natural Gas Fired Reheating furnace( 250 & 300MT furnace) - Simufact Software for forging operation simulation. - Finished dimensions of plate:7100mm Lx 2420mm Wx 200mm thk 14
15 Forging : Done on 9000T Hydraulic Press( NKMZ Make) Forging Operation in progress 15
16 Forging ( 2 nd Route) - Another route was partial forging to an intermediate size of mm thickness which were further rolled at Hot plate mill at 1200 C. - Advantage : a) Closer dimensional tolerance/ lesser machining allowance. b) Improved permeability for ultrasonic testing. 16
17 Heat Treatment - Solution treatment at 1050 C. - Challenge : Distortion during heat treatment. Machining - Done on horizontal boring machine to remove bow and twist introduced during hot handling. - Machined plates were subjected to different metallurgical tests as per customer requirement. 17
18 L&T Special Steels & Heavy Forgings 10/02/2014 L&T Special Steels & Heavy Forgings 18
19 Test Results -Chemical composition HEAT NO C Mn Si P S Ni Cr Cu Co B Nb N(ppm) A A A A Specification Max Max Max Max. - Mechanical Properties Max Max Max Max Max. HEAT NO UTS 0.2% PS %El on 50mm ( MPa) ( MPa) GL %RA A A A A Specification 485 Min. 205 Min. 30 Min. 45 Min. 19
20 Test Results -Microstructure ASTM Grain size was found to be 3-4 as per ASTM E-112. Ferrite content was found to be ~0.3%. -Magnetic Permeability µ( Customer specification of 1.05µ) - Ultrasonic testing Plates tested as per SA388 by normal probe technique using normal probe. All the plates met the S1 requirement of ASME Sec VIII Div.2. 20
21 Results and discussions -By maintaining the Cr and Ni equivalents ratio, the delta ferrite and hence improved magnetic permeability could be obtained. -In the initial heat chemical segregation was slightly on higher side. The super heat at the time of casting was reduced in the subsequent heats and improvement observed. -Mechanical properties were found to be uniform across the width and along the length of the plate. -Proper controls during hot working ensures that good ultrasonic permeability can be achieved in the forged plates. 21
22 Conclusions It is possible to make high thickness stainless steel plates and forging in India and LTSSHF is geared up to meet future challenges in manufacture of stainless forging for the country and exports. 22
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