Tailor-made bright steel solutions

Transcription

1 Tailor-made bright steel solutions

2 02 SChmolz + Bickenbach GROUp SChmolz + Bickenbach GROUp 03 SCHMOLZ + BICKENBACH Group: Production of specialty steel long products Providing Special Steel Solutions About s+bi s+bi Group is one of the world s leading providers of customised solutions in the special steel long products business. A global name in tool steel and stainless long steel, the Group is one of two largest companies in Europe for alloy and high-alloy engineering steel. With around 10,000 employees at its own production and distribution companies in over 35 countries across five continents, the Company supports and supplies customers wherever they operate. Besides the comprehensive Production and Sales & Services portfolio, our customers benefit from the Company s technological expertise, consistent high quality worldwide and in-depth knowledge of local markets.

3 04 SCHMOLZ + BICKENBACH BRIGHT STEEL S+bi bright steel Special steel solutions for every field of application s+bi provides its customers with almost the entire range of bright steel in many qualities and dimensions. Our wide product range is completed by a comprehensive array of services. From individual consulting through extensive processing to logistical solutions, we offer you excellent technical know-how and a maximum of flexibility. Our Sales & Services network ensures that our products are available in Germany, in Europe and around the world.

4 06 QUALITY AND SERVICE Quality, service and individual processing s+bi Blankstahl offers you the complete service spectrum, from production to distribution. We obtain the steel from our own plants or external suppliers at the world's best conditions. When doing so, our long-standing cooperation with renowned steel producers ensures constant quality standards. To permanently guarantee these to you, not only the producers but also the steel they produce is subject to continuous controls. These go so far that on request we also certify our producers jointly with you. As a result, our bright steel fulfills the high quality requirements of the automotive and mechanical engineering industries. Our cross-matched range of services benefits you by ensuring that you always receive your steel products in tested quality from a single global source. You also have access to our comprehensive array of services. These range from technical advice by highly qualified teams of engineers to a wide variety of processing possibilities. From simple saw cuts to processing with the tightest tolerances: from us you receive virtually everything that is technologically feasible in relation to short lengths and end-processing. Our bright-steel assortment comprises several thousand articles in drawn, peeled and ground finishes, which are polished as standard. Whether for country-specific standard qualities or customer-specific special materials for sophisticated components: with s+bi Blankstahl you have a service partner for every steel solution if you wish, even for ready-toinstall components.

5 DRAWN BRIGHT STEEL 09 Drawn bright steel Drawn bright steel is produced from hot-rolled steel bar or wire by chipless drawing The drawing process results in substantially higher dimensional accuracy than with hotformed steel products. Dimensional accuracy itself is an important precondition for workability on multi-spindle automatic lathes which allow the production of high-precision turned parts as specified in drawings. The drawing process also results in increased strength characteristics (tensile strength and yield point). In the case of steel grades with low carbon content, the drawing process also improves their machinability. For all steel grades, the strain hardening that results from the drawing process can be reversed in a subsequent heat-treatment process. In our most modern production lines, we draw bright steel with high dimensional accuracy and surface quality, as well as defined mechanical characteristics, from bar to bar, from coil to bar, and from coil to coil. To enable large cross-sections also to be drawn from bar with maximum precision, we employ bar-drawing benches with a drawing stress of up to 100 tons. Thanks to the most modern interlinking of the plant components, we can descale, draw, straighten and saw bright steel from rolled raw material without extensive handling. For efficient production, an eddy current testing system for surface defects as well as the end-processing systems are integrated in our production lines. With coil-drawing we produce bright steel with a diameter of up to 40 mm from coil. Here, too, in-line production extends from bending-up, descaling, shearing and straightening through eddy-current testing and endprocessing to weighing and packing. Drawn bright-steel bar is always straightened and polished after it has been drawn. Thinner dimensions can also be supplied wound into coils. On request, the coils can also be laid in layers. We supply drawn bright steel in a wide range of cross-sectional shapes according to DIN EN in tolerance class IT 11 or IT 9.

6 10 PEELED BRIGHT STEEL GROUND BRIGHT STEEL 11 Ground bright steel Ground bright steel is drawn or peeled round material which has been additionally ground and polished to achieve an even better surface quality and an even greater dimensional accuracy. This surface quality is therefore particularly suitable for surface finishing with high-gloss characteristics. The high dimensional accuracy of ground bright steel is of outstanding importance wherever it is used for machine parts without further surface treatment. We supply ground bright steel according to DIN EN to tolerance class IT 6. Peeled bright steel Steel for general applications We supply peeled round material according to DIN EN Peeled bright steel is exclusively round material (usually 14 mm diameter and higher). Compared to rolled steel, the material has greater dimensional accuracy and a bright, smooth surface. This kind of bright steel is peeled from rolled or forged steel bar by rough-turning and afterwards it is straightened and polished. When peeling, the chip takeoff is measured to such an extent that un avoidable surface defects resulting from the manu facturing process, such as rolling marks, cracks, pores, splinters or decarburisation seams are removed. We supply peeled bright steel according to DIN EN in tolerance class IT 11 or IT 9. Other tolerances can be supplied upon request. General engineering steel according to DIN EN and DIN EN stands for unalloyed steel grades which are mainly used in steel construction and mechanical engineering. These steel grades can be given special mechanical-technological characteristics. The following engineering steel grades are standardized in DIN EN :» S235JRC +C and +SH [FN]» E295GC +C and +SH [FN]» E335GC +C and +SH [FN]» S355J2C +C and +SH [FF] Strength-controlled steel grades: FN = rimming steel not permitted FF = fully killed, with sufficient content of nitrogen-binding elements, normalized on request.

7 12 Case hardening steel FREE CUTTING STEEL 13 Case hardening steel Steel according to DIN EN and DIN EN for case hardening Free cutting steel Steel according to DIN EN and DIN EN for high-speed machining Case hardening steel according to DIN EN and DIN EN are steel grades with a relatively low carbon content, which are used for workpieces whose surface layers are normally carburized or carbonitrided before they are hardened. This gives them substantially greater hardness in the surface layer while maintaining the better toughness of the core zone. Unalloyed case hardening steel is used for low-stressed parts such as hubs, shafts and levers for vehicle and general mechanical engineering. Depending on the alloy, alloyed case hardening steel is used for parts with medium to high core-strength and toughness. Such parts include highly stressed gearwheels and control components in vehicles and aircraft construction and others. Unalloyed steel grades: e.g. C10E, C10R, C15E, C15R Alloyed steel grades: e.g. 16MnCr5, 20MnCr5, 20MoCr4. Other steel grades on request. Alloyed steel grades with controlled sulphur content: e.g. 16MnCrS5, 20MnCrS5, 20MoCrS4, 20NiCrMoS2-2 The standard conditions are as follows: +C = cold drawn +SH = peeled, from 14 mm round +A = soft annealed +TH = treated on hardening strain +FP = treated on ferrite-perlite material structures +AC = spheroidized In some cases, these grades can also be supplied with an additional lead content ( %). Compared to sulphurized steel grades, free cutting steel (DIN EN and DIN EN ) shows a substantially improved machinability and surface finish which allow shorter production times. Soft free cutting steel: e.g. 11SMn30, 11SMnPb30, 11SMn37, 11SMnPb37 These grades can also be supplied with added tellurium and/or bismuth. Heat-treatment for special magnetic properties can be agreed upon request. Free cutting case hardening steel: e.g. 10S20, 10SPb20, 15SMn13 Free cutting heat-treatable steel: e.g. 35S20, 36SMn14, 38SMn28, 44SMn28, 46S20 These steel grades are normally supplied in cold-drawn condition. Other conditions can be agreed upon request: +SH = peeled Additionally heat-treated conditions: +A = soft annealed +SR = stress-relieved +QT = quenched and tempered

8 14 Heat-treatable STEEL Other STEEL GRADES 15 Wind energy: We produce the basic material for up to per rotor blade Heat-treatable steel Steel according to DIN EN and DIN EN quenched and tempered to be high-strength Heat-treatable steel according to DIN EN and DIN EN are steel grades that are intended for quenching and tempering. In addition, through inductive surface hardening, they can also be given maximum wear resistance. They are used for highly stressed screws, springs and piston rods, where especially the combination of high strength, wear-resistance and toughness is very important. Unalloyed steel: e.g. C22 to C60, C22E to C60E, C22R to C60R E = high-grade steel R = high-grade steel with a controlled sulphur content of to % Other conditions: +C = cold drawn +SH = peeled, from 14 mm round +A = soft annealed +SR = stress-relieved +N = normalized +QT = quenched and tempered For improved machinability, these steel grades can also be supplied with added lead of 0.15 to 0.30 %. Alloyed steel: e.g. 38Cr2, 46Cr2, 34Cr4, 37Cr4, 41Cr4, 25CrMo4, 42CrMo4, 50CrMo4, 36CrNiMo4, 34CrNiMo6, 30CrNiMo8, 51CrV4. Grades 38Cr2 to 42CrMo4 can also be supplied in sulphurized condition with S = to %. We supply other steel grades on request. Other steel grades Cold heading and cold extrusion steel according to DIN EN After heat treatment, this steel is characterized by good cold formability. The following conditions are available: +C = cold drawn +SH = peeled, from 14 mm round +A = soft annealed +FP = treated on ferrite-perlite material structures +AC = spheroidized Additional surface treatments such as phosphating or polymer coating are possible on request. We issue material testing certificates according to DIN EN The contents and tests to be certified must be agreed upon when ordering.

9 16 DIMENSIONS DIMENSIONS 17 Dimensions Lengths according to DIN standard or standard commercial lengths More than Our bright steel assortment comprises more than 5,000 articles with approximately 400 material variants in drawn, peeled and ground finishes. Dimensional ranges for our bright steel:» Drawn from 6 to 80 mm round» Peeled from 14 to 125 mm round» Ground from 6 to 125 mm round» Squares, hexagons and octagons up to 80 mm» Dimensional limits are dependent on the quality. We produce steel in lengths according to DIN standard or in standard commercial lengths. We supply special fixed lengths, short lengths, and specially processed end executions on request. Our steel shows permissible deviations from nominal dimensions according to DIN and ISO standard tolerances for bright steel. If requested, all tolerances can be supplied up to ISO tolerance class IT 6. We also supply special sections in bars or coils in all executions in order to match drawings or samples upon request. with approximately

10 18 TOLERANCE Fields Production programme special shaped sections 19 Production programme for special shaped sections Cost-efficient alternative for a large variety of applications Our hot rolled or bright drawn special sections are a cost-efficient alternative for construction in many fields of application. For the production of customer-specific special sections, high-performance facilities are available at our premises. On several winders, we draw not only special sections but also standard crosssections from coil to coil, which are prerolled in our own conductive hot-rolling mill. We can also supply special shaped sections only pre-rolled to bar or coil. Tolerance fields (example: h tolerance) Finished state h6 h7 h8 h9 h10 h11 h12 Drawn R R R, S, H R, S, H Peeled R R R R Ground R R R R R R R Polished R R R R R R R R = round bar S = square bar H = hexagonal bar Tolerance fields (example: h tolerance) Nominal dimension (mm) h6 h7 h8 h9 h10 h11 h12 > 1 to > 3 to > 6 to > 10 to > 18 to > 30 to > 50 to > 80 to > 120 to > 180 bis The above dimensional limits are negative deviations from nominal dimension. For example, for a nominal diameter of 20 mm with tolerance field h9, valid dimension is 20 mm +0 / mm, i. e mm to mm. The possible shapes are extremely diverse and adapted as far as possible to the individual requirements of our customers. Except for air hardening steel, all kinds of steel can be delivered. Weights per meter from 0.22 to 3.5 kg/m are possible, and up to 4.10 kg/m for particularly suitable cross-sections. In addition to our comprehensive technical possibilities, a team of experienced engineers is at your disposal for the development of individual shapes. They can provide you with solutions for almost every field of application.

11 Production programme special shaped sections 21 Weights per meter from to possible Production programme for special shaped sections Section Flat sections Square sections Sectional shape Sharp edges or with mill edges Rounded edges R approx. 1/3 thickness Round side surfaces R approx. 1/2 thickness Round, both sides flattened Bevelled edges, bevel approx. 1/3 thickness Sharp edges or with mill edges One side bevelled, sharp edges or mill edges All sides bevelled or rounded Width max. mm Cross section min. mm 2 Cross section max. mm

12 END PROCESSING 23 End processing For efficient production, end-processing system are integrated in our production lines Standard for commercial lengths +C (K), +SH (SH), +SL (SL) Round in mm Square in mm Hexagonal in mm Chamfer Standard length in mm Chamfer + face , 45, Chamfer + face + centre , 45, Tap max. 30 mm on request on request

13 24 SHORT LENGTH PRODUCTION HEAT TREATMENT 25 Approximately Normalisation from short pieces per year to Short length production Heat treatment In our short length production plant, bright steel is manufactured for further processing purposes in accordance with customer requirements in diameters of 8 to 80 mm, in lengths of between 25 to 2000 mm, and up to a maximum piece weight of 25 kg. Depending on the machinery used, processing lengths (turning) are 10, 50 or 120 mm. Depending on the machine and diameter, length tolerances range between ± 0.05 mm and ± 0.10 mm. On high-performance automatic machinery we can saw, deburr, turn, plan, chamfer, center and degrease. Furthermore, end processing according to drawing can also be provided on request. Respective combinations can be freely selected. In addition to that, features relating to process safeguarding can also be checked. Over and beyond the above-mentioned, we can offer further services such as washing, length measurement, straightness testing, demagnetisation, weight recording, stamping and packaging. By means of fully automatic packaging systems, the finished short pieces can be customer-specifically packed either as bulk freight or in layers in customer owned containers. The packing units can be small or large, as per customer request. For special customer requirements and targeted applications, our bright steel products can be heat treated. Under an inert gas atmosphere, we can perform stress-relieved, soft and spheroidised annealing as well as normalisation in the temperature range from 560 C to 900 C. For highest strength requirements, we can anneal round and hexagonal cross sections and tubes in our single-bar quenching and tempering plants. In these facilities we are able to adjust mechanical-technological properties which cannot be achieved by conventional means.

14 26 Eddy current testing Eddy current testing Differential coils achieve the required high defect resolution To detect surface defects, depending on the cross-sectional shape and given recording limits, either the feed-through coil method or the rotating system method is used. For round material cross sections, the two methods can be used alternatively or together. For non-round cross sections, only shape-adapted feed-through coils can be used. To achieve the required high defect resolution, in most cases differential coils are used for the eddy current surface test. The differential connection is invariably aligned with the scan direction of the coil or rotating probe, i.e. in the case of the feed-through coil, in longitudinal direction of material, and in the case of the rotating probe, in circumferential direction. This results in a specific sensitivity to different types of defect. Specifically, the encircling feed-through coil is particularly sensitive to short longitudinal and transverse-oriented defects as well as to local flaws such as holes, breakages and peeling shells. On the other hand, the rotating probe is particularly sensitive to detect open longitudinal surface defects, such as overlaps, seams and tension cracks.

15 ULTRASONIC TESTING 29 Ultrasonic testing Our most rigorous test that can be technically and economically performed When steel is produced, a sporadic occurring of internal material discontinuities cannot be completely avoided. To ensure that highest requirements for the internal quality of the bright steel are achieved, we can perform ultrasonic testing. This method of testing is a so-called non-destructive impulse-echo process. Depending on the application, with the ultrasonic method that we use, we can test for inclusions up to a maximum circular disc reflector also known as flat bottom hole size of 0.7 mm. In case of round cross sections, the testing method we use also enables us to detect internal faults in the full volume or full cross section with a length of 5 mm or more up to 0.10 mm below the surface. This test is currently one of the most rigorous checks that can be applied technically and economically to bright steel bars and is even below the limit value of the applicable DIN EN standards. Typical components that place maximum demands on the internal quality of bright steel are, for example, individual parts of the common-rail diesel fuel-injection system as well as engine and gearbox components that are designed for high fatigue strength.

16 30 MATERIALS TECHNOLOGY Materials technology Excellent technical Know-how for the very best steel solutions s+bi materials technology offers our customers the reliable basis for receiving individual and high-quality steel and aluminium solutions. Our technicians know-how ensures that we understand our customers specific requirements and provide you with the optimal steel. Our materials technology is supported by the latest testing equipment. This enables us to perform all chemical, physical and mechanical-technological tests that are necessary to determine the characteristic properties of the following steel grades:» Free cutting, case hardening and cold heading steel» General engineering and heat-treatable steel» Stainless, acid- and heat-resistant steel» Tool and high-speed steel We use the following methods and equipment for determination:» carbon/sulphur (C/S) analyser» chemical analysis by emissions spectrometer, stationary/mobile» strength and toughness testing by tensile and notched bar impact tests at high and low temperatures» Vickers, Brinell and Rockwell hardness testing and microhardness testing» testing of magnetic properties including hysteresis» determination of microstructure, purity degree and grain size by microsections» detection of internal material flaws by ultrasonic testing» detection of external material flaws by magnetic particle inspection testing and eddy current testing» roughness measurements Quality Management Awarded with the Ford Q1 Preferred Quality Award In order to fulfill the highest requirements such as those of the automotive industries, the automotive supply industries and the mechanical engineering industries we target at a zero-error policy whose main focus is on preventing production errors. In meeting this aim over the long term, we rely on the permanent optimisation of our processes and employ the following tools and/or methods:» Project planning/advance quality planning» Statistical process control (SPC)» Process and machine capability analysis» Measuring system analysis (MSA)» Failure Mode and Effects Analysis (FMEA)» Audits (product, process and system audits)» Benchmarking» 8-D reporting» Initial sample routine (PPAP/VDA/IMDS record) In addition, we have been certified by TÜV Nord in accordance with DIN EN ISO 9001:2008 or ISO TS 16949:2009 and by TÜV Rheinland in accordance with AD 2000-Merkblatt WO (Pressure Equipment Directive) and awarded by Ford with the Q1 Preferred Quality Award.

17 32 Distribution Distribution 33 From several locations in Germany we deliver our steel throughout Europe and around the world. s+bi Blankstahl GmbH Locations s+bi Blankstahl GmbH Eupener Straße 70 D Düsseldorf Fon +49 (0) Fax +49 (0) s+bi Trossingen Gottlieb-Daimler-Straße 2-4 D Trossingen Fon +49 (0) Fax +49 (0)

18 34 Environmental and Energy Management System Comprehensive environmental management system since Environmental and Energy Management System of s+bi Blankstahl At s+bi the responsible handling of resources and protection of the environment are of paramount importance. Already in 2003 we started to build up a comprehensive environmental management system according to the ISO international standard. s+bi Blankstahl GmbH is certified to ISO 14001:2009. This is subject to regular internal monitoring. According to the guidelines of the ISO Environmental Management standard, all of the company's processes are analyzed and classified for their environmental compatibility. Wherever necessary, optimisation measures are continuously defined and implemented. An effective organisational structure, defined processing methods and operating procedures ensure that the sustainable corporate goals for responsible handling of resources and protection of the environment are constantly pursued. In 2012, s+bi Blankstahl GmbH, supplemented its environmental management system by adding an energy management system in accordance with ISO 50001:2011. In line with the specifications of this standard, all energetic processes are first checked with regard to their energy efficiency and then integrated into strategic and operational energy targets. The assessment of these energetic processes involves differentiated acquisition and evaluation of energy data, which creates a basis for identifying approaches that will facilitate the long-term improvement of the energy balance. For this reason, the planning stage of new projects already includes an energy analysis to ensure that energy issues can be taken into account at implementation stage.

19 S+Bi Blankstahl GmbH Eupener Str. 70 D Düsseldorf Subject to amendments, errors and misprints. Product-specific data sheets have precedence over the information in this catalogue