Steel - ISMT Limited

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Carbon, Alloy and Bearing Steel for Various Industries Application.

ISMT is an established market leader in the production of special engineering steels. We produce carbon, alloy and martensitic stainless steel bars with a special emphasis on ultra-clean steels, free machining steels, bearing steels, and on other specially engineered steel grades. With over 15 years of experience in the manufacture of special steels our strength lies in our ability to produce very clean steels consistently and cost effectively; to produce hard to manufacture free machining steels; to develop and custom produce steels that meet specific mechanical or metallurgical requirements; and to deliver small lots of steels.

Modern Equipment and Methods

We operate one of the most modern alloy steel plants in the country located at Jejuri, near Pune. All our steel is produced through the electric arc furnace (EAF) route, is ladle refined, vacuum degassed, continuous cast and rolled. These primary equipments are supplemented by best in class quality enhancing devices such as an automatic mould level controller, non-sinusoidal tundish oscillators, electro-magnetic stirrers etc., with the singular objective of producing the best steel

Carefully Chosen Inputs

The quality of inputs used for melting has a direct bearing on the quality of the output. For this reason, we melt a very carefully chosen mix of virgin metal (pig iron and DRI) and clean scrap so as to control the appearance of tramp elements. We have a trusted set of suppliers all of whom are periodically audited to ensure adherence to our standards. In addition, we test all incoming material for radiation and other hazardous contaminants

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Clean Steel Process

ISMT prides itself on manufacturing the cleanest steel in the country, on par with the best worldwide this is entirely attributable to our steel making practices. While good equipment is a prerequisite for making Clean Steel, at ISMT, we believe that good practices are even more vital. While modern equipment may be procured at a cost, good practices are much more difficult to develop, and institutionalize it takes determination, time and painstaking effort. For this reason, throughout our 15 years of steel making history, we have focused on developing process knowhow, training people, and creating a committed quality culture. We are proud to say that our processes and practices are second to none. We follow a strict de-oxidation practice to ensure that macro inclusions of Alumina and Silica are floated out quickly from the molten metal. We ensure that the slag in the LRF is synthesized quickly and that the slag volume and chemistry are appropriate for complete slag killing. Similarly, low re-oxidation at the caster is ensured by controlling the superheat, achieving free opening consistently, and by adhering to proper tundish and mould practice.

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Application Based Steel Making

At ISMT, we like to understand where our steel is used. Where possible, our Technology Process Group (TPG) interacts with customers at the shop floor and at the R&D level to translate the customer's product requirement into a steel specification and a steel making process specification. This "Application Based" approach enables to deliver the most suitable and cost effective product. Today, given our history and our approach, we have developed an understanding of hundreds of applications that use our steels and we can use that experience to help you either select a steel or to develop a new grade appropriate to your requirements.

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Process Flow Chart For Manufacture Of Carbon and Alloy Steels

PROCESS FLOW

FACILITY

MAJOR ACTIVITIES/
PROCESS CONTROL
CHECK POINTS

Scrap / Metallics

Primary Melting

SECOUNDARY REFINING
AND FERRO ALLOY ADDITION

VACCUUM DEGASSING

CONTINUOUS CASTING OF
160/180/200/225 MM ROUNDS

INSPECTION OF BLOOMS

AS COST
DESPATCH

ROLLING

FINISHING OPERATIONS
AND INSPECTION

METALLURGICAL
TESTING

HEAT TREATMENT

DISPATCH

50 MT ultra high power (36 MVA)electric arc furnace with eccentric bottom tapping system. Facility for continuous charging. Consists of auto melt control unit.

50 MT refining furnace.
Ladle with free board of 500 mm (8MVA-transformer capacity).
Auto feeding arrangement for ferro alloys and cored wire.

Five stage steam ejector.
Facility for addition under vacuum.
Auto feeding arrangement for ferro alloys and cored wire.

Two strand round caster.
In mould electro-magnetic stirring.
Double radius 12/18 m. PLC controlled spray-cooling zones.
Auto mould level controller(AMLC). Argon shrounding during casting.

Walking hearth reheating furnace.
On line descaler.
Twelve strand, Two- high continuous rolling mill.

Band saw machine.
Straightening machine

Vacuum emission spectrometer.
Carbon sulphur determinator.
Hydrogen, oxygen, nitrogen gas determinators.
Tensile testing machine.
Impact testing machine.
Hardness tester.
Magnetic crack detector.
Mobile spectrometer.
Metascope.
Metallurgical microscope.

Electrically operated bogie hearth furnace for: annealing, normalising, spheroidised annealing.

1.1	Checking of charge mix as per standard.

2.1	Addition of fluxes for early slag formation.

2.2	Check for chemistry.

2.3	Process observation and monitoring.

3.1	Addition of fluxes for early slag formation of desired chemistry for achieving a high degree of cleanliness.

3.2	Addition of alloying elements.

3.3	Check for chemistry.

3.4	Process observation and monitoring.

3.5	Superheat control.

4.1	Check for chemistry before trimming addition

4.2	Process observation and monitoring.

5.1	Check for as cast macro and chemistry.

5.2	Control of parameters with respect to casting speed, mould oscillation ,EMS frequency and current and tundish temperature.

6.1	Macro routine check.

7.1	Monitoring of reheating furnace controls.

7.2	Checking of dimension and surface quality during rolling.

8.1	MPI/pickling and inspection, eddy current testing.

8.2	Ultrasonic testing.

8.3	Cut to length.

8.4	Colour coding.

8.5	Straightning of bars.

8.6	Spark / spectral testing of the lot for mix-up detection by the mobile spectrometer / metascope.

8.7	Bundling and tagging.

9.1	Metallurgical tests like chemistry, macro, micro inclusions, grain size, decarb, step down, gas analysis, blue fracture, mechanical properties and other required test.

9.2	Testing and certification as per technical delivery conditions.

10.1	Monitoring of heat treatment cycle.

10.2	Checking of hardness, micro structure and mechanical properties.

PRODUCTION INFORMATION

Installed Capacity	350,00 MT/annum
Process Route	EAF - LRF - VD - CCM - RM
Heat size	45 MT
Products	As Cast Rounds Rolled Round Corned Square (RCS) Bright Bars (Peeled / Turned) Cold Drawn / Cold Finished)
Size Range As Cast Rounds Rolled Rounds Round Corned Square(RCS)	160,180,200 And 225 mm dia. 25.4 to 115 mm dia for all application 125 to 170 mm dia for seamless tube industry 45 to 75 mm and 125 mm
Standard Hot Rolled Sizes Rounds RCS	25.4,26,26.4,27,28.3,30,32,34,36,38,40,42,45,48,50,52, 56,60,63,65,70,75,80,85,90,95,,100,105,115,125,137,150, 170MM AND AS CAST - 160,180,200& 225MM 45,50,52,55,60,63,65,70,75 MM AND 125 MM Additional size/ shapes upon specific request/agreement.
Supply Lengths	Standard 3 to 6 m with 10% shorts down to 1 m or user defined.
Straightness Tolerance Hot Rolled Hot Rolled and Machine Straightened Cast Product	3.0 mm per meter 1.5 mm per meter 5.0 mm per meter
Length Tolerance for fixed Length Supply	+ 50, -0.00mm
Condition of Ends	Standard Gas Cut / Hot Sheared (as per customer requirements)
Standard Size Tolerance for Hot Rolled Bars / Billets

Nominal Size (mm RCS)
Over	Upto and including	Tolerance on size	Ovality
25.4	28	+0.25	0.40
28	31	+0.28	0.45
31	34	+0.30	0.50
34	38	+0.36	0.60
38	50	+0.40	0.60
50	64	+0.8,-0	0.80
64	89	+1.2,-0	0.80
89	114	+1.6, -0	1.20
114	139	+2.0,-0	1.50

Nominal Size (mm RCS)
Over	Upto and including	Tolerance on size	Ovality
-	50	+0.6	0.60
50	64	+1.2,-0	0.80
64	89	+1.8,-0	1.30
89	100	+2.4, -0	1.80

Tolerance on weight Kg per meter shall be +4%, -0%

For cast rounds size tolerance shall be +3mm and Ovality 2.5% of dia.
Alternative tolerance upon specific request / agreement.

Grades (lllustrative)
Plain Carbon Steels	SAE 1008,SAE 1010, SAE 1012, SAE 1019, SAE 1026, SAE 1035, SAE 1035, SAE 1040, SAE 1045, SAE 1518, 070M20, 080M40, 080M46, 070M55, CK35, CK45, CK55, CK60 etc.., and equivalent.
Case Hardening Steels	665M23, 635M15, 637M17, 815M17, 820M17, 822M17, SAE8617, SAE8620, 15Cr3, 16MiCr5, 20MnCr5, 15CrNi6, SCM415, SCM420, SCM421 etc., and equivalent.
Spring Steels	55Si7, 60Si7, 37MnSi5, 50CrV4, 38xc, 50Cr4V2, 51CrMov4, 52Cr4Mo2v etc.,and equivalent.
Free Cutting Steels	SAE 1117,SAE 1137, SAE 1140, SAE 1141, 216M36, SAE 1144, EN-8M, EN-1A etc., and equivalent.
Ball Bearing Steels	SAE 52100, 103Cr2, 100Cr6, SUJ2 etc., and equivalent.
Micro Alloyed Steels	HMnV, 38MnSiVS5, 49MnVS3, C7056 etc., and equivalent.
Other Alloy Steels	SAE 4130, SAE 4135, SAE 4140, SAE 4340, 817M40, 34Cr4, 37Cr4, 41Cr4, 25CrMo4, 42CrMo4, 40NiCrMo4, 40NiCrMo15, SCM435, SCM435, SCM440, SA182-F11, SA 182-F12, SA 181F11, T-5, T-9, T-23, T-91 etc., and equivalent.
Ferritic Stainless Steels	AISI-410, AISI-420
Tool Steels	H-11 and H-13

Control Chemistry		Tramp Elements(max.)
Carbon	03 points	Tin	0.02%
Manganese	05 points	Copper	0.15%
Sulphur	10 points	Nickel	0.20%
Chromium	05 points	Molybdenum	0.05%
Molybdenum	05 points	Boron	4 ppm max

Grain Size Guarantee

ASTM 5 to 8

Alternative grain size upon specific request / agreement.

Inclusion Rating Guarantee
Carbon & Alloy Steels	Thin series ABCD - 2max. Thick series ABCD - 1,5 max or as per cusotmer requirements.
SAE 52100	Thin and Thick series A - 1.0 max., B - 0.5 max., c - nil, D - 0.5 max.
Resulphurised Steels	Thin and Thick series A - 3.0 max., BCD - 2.0 max.
	Alternative inclusion rating upon specification request / agreement.

Oxygen Level
Carbon Alloy Steels	25 ppm max.
Bearing Steels	15 ppm max.
	Alternative Oxygen level upon specification request / agreement.

Hydrogen Level

2 ppm max.

Nitrogen Level

80 ppm max.

Titanium Level

30 ppm max. in Ball Bearing Steel.

Calcium Level

10 ppm max. in Ball Bearing Steel.

NDT Facilities	Ultrasonic testing, Spark, Spectral, Mobile spectrometer, MPL testing
Finish Supply Condition	As Rolled	Bright Bars
	Annealed	Drawn
	Normalised	Peeled
	Spheroidised Anealed	Ground
	Quench & Tempered