Manufacturing

Manufacturing

PRODUCTION

“Maharashtra’s First & Only Company to adopt LRF – Providing the Pure Quality of steel”

Why LRF

ADVANCE TECHNOLOGY – LADLE REFINING FURNACE

High quality of raw material is melted in induction furnace which also has a few gases. In order
that all these gases completely escape and impurities are totally removed, molten liquid is
transferred into Ladle Refining furnace where additional heat is provided.

A Ladle Refining Furnace is used to raise the temperature and adjust the chemical composition
of molten metal.

With the help of LRF, two crucial elements like Sulphur & Phosphorus can be controlled in exact
proportions to produce a better quality of steel.

Additionally, LRF treatment helps float inclusions in steel and removes dissolved gases.

Induction furnace + LRF lend high quality TMT bars, specially of 500D grade needed for large
scale infrastructure projects.

Benefits of In- House Billet

Hot Billets immediately after casting are easy to roll and rough. This enhances ductility, malleability of steel to a great extent

TMT bars manufactured using Billets have properly balanced chemical composition.

Roughing & rolling can be done in hot condition which results in retaining mechanical properties of steel

THERMEX TECHNOLOGY QUENCHING & SELF TEMPERING (QST)

Thermo Mechanical Treatment in Quenching Box

The process ensures that water passes over the entire surface of TMT bars

and to cause martensite (outer surface) to be hard for strength & Pearlite (inner surface) to be soft due to inner heat.

After quenching, the bars are placed on the cooling bed

so as to reach room temperature where its inner heat escapes and stress releases. This enhances ductility of steel to a great extent.

Self-tempering of bar is done

on automatic rack type cooling bed to achieve high ductility & stress ratio.

High Standard, The Preferred Choice

PRE-PROCESSING TEST: RAW Material TESTING UNDER 5KG LAB FURNACE

From each incoming vehicle of raw material, a random sample is taken from different places and melted in our 5 kg furnace.
This furnace is an exact mini version of our main induction furnace. A sample of this formed hot molten liquid is tested on the
spectrometer. Initially, the chemical constituent is checked. Raw material is accepted only if final metal recovery is greater
than 80% & phosphorus and sulphur is less than 0.055.


ADVANTAGE OF 5KG LAB FURNACE TESTING :

Reduction in liquid molten waste (slag) from induction furnace.

Increase in efficiency of manufacturing process, once the waste
is minimized at the initial stage.

Tested raw material always results in controlled chemical
composition of final product.

CHEMICAL TEST ON SPECTROMETER

IN PROCESS TESTING:

Testing of liquid molten at Induction Furnace:

While finalizing the liquid metal in melting furnace, a sample is drawn from it at every 25 minute’s interval and tested on modern German spectrometer for chemical composition.

POST TESTING

Tensile test on computerized UTM:

A 100-ton capacity of UTM (Universal Testing Machine) is installed in the plant to test mechanical properties of TMT bars. Each bar from the lot is tested on the UTM.

BEND RE-BEND TEST:

Quenching & Self Tempering (TMT) Process

The bending test of TMT bar is performed to test the ductility of steel without affecting the steel strength. This test is conducted as per IS 1599 and using appropriately sized mandrel as specified in IS 1786:2008.

RING TEST/ETCHING TEST:

Ring test is performed to check the quality of quenching that affects the mechanical properties of the bar.

TMT bar Cross section surface is dipped into a solution of ethanol (92% to 95% ) & nitrate (5% to 10% ). It forms distinguishing colour circles that represent the quality of quenching done on a bar.