MANUFACTURING PROCESS
1. Reheating: Hot rolled coils pass through a pickling line, where scale breaker machines and hydrochloric acid solutions are used to remove any surface scale and/or oxide film that which causes surface flaws during the final stage of cold rolled steel processing.
2. Roughing: In this process, slabs whose surface scale share has been removed are made into rolled materials with the proper shape, thickness, and width. In the entry and exit area of the roughing mill, an edger rolls the strip in the width direction using an Automatic Width Control (AWC) system.
3. Finishing Rolling: The purpose of finishing rolling is to adjust the thickness and width of a coil to the specified dimensions and to produce a smooth surface and shape at the desired finishing temperature appropriate for its intended use. Our up-to-date equipment, including Work Roll Shift Mills, Pair Cross Mills and On-line Roll Grinders (ORG), enhances plant productivity and improves the quality of the finished coils by controlling the crown shape.
4. Run-Out Table and Coiling: Steel strips, after the finishing mill, are passed to the run-out table where they are coiled. While being rolled on the table, the strips are sprayed with water to cool them to the proper temperature for coiling.
1. Pre-Treatment Process: Some rolling oil and other contaminants remain on the surface of cold rolled steel sheets following processing. These are removed by passing the electrically charged sheet through an alkaline solution which induces an electrochemical reaction.
2. Annealing: The material properties of the pre-treated steel sheet can be altered and improved through recrystallization during the annealing process.
3. Hot-Dip Galvanizing: After passing through the annealing furnace, steel sheets are dipped into a zinc pot where molten Zn is coated onto the surface. The desired coating weight is achieved by removing excess zinc before solidification with high-pressure air from an air knife.
4. Galvannealing: The surface of a steel sheet, after the air knife, can be coated with a zinc compound prior to reheating in an annealing process. Zn atoms diffuse into the Fe to create a Zn-Fe series alloy.
5. SPM & Chemical Treatment: In order to achieve a flat surface and an elegant finish, the steel sheet is processed with a skin pass mill. In order to prevent the white rust, which often forms on the surface of activated zinc, and to improve corrosion resistance, the surface is coated with a Cr-free resin.
6. lnspection & Coiling: In order to achieve a flat surface and an elegant finish, the steel sheet is processed with a skin pass mill. In order to prevent the white rust, which often forms on the surface of activated zinc, and to improve corrosion resistance, the surface is coated with a Cr-free resin.
1. Preliminary annealing: In the preliminary annealing process, the scale that may form on the hot-rolled steel is removed after delayed passage through the water breaker and hydrochloric acid bath. This initial heat treatment process improves the cold rolling properties and magnetic properties of the steel.
2. Cold rolling: In order to obtain specific thickness and material properties, a reduction ratio of 40-90% is usually used. Automatic control of edging machine and edging machine for uniform thickness and width.
3. Annealing: Annealing is the process of transforming cold-rolled tissue into recrystallized tissue through heat treatment. For grain-oriented electrical steel, there are two different annealing methods: decarburization annealing and high temperature annealing. Decarburizing annealing removes excess carbon from the steel and applies a magnesium oxide coating. High temperature annealing produces a secondary recrystallization structure with superior magnetic properties.
4. Insulation coating: In this process, the insulation coating is applied by the continuous coater roller to minimize eddy current losses proportional to the thickness of the sheet. A series of coating machines are used to apply the insulating coating solution to the top and bottom of the sheet. Grain-oriented electrical steel has two layers of coating, one layer is the bottom coating of dark brown Forsterite (Mg2SiO4) as the main component, and the other layer is the transparent insulating coating containing phosphate. For non-oriented electrical steel, various coating methods with different thicknesses and compositions are used according to the specific requirements of the end use and users. Silicon steel (electrical steel) process
1. Billet Conditioning: This process is intended for checking the surface quality of billet and removing any defects. Shot blast is used to remove any scale from the surface. Magnet particle testing and visual inspection are also used to identify any defects which must be removed using a grinder. Ultrasonic testing and dimension and geometry checking are also applied as part of the internal quality assurance process.
2. Reheating: The temperature within the furnace and the duration of reheating depend on where the product will be used. To avoid decarburization, which can affect the surface quality of the product, a billet is pre-heated sufficiently at a low temperature before being rolled within the reheating furnace. For this purpose, the fuel and air ratio are strictly controlled.
3. Rolling: The temperature, draft and speed of deformation with which the product is rolled are controlled to meet customer requirements for material features. Further measures to ensure the surface quality include the adjustment of roll roughness and gap, detection of any cracks and dimension correction.
4. Cooling: Coiling temperature at the laying head, the air flow and movement speed of the blower on the cooling bed and the cooling speed of the insulation cover are controlled to ensure that the product has the features required for each application. High carbon steel Wire rods are subject to fast cooling to achieve the microstructure required for successful drawing while low carbon steel is subject to slow cooling to ensure that the product provides the softness required for the customer to eliminate an annealing process.
5. Inspection: Samples are taken from the front and rear edges of the product after rolling and cooling for testing to identify any defects in the dimension or surface or material integrity. Packaging and tagging are also inspected according to customer requirements prior to shipping.
1. Pickling: Hot rolled coils pass through a pickling line, where scale breaker machines and hydrochloric acid solutions are used to remove any surface scale and/or oxide film that which causes surface flaws during the final stage of cold rolled steel processing.
2. Cold Rolling: Pickled coils are cold rolled in tandem mills to a specified thickness, typically 40 to 90%, of original material dimensions. Fully automated shape adjustment is ensured through state of the art process machinery.
3. Electrolytic Cleaning: The purpose of electrolytic cleaning is to remove lubricant oil and contaminants on the cold rolled steel prior to the annealing process.
4. Annealing: This is a highly productive manufacturing method whereby steel products with extra deep drawing qualities and high tensile strength can be produced. Two annealing methods are commonly used: batch annealing and continuous annealing.
5. Skin Pass: This final rolling process is performed in order to remove minor surface defects such as stretch marks and to produce a smooth, lustrous surface. Skin Pass results in a further thickness reduction of about 1%.
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