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Submerged Arc Welding

Submerged Arc Welding Production Advantages

Author - Venuswires

Steel is being used hugely in wide range of applications, particularly the construction of buildings, ships, bridges and industrial/enterprise lines. The definitive attributes of steel like it being rust resistant, temperature tolerant, extremely high strength and high elasticity make it an uncontested choice. Along with the increasing use of SS and other steels in fabrication activities, sciences have been also geared to develop dedicated techniques of conditioning it. This becomes particularly relevant because steel is a difficult material to be worked upon; especially if it’s welding is attempted. Submerged arc welding (SAW) or submerged melt welding is one such technique of welding the steel alloys of diversity. The results through this technique are very refined and finesse driven to suit the precise applications that are least tolerant to dimensional changes.

The advantages of sub arc welding make it the preferred choice for steel fabrication. Most of the advantages are actually derived from the process itself that involves the presence of a flux channel that shields the entire welding zone including the arc, the weld point and the electrode that is being consumed. This is also the reason that it is called as ‘submerged’! Here are the prime advantages of submerged arc welding –

1. The flux in the molten state allows high current to flow through it. This higher current reinforces the efficiency of the entire welding process. The direct implication is the intensification of the heat that makes welding more efficient. This further means that sub arc welding will be effective to develop thicker and deeper joints that are not possible by other arc techniques.

2. The high heat concentration in the welding joint increases the speed of process significantly. The timelines are thus reduced and more of the work could be done.

3. Welding distortions are the undesirable characteristics that are hard to eliminate in steel joints. However, with the submerged melt welding technique these distortions and anomalies are less existent because the high heat and better speed of metal deposition negates the possibility of the inconsistencies.

4. The presence of the flux channel eliminates the sparks and flashes and also prevents the splatter and splash of molten metal on the welding workers. This is a great advantage that is directly related to flux.

5. Quality of the weld is high with superior level of uniformity and also corrosion resistance.

6. The presence of flux that shields the arc and weld joint throughout also prevents the contamination of the metal deposition. This is a fine advantage derived from sub arc welding.

7. This type of welding technique is useful in outdoor where there is high wind speed as the flux prevents the impact of wind on process.

8. There is no requirement of the preparation of the edge before attempting the welding.

These advantages are superb and makes sub arc welding the best choice for steel fabrication tasks.

Welded and Seamless Stainless Steel Tubing Fabrication

Welded and Seamless Stainless Steel Tubing Fabrication

Author - Venuswires

Stainless steel could be called as one of the finest innovations in the evolution of mankind. SS is a much later intervention as compared to the base metal iron, the discovery of which was made in the primitive ages in different Iron Age cultures. Steel is a more superior variant and is an alloy that is now used in multiple applications because of its noted characteristics like rust and corrosion resistance, high stress tolerance, high elasticity and extreme strength. To suit the different application areas, we have also developed capabilities to make variety of products from SS. Stainless steel tubing is one such product segment. These tubes are made in different dimensions, thickness, composition and welded and seamless stainless steel tubing types.

It is interesting to note that while stainless steel is very sturdy and elastic alloy of iron, the same attributes also make the fabrication and molding/conditioning of it very difficult. Hence, the fabrication methods are very specialized so as to ensure the best results and precision dimensions. The techniques to manufacture welded and seamless stainless steel tubing are different and warrant certain pre-requisites to develop the products of desirability. Here is an overview about the processes involved in the fabrication of these two types of SS tubes.

The welded stainless steel tubes

The process involves the use of steel rolls that are unfolded and cut into specific widths depending on the dimensions of the tube to be produced. These SS strips of definite width are then subjected to machining to generate the cylindrical shape. The two ends are then welded together through the welding rolls to make it a tube. The basic function is now complete with the formation of SS tube but the finishing and precision tasks are still to be worked and these include the ‘weld bead conditioning’. For the thin walled tube, ‘weld forgiving technique’ is used while for the thicker walled stainless steel tubing, ‘weld rolldown’ technique is employed. The SS tubes now need to be sized as per the requirements of dimension, roundness and straightness.

Seamless stainless steel tubing

Seamless stainless steel tubes do not have any weld joint and thus are matched for specific applications that are precise and require uniform surface characteristics like for flow of fluids in engine parts or industrial ambiences. The seamless SS tubes can be made through any of the three processes which are –
Piercing –

a SS bar is fed through a piercing machining that makes a hole in it. This is following by rolling and heating process to develop the tube

Extrusion –

it involves feeding a SS bar into a tube which is worked through a dye to make the stainless steel tubing

Gun drilling –

a round SS bar is inserted in the drill that transforms it into a tube. The finish is superior although the technique is expensive!

Through such refined processes, the industry now has diversity of SS tubes products to make use of in different applications.

How stainless steel helps with stand natural disasters

How stainless steel helps withstand natural disasters

Author - Venuswires

Humans have been engaged in discoveries and innovations since the oldest days & even prior to civilization. The objective has been to simplify life and living and improve the quality, strength and durability attributes. In our long journey of evolution till age, there were definitely some milestone achievements and iron and steel could be counted among this segment. Though the development of iron and steel are separated by centuries of a gap, these two products have changed the landscape; especially if talk of their uses in the construction sector. Steel has now become the indispensable component in the making of sturdy and magnificent structures that could be really boasted of. Stainless steel rods and other products are actively utilized to ensure high strength and resilience of the building against all types of disasters including the natural calamities. It won’t be incorrect to say that stainless steel helps to withstand the adverse impacts and losses caused by natural disasters! Let’s see how steel has become such important in negating the impacts of natural calamities.

1. High strength and resilience

Stainless steel is an alloy of iron that is produced by adding minor quantities of elements like chromium, carbon and others. Various types of steel like 304, 316 have differing alloying compositions. However, every type of SS is invariably known for the extremely high strength and resilience against stresses. Stainless steel pipes and tubes and also wires are therefore used in buildings, bridges and other structures to deliver high strength and thus ensure long life without any issues. High impact storms cannot affect SS structures thus preventing the losses.

2. Corrosion and rust resistance

Another salient attribute of SS is its rust resistance. Steel is almost unaffected by the rusting agents like water/moisture, salinity and oxygen. The stainless steel pipes and tubes that are used to make bridges have proved highly versatile and developed least signs of corrosion even after decades and centuries in different parts of the world. When the natural disaster like cyclone, storm etc strikes then these SS structures stand tall without any losses; because rust cannot destroy the base material that remains intact.

3. Elasticity quotient is very high for stainless steel

Stainless steel is an alloy with one of the highest elasticity quotients among whole range of products. This means that the effect of vibration like during earthquakes is minimum on the buildings and structures that are built with stainless steel rods and girders. The steel rods that are used as reinforcements in the concrete pillars prevent the collapsing of the structure thus averting huge losses.

4. Temperature tolerance

SS is very tolerant to temperature induced changes. This means that the extreme temperatures cannot effectively denature the steel and the properties of elasticity and strength are retained. Very low temperatures do not make steel brittle while high temperatures do not melt it. Thus SS is perfect construction option in high temperature variability climates.

5. Extremely long life and least metal fatigue!

Stainless steel rods and wires do not develop much of metal fatigue when under continuous stress. Therefore these are used in making mammoth size suspension bridges that brace the sea storms without getting broke.

These qualities of stainless steel make it a fine construction and reinforcement material and also prevents the losses from the natural disasters of diversity.

What Makes Special Bar Quality (SBQ) Steel So Special?

What Makes Special Bar Quality (SBQ) Steel So Special?

Author - Venuswires

Our romance with metals and metallurgy is very old and communities were inspired to do the refinements towards making use of metals in various tasks; however, the major push was received through the consistent and broad demand in the royal artilleries which led to further interventions in metallurgical pursuits. The iron was among the first inventions and it has continued to dominate the demand spectrum till age when we stand at the high point of development.

One intervention that could be hailed as very special is that of ‘steel’ – an alloy derived from iron but which carries marvelous attributes of extreme sturdiness, corrosion resistance and capacity to bear stresses! These attributes make it a valuable product in construction and engineering – that constitute the backbone of development and growth synergies for last two centuries! With such significance of steel, attempts were made towards further improvisations like special bar quality (SBQ) steels.

SBQ steels demanded for high stress applications!

Special bar quality (SBQ) steels can be defined as those which are developed for challenging and high stress applications. Thus, these steels stand out different & tall among a diversity of grades that are in use in the enterprising processes. The SBQ steels have thus emerged as the mandatory requirements in various applications like those defined by high speed machining, high stress and high tensile strength among other finer attributes of engineering and metallurgy. The SBQ steels are today offered by manufacturers in the form of stainless steel bar, steel round bar, flats, tubes and other products of demand and relevance in manufacturing economy. These are mostly used in the development of bearings, high speed shafts, gears and other vital products that have to be resistant to the metal fatigue through prolonged and continuous use as moving parts in machineries/automobiles.

How are SBQ steels made special?

Speaking from the perspective of a metallurgist, special bar quality (SBQ) steels exhibit very high stress resilience and associated metal fatigue tolerance. These attributes define precisely the SBQ steels and make them apt for versatile applications where authentic efficiency parameters are strictly demanded. However, to ensure such high characteristics, the manufacturers of SBQ steels need to be guarded throughout so that there are no discrepancies. The most fundamental parameters that are controlled include the chemical composition and purity quotient of the steel and the mechanical properties like hardening that is achieved through thermal treatment processes. Impurities in the steel could drastically bring down the fatigue life cycle duration of the component while cleaner steels have very high metal fatigue tolerance even under continuous run conditions!

The purity is also directly related to the thermally induced hardness (stress) resilience attributes; because it could be affected if impurities are present in the steel body. Stainless steel bar, steel round bar, flats etc made with SBQ steel thus guarantee the best results when converted into components of practical use.

 The weldability of stainless steels

The weldability of stainless steels

Author - Venuswires

Steel is an alloy with base metal iron in majority proportion while other components that are present in it could vary thus forming different types of alloy grades. While steel and stainless steel have emerged very demanded because of their desirable attributes of extreme hardness, stress tolerance, and corrosion resistance, the secondary and tertiary level manufacturers of steel products encountered difficulty in welding and fabricating the steel products; mainly because steels behave differently as compared to iron due to their specific microstructures! Now, we have specialty welding techniques for different types of steels and elaborate manuals have been also developed consequent to deep researches on steel welding techniques. The weldability of stainless steel is now a different niche and requires a precise understanding of the parameters apart from specific skills and wider experience on the part of the welder. Here is an overview of different steel types and the welding processes best suited to them.

The most important attributes related to steel welding is the implications on HAZ or heat affected zone which suffers super high temperatures. Due to this heat impact, the mechanical properties of this zone could be altered and moreover, the susceptibility to corrosion could be increased – an implication that is undesirable. HAZ often develops cracking characteristics during cooling post welding. The welders have to take appropriate precautions to prevent such results; while the precautions also differ from one to other type of steel.

The austenitic stainless steel

These steels contain 18 – 28% chromium and 8 – 22% nickel and can be welded through the arc welding techniques. The most commonly employed welding techniques for austenitic steels are MIG, TIG, MMA, and SA. There is no requirement for heating before or after welding and toughness is generally good. However, to reduce the possibility of HAZ cracking, it is recommended that filler materials are used which are slightly differing alloys of steel. For example, when welding type 304 SS, type 308 SS filler material could use. Generally, presence of 5 – 10% ferrite alloys is considered good while welding the austenitic steels. The appropriate balance of the two could be found through the Schaeffler Diagram.

Ferritic stainless steel

The ferritic stainless steel contains chromium in the range of 11 – 28%. Stainless steel grade 430 and 407 are common types under the ferritic SS. These steels could be welded through the fusion techniques but the welder needs to take precautions to prevent the development of coarse grains in the HAZ. The coarse-grained structure generally reduces the toughness. Use of austenitic fillers and pre-heat application are recommended.

Martensitic stainless steel

This type of steel has a chromium content of 12 – 18% but the carbon content is high which makes it hardenable, particularly the HAZ that suffer the extreme heat. Use of matching welding material is considered good option to avoid HAZ cracking.

Duplex stainless steel

These steels have equal proportions of ferritic steel and austenitic steel with chromium content in the range of 22 – 26%. These could be welded easily through different techniques but the heat input and filler choice are important here.

 5 WAYS BRIGHT BARS CAN IMPROVE YOUR BUSINESS

5 WAYS BRIGHT BARS CAN IMPROVE YOUR BUSINESS

Author - Venuswires

The manufacturing sector is one of the oldest segments of the economy and still continues robustly, serving a mammoth diversity of products and materials for the primary, secondary and tertiary needs of the social economy. However, this sector demands competitiveness skills on the part of the entrepreneur who has to maintain the cost coupled with quality and ease of production in consonance with the emergent demand dynamics. These balances are not easy for sure! To aid the manufacturing and enterprising orientations, various technologies and process improvements have been developed which are aimed at supporting the entrepreneur in the above mentioned challenges. In the iron and steel sector, secondary firms and ancillaries seek such products and technologies that help them maintain a healthy operational and fiscal momentum. Leading bright bar manufacturers in India opine that these can be helpful in improving the business capacities and worth. Let’s see how these could improve a business!

High accuracy in dimensions

Stainless steel bright bars are known for the high accuracy dimensional attributes that make them perfect for manufacturing specialty products of direct use like the fasteners, tools and custom implements. All such applications require a high degree of dimensional accuracy which bright bars offer. The enterprises that rely on the SS bright bars get an advantage due to perfect dimensions and thus very high quality is ensured that fetches good rates in the market for the manufacturer.

High strength and hence superior impact resilience during machining

SS bright bars, in particular, have the high strength and impact resilience and hence these are well suited for rigorous machining operations towards making diverse components or tools of custom and generic use. Stainless steel is a highly elastic alloy and thus has high tensile strength also; it does not loose shape and dimensions easily through the machining impacts. Stainless steel manufacturers are offering different sizes and grades of SS bright bars towards the needs of enterprises.

Better surface characteristics in terms of finish

Bright bars are known for the high quality surface finish which is exhibited in the form of straightness and end point cross section. This reduces the requirement on the part of the manufacturer to further work out perfection like through grinding and polishing. Thus overall, a better cost economy is developed in the production process.

Less maintenance

Stainless steel bright bars, as said above are very sturdy and resilient against impacts and hence there is the least wear and tear during warehousing and transportation of these. The cost of maintenance for these bars is thus negligible.

Less wear and tear cost for the machines that work on the bright bars

Wear and tear of the machines that are fed with the SS bright bars is much reduced because of the high dimensional accuracy and hence stability during the machining process. The processing time ‘vibration’ is least with the SS bright bars and this also reduces the wear and tear of the machine.

These five attributes make the enterprising with stainless steel bright bars much economical and quality oriented for the company and thus improves its overall business worth!

APPLICATION AND USES OF BRIGHT BARS

WHAT ARE APPLICATION AND USES OF BRIGHT BARS?

Author - Venuswires

Steel could be called as one of the best metallurgical inventions till date as it led to the expansion of the social economy at swifter rates. Today, it is rightly said that there is a little bit of steel in the life of everyone! This important metal, rather alloy has entered such deep in the lives of ordinary social dweller and in the industrial verticals that it has now become an indispensable element of the social economy.

The iron and steel companies have responded actively towards the emergent demands of the enterprises and ancillaries and have developed a wide array of products to suit the requirements of diversity. One such product is the bright bars that are made in different steel grades and the definitive attribute of these is the precise dimension – a quality which makes it the preferred choice in the manufacture of various products that demand high dimensional accuracy and finesse. These are made in different sizes and forms like the rounds, flats and squares and hexagonal. Stainless steel round bars are among the most demanded type bright bars in the manufacturing sector and are used in the making of implements and machine components. Some common applications of bright bars in the manufacturing sector are –

In the making of fastener products

Stainless steel round bars are in high demand for making different types of fastener products like bolts, nuts, pins, and rivets which could be micro size to mega size also depending upon the application and customs requirements. The bright bars in round shape are perfect base material for machining and making these fasteners that are used in industrial ambiences or the domestic applications.

Manufacture of tools

Round bars manufacturers in India and around the world are supplying high grade SS base material for the making of tools and implements of direct use by technicians and mechanics. The round bright bars are a good choice for machining them economically and derive tools in custom shapes and forms.

Manufacture of machine components

Bright bars in different shapes and sizes are directly used for manufacturing the machine components like the smaller ones used in the automobile engines. The manufacturers are supplying very high quality SS base products to the ancillaries and brands for making these machine components.

Engineering and construction sector

Stainless steel round bars and flats are often used in construction and engineering projects. These provide immediate stability and strength and hence the project could be quickly accomplished through the modular bright bars products.

Rails and trellis

Square, round and flat bright bars are used in the manufacture of trellis and fences or rails in buildings. These days, the demand for SS bright bars is high for making fancy trellis and staircases.

Automobiles

Automobile frames and chassis are now being made with different grades of steel bright bars in flats, squares, and rounds.

All such uses of steel bright bars have emerged because of the precise dimensions in which these products are made available by the manufacturers. The applications mentioned above have the common demand of accuracy and stability which is ensured through the quality SS bright bars.

Reasons Why Stainless Steel Products Are First Choice in Many Industries

Reasons Why Stainless Steel Products Are First Choice in Many Industries

Author - Venuswires

Humans have been engaged in the metallurgical pursuits since very old days and have been pretty impressive with their inventions! The earliest of such inventions include copper, bronze, and the iron and these metals heralded new eras of development. Iron, in particular, found much demand & acceptance because of the abundance of the natural ores and the good abilities of extraction and refinement. Continued affinities with iron led to more innovations and steel could be called a marvelous result! More researches in metallurgy led to the manufacture of stainless steel which is much superior along many dimensions and therefore has become the first choice for many manufacturing sectors of the economy. Stainless steel manufacturers around the world are making primary products that are in high demand in different enterprises and ancillaries. Here are the reasons why SS products are the first choice in many industries –

Highly rust and corrosion resistant

This is a most important attribute of stainless steel and almost defines this metal alloy. Stainless steel has low carbon content and high chromium content (which should not be less than 10.5%). Nickel and other elements may be also present. The most common type which 304 SS has 18 – 8 composition of chromium and nickel respectively.

The rust and corrosion resistance of stainless steel is derived from the formation of a layer of chromium oxide at the surface. This layer is highly versatile and resists the action of moisture and other corrosion agents like salt water and milder acids of the environment. Therefore SS remains unaffected for life in conditions in which ordinary iron or simple carbon steel would lose. Corrosion resistance makes the components made with SS very durable and of high quality.

Very durable

The durability of the stainless steel is mainly the function of its rust and corrosion resistance which makes it highly resilient. Therefore enterprises rely on SS to make the machine components so as to reduce the wear and tear.

High strength and sturdiness

SS has a specific arrangement of the atoms of elements that are used in the making of this alloy. This structure/matrix of the stainless steel makes it one of the toughest options in metals and therefore many industries prefer SS as the base material, says the expert at a leading stainless steel manufacturer and exporter in India.

High elasticity quotient/impact resistance

It may sound weird to any layman but stainless steel has one of the highest elasticity values among many metals; courtesy to its alloying composition and resultant adjustment of the atomic matrix. High elasticity makes it the perfect choice for manufacturing products that have to bear high impact forces and tensions. Metal fatigue is very little in SS. Stainless steel wire manufacturers offer different products like for enterprise ambience pulleys, lifts, and such other high tensile applications.

Heat/fire resistant and temperature independent

Stainless steel can bear high temperatures like in fire and combustion chambers. It can also withstand lower temperatures. These qualities make it suitable for making food processing machinery and other enterprise machines.


Easy fabrication techniques available

Stainless steel can be easily cut into different forms and fabricated also like through specialty MIG and TIG welding techniques to make a large variety of products.

These qualities of SS are unparalleled and thus make it the best choice for many industries of the global economy.

http://www.venuswires.com/round-bars/

THE DIFFERENCE BETWEEN ROUND BAR, DRILL ROD AND SHAFTING

Author - Venuswires

Humans have developed frontline competencies in the segment of metallurgy because the involved processes allow us to derive metals and alloys and forge them in desirable forms so as to meet innumerable dimensions of life and development. Truly speaking, our developmental process is much indebted to the reliance on metals; hence the synergies with metallurgy! Depending upon the nature and requirements of the application, various techniques are employed to manufacture metal products. Rods and bars are some very common products and the use of these range from building constructions and axles to frameworks and supports of diversity. Stainless steel bars manufacturers in India are getting brisk with their productions to meet the exponential demand in different infrastructural and engineering works. An expert from a leading manufacturer of steel rods talked about the common products from the metal mills and offered differences between them. Here is an overview –

Round bar

As the name suggests, round bar is a cylindrical length whose diameter could range from ¼ inch to 2 feet, depending upon the nature of the application for which it is meant. Round bars are made in different metal choices like steel, stainless steel, aluminum, and brass. Steel round bars could be hot rolled or the cold rolled types. The hot rolled bars are made for uses where finish and precise measurement are not strongly required like construction sector; while cold rolled bars are more finished and precise in dimensions and are used in the making of supports, frameworks, braces, axles and motor shafts. Stainless steel round bar is made for applications where rust and associated corrosion resistance is demanded.

Aluminum round bars are light weight and easily machinable apart from being corrosion resistant. Brass round bars, on the other hand, acquire high level finish after polish and are corrosion and (electrical) spark resistant.

Drill rod

Drill rods are invariably manufactured from tool steels because of their inherent sturdiness. Drill rods are generally round in shape but acquire different patterns on the surface and frontal ends which enable them to deliver the material removal functions along with high tolerance. These are mostly used in the making of drill bits, dowel pins, shafts, and reamers. In most cases, to increase the hardness, the drill rod is heated till red hot and then cooled down by plunging into the water or oil; oil hardened tools are superior to the water hardened ones.

Shafting

Shafts are actually the steel round bars which are otherwise assured for the highest level of accuracy and precision in dimensions. Only fewer stainless steel round bar manufacturers have developed the ability to manufacture these with utmost accuracy and finish; because the manufacture of these requires induction hardening process which is a non-contact technique. It involves placing the rods in the strong electromagnetic field to heat it and then it is plunged in water, oil or specific polymer after which hardening is achieved. The uses of these include the motor and pump shafts, drive shafts and brush bearings among others. In most such applications, the straightness of the shaft is a demanded attribute because it moves at a high speed!

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