Name: Muhammad Rehan

Roll No: 18MME-S2-321

Section: S2
Semester: 5th

Assignment No: 1
Submitted to:
 Billet casting defects, their reasons and remedies
Billet: ’

A billet is a segment of the metal, that's used for rolling into bars, rods and sections, etc It can
be produced with the ingots; or directly by perpetual casting Billets are also used as the, raw
materials in the extrusion: forging, rolling and they are other are such as; metal-processing
operations.

Continuous casting of steel billets:’

Continuous casting of steel is a process in which we used a liquid steel as a raw material and it is
continuously solidified into strand of metal Depending on the dimensions of a strand; these
products which are semi-finished known as slabs, blooms or billets.;
Steel billet
It has the square cross section with one side normally 150 mm or less It feeds material for rolling
of steel in light section mills; bar mills; and wire rod mills etc They are aslo used in forging of
certain products etc This process of continuous casting was invented in the 1950s and it was to
increase the productivity of steel production Previously only ingot casting was available which
has its benefits and advantages but aslo does not always meet the productivity demands So, Since
then the continuous casting has developed for further to improve on quality, yield and cost
proficiency.
Continuous casting of steel has now the method of choice by all the steel producers replacing the
old method such as ingot casting and it also Distinguished by its many uses this process has gone
through many improvements and was and still is the subject of wide range of studies both
mathematically, empirically Continuous casting of steel billets is one of type of continuous
casting adopted and used in steel industry from which the steel billets are produced continuously
This process required great control of operating parameters in orders to produce continuous and
sound billets etc The process divided into a number of steps and it is starting by pouring hot
liquid steel from the steelmaking furnace into ladle, where steel chemistry is adjusted in
secondary steelmaking and then pours into the distributor From the distributor into the casting
mold after this Steel begins to solidify in the copper casting mold by indirect cooling and an area
which has was subjected to many studies and From mold the cast billet may undergoes
secondary cooling with water sprays or other colling agents.
The steel billet production may get a boost in 1960s and since at this time the mini-mill concept
evolved by combining the two factors electric steel making with the continuous casting and a
lean organizational structure in order to produce a profitable new culture of steel production The
billet producers though highly profitable protected in the production of high quality continuously
cast products etc.
The process of the continuous casting of a steel billets is illustrated following:
Steel ladle: Liquid steel here it is a transferred from steel making facilities to the billet casting
machine in the steel ladle. And During this transfer they have opportunities available for its
control of cleanliness, composition and, temperature of the liquid steel etc If these opportunities
are not used then the it is delivered to the billet casting machine has dirty and either too hot or its
may be too cold. Casting of quality billets is then are much more difficult task. During the switch
of liquid metal to the billet caster, a trouble is the oxygen (O2) absorption from the air, furnace
slag, and the ladle refractory lining. It is vital to limit O2 choose up at some stage in every switch
step. Slag overflow withinside the metal ladle is to be averted from the steelmaking furnace at
the stop of the tapping. The floor of the metal withinside the ladle is wanted to be protected with
a artificial slag (i) for stopping O2 absorption from the air, (ii) for the absorption of non-metal
inclusions, and (iii) for the minimization of the warmth loss. In a few flowers, metal ladle is
protected at the pinnacle with a ladle cover. Further at some stage in casting, the metal ladle is
equipped with a refractory tube to save you O2 choose up because the metal is poured into the
tundish. Flow of metal from the ladle to the tundish is managed with a slide gate valve. In a few
flowers the load of the metal ladle is continuously measured with the assist of load cells.
Tundish: Tundish have to play advance roles during the continuous casting of a steel billets. It is
acts as a distributor during casting and discharging steel to the several strands of a billet casting
machine. It also has facilitates that control of the flow of the liquid steel into the mould and since
it has a constant and lower hydrostatic head than the steel ladle . This is crucial in particular at
some stage in the start-up of the caster, because the tundish may be packed with metallic to its
everyday steady-nation degree earlier than beginning the pouring of the liquid metallic
withinside the mould. The different crucial phenomenon which can take location withinside the
tundish is the floating of inclusions which facilitates withinside the cleanliness of the solid
product. Further the tundish also can be used as a reactor as well, for the addition of sellers such
s calcium (Ca), for inclusion morphology control.
Because of the above functions, the form and the scale of the tundish are dictated in particular
via way of means of the want of controlling the fluid flow. Since the warmth size, dimensions of
the solid billet, variety of strands, strand spacing, and pouring fee vary from one plant to some
other plant; a completely unique best tundish design does now no longer exist. However the
subsequent are the important thing capabilities of a well-designed tundish.

 The tundish design has maximize the float--out of inclusions and For this tundish volume
large is to be, although other mitigating factors limit its size for example if its heats
different composition have then they are to be cast in sequence, without interruption of a
casting operation, and its volume of the ‘mixed’ steel in the tundish must be minimized
since the mixed steel is off grade and can represent a yield loss and after it the residence
time of steel flowing each of the strands must be the same for ensuring the quality of the
quality of the steel.
 The short circuiting of steel through the tundish is to be minimal, i.e., to the extent
possible, plug flow is to be achieved.
 The flow pattern within the tundish is to allow a lot of of the steel to maneuver getting
ready to the surface wherever inclusion floating out is absorbed by the tundish slag. This
 is important since the space the inclusions will pass buoyancy alone is small within the
time out there in the tundish.
 Dead volume is to be decreased since it effectively reduces the continuance of the steel.
 Turbulence from the incoming ladle stream have to be compelled to be isolated, notably
once open stream pouring from tundish to the mould. The turbulence influences the
roughness of the tundish stream and also the entrainment of gas within the mould pool.
 The depth of the tundish is to be sufficient, in far more than concerning five hundred mm,
to forestall vortexing at the nozzle wells, which might draw the scoria lower down within
the mould
It has Defects There is a major problem with tundish operation and; it is the clogging of the
pouring nozzles by solid inclusions such as alumina; and it is Even though the inclusions which
are small as compared with the diameter of the nozzle it; means they usually adhere to the
refractory via through the boundary layer and eventually and; by successive build-up, form a
bridge across the nozzle choking of the flow; so, The problem is severe for the casting of small
billets, which may be require smaller diameter of nozzles. So, When casting bigger sections
using larger nozzles, And is often flushed continuously through a nozzle to prevent excessive
build-up. Nozzle clogging has not a problem if the inclusions have in the liquid state. Hence for
the trouble free casting of the Al killed steels into the billets, Ca is added in the correct amount to
yield calcium aluminate inclusions. Pouring price thru the tundish nozzle is done with the aid of
using distinct techniques relying at the segment length being forged. For large sections, using a
refractory tube among the tundish and mould, a stopper rod or a slide gate valve is commonly
used to govern the glide, automated glide manipulate to obtain a steady meniscus degree and
casting velocity is commonly used. In case of smaller segment billets, with open flow pouring,
there's commonly no glide manipulate on the tundish. The glide price is then adjusted with the
aid of using the choice of the appropriate nozzle diameter and protection of particular metallic
hydrostatic head withinside the tundish. Meniscus degree manipulate is then received with the
aid of using various the casting velocity. Maintenance of the liquid metallic head withinside the
tundish is finished either manually or with the aid of using non-stop weighing the tundish with
load mobileular and connecting the sign to the slide gate valve at the ladle. The ordinary time
had to forged a warmness of the liquid metallic is round one hour, which is to be matched to the
time of 30 to forty mins up to 2 hours wished for the deliver of warmth to the billet casting
machine.
Mould : The mould is the ‘heart’ of the casting machine. It is also the primary device for the
heat removal. The functions of the mould are (i) to remove superheat from the liquid steel, (ii) to
grow a solid shell of sufficient thickness, (iii) to contain the liquid pool below the mould without
break-outs, and (iv) to support the shell in its initial growth. Since the mould governs the heat
removal, the design and the operation of the mould greatly affects internal and the surface quality
of the cast billets. Freedom from surface cracks is very important especially if the cast billets are
to be hot charged in the reheating furnace for rolling since surface cracks oxidize and form defect
of oxide seams during rolling.
The mould may be straight or may have a curvature of 4 m to 15 m in radius. Curved moulds are
used with curve strands to reduce the height of the casting machine and the capital cost. Straight
moulds help in the inclusion distribution in the cast product. In case of the curved mould,
inclusion floating can be trapped preferentially by the solidification front adjacent to the inside
radius face to form a band. Since this does not happen in the straight mould, the inclusions are
more evenly distributed. The extent to which this concern is valid depends on the cleanliness of
the steel entering the mould and the quality requirements needed for the cast billets. In any case,
cast steel leaving a straight mould is generally bent gradually to a horizontal orientation to
reduce the caster height. However, in some plants, the moulds and the sub-mould region are
straight so that the cast product is not subjected to mechanical bending forces that may generate
cracks. With a curved mould, the steel strands need to be straightened to a horizontal position
prior to being cut into lengths.
Regardless of whether moulds are straight or curved, the basic designs of the moulds are the
same. Tube moulds are used for the continuous casting of the steel billets. These moulds consist
of copper (Cu) tube positioned concentrically inside a steel baffle with cooling water flowing
through the annulus between the two. The wall thickness of the Cu tube ranges from about 6 mm
to 20 mm. The thicker wall tube moulds are used for the larger sections. Mould tubes are
fabricated from different grades of Cu alloys. Cu alloys containing phosphorus, silver (silver
bearing), or chromium and zirconium are commonly used materials for the mould tubes.
During the casting, the mould is lubricated and reciprocated to prevent the steel from sticking to
the Cu, which would result in rupture of the solid skin. The oscillating mould generally follow a
sinusoidal wave form, the frequecy and amplitude of which are  adjusted to ensure that for a
fraction of a second during the down stroke, the mould is moving more rapidly than the
descending strand. This period of ‘negative strip’ has been found to influence the formation of
oscillation marks on the surface of the strand. The lubricants employed normally depend on the
section size being cast.
In case of small sections such as 100 mm square billets, in which steel is poued in an open
stream from the tundish to the mould, rapeseed oil or synthetic oil is used. The oil is pumped to
an oiling plate at the top of the mould from which it seeps down the inside of the mould wall.
The precise lubrication action of the oil, which pyrolyzes in contact with the liquid steel, is not
very clear. When casting larger sections, the steel is introduced into the mould through
submerged entry nozzle. In this case, the lubrication is done by adding casting powder to the
meniscus, where it contact the steel, melts, and drawn into the gap between the solidifying shell
and the oscillating mould. The composition of the powder consisting typically of oxides, carbon
and calcium fluoride, is adjusted to control its melting range and viscosity. Depending also on
composition are the thermal conductivity, and thickness of the mould powder layer in the
mould/steel gap, which influence the rate of heat extraction by the mould.
A variety of oils such as vegetable, synthetic and blends can be used. Although the flash point of
the oils is a key property, the boiling range, relative to the maximum hot face temperature is
more meaningful to be considered fundamentally. The feed rate of lubricating oil is typically in
the range of 0.014 to 0.17 (typical value 0.05) milliliters per minute per mm of mould periphery
for a 125 mm square billet. However, with respect to industrial hygiene, billet quality and cost,
the lower the achievable oil rate, the better it is.
The important aspects with respect to the mould of a billet casting machine is as follows.
The Heat which is transferred from the strand surface and is transferred to the mold cooling
water so, through a series of thermal resistances such mentioned firstly the air gap separating the
mold and the strand, secondly the mold wall, and third one the mold cooling water interface. Of
these, the air gap constitutes the largest resistance to heat flow and accounts for as much as 84
percent of the total resistance. Therefore The pattern of heat removal in the mold has dependent
largely on the dynamics of the gap formation. The gap between the mold and the strand has a
complex function of several variables. Further the gap dimensions vary in both the longitudinal
(withdrawal) and transverse directions, resulting in a non-uniform heat removal pattern.
Although considerable light has been shed on the mechanics of gap formation, it has still the
poorly understood phenomenon.
While reading time averaged temperature profiles in a mold, it's far obvious that the temperature
profiles at extraordinary places are similar, with a top simply under the metallic degree and a
steep discount in temperature thereafter. The drop in temperature stems immediately from a
discount in warmness elimination with distance down the mildew due to improved air gap, shell
thickness and mold distortion. It is likewise visible that the temperature on the off nook places is
extensively chillier than the corresponding mid-faces places. This is due to the fact the distance
has a tendency to shape first withinside the corners, due to dimensional warmness flow, and
unfold throughout the face.
The warmness flux peaks on the meniscus degree and reduces thereafter, due to an growth
withinside the width of the air gap. Carbon degree withinside the metallic has additionally a role
to play on mold warmness switch due to the shrinkage related to the delta-gamma segment
switch.
The tube mold meeting hired in billet casting is easier in layout however it's far extra at risk of
thermal distortion all through operation seeing that the mildew is now no longer supported over
its whole length. During operation the mildew tube is subjected to a non-uniform warmness
elimination sample and acquires a non-uniform temperature distribution. The billet mold distorts
in reaction to the temperature change, and its thermo- mechanical behaviour is connected to
some of first-rate issues. It has additionally being located that a part of the whole distortion all
through operation is everlasting, thanks to the value of the stresses springing up from the
differential thermal enlargement, coupled with the bodily restraints of the mildew assist machine
and the geometry of the mildew tube itself. Factors which have an impact on the poor taper and
the height bulge, in addition to its role relative to the pinnacle of the mildew encompass cooling
water velocity, water first-rate, metallic degree, role of constraint relative to the pinnacle of the
mildew, wall thickness and the sort of mold tube assist.
Process variables have a stated impact on the warmth switch. Carbon content material of the
metallic, mold taper, pouring exercise, lubrication, and casting velocity are major manner
variables that have have an impact on on the warmth switch.
In addition to the warmth extraction, mold oscillation and lubrication are essential to the non-
stop casting. Mould shell friction should be minimized so as to cast off metallic sticking, tearing
and cracking. Oscillators are easy machines which reciprocate the billet mold to assist save you
the metallic from sticking to the mildew wall. The mold is usually oscillated in a sinusoidal
mode, with regular stroke and oscillation frequency parameters being 10 mm and a couple of
hertz (Hz) respectively. Mould oscillation parameters for minimizing of sticking and the
oscillation mark intensity are stroke and poor strip time. Negative strip time is described because
the term all through which the mold actions quicker downward than the strand withdrawal rate.
Mould lead is the distance the mildew actions beyond the shell all through the poor strip. For
billet casting, the advocated mold lead and the poor strip time values are three-four mm and 0.12
– 0.15 seconds respectively. Casting machines with poor strip instances under 0.1 seconds and
mold leads under 2-three mm are at risk of mold shell sticking specially if the meniscus is
fluctuating. Mould leads more than five mm can also additionally make a contribution to deeper,
non-uniform oscillation marks.
The floor of the constantly solid billets are characterised through the presence of oscillation
marks that shape periodically on the meniscus because of the mildew reciprocation. Each
oscillation mark is a neighborhood melancholy of the metallic and consequently reasons an
growth regionally withinside the width of the metallic/mold gap. Consequently, warmness
elimination is regionally decreased withinside the area of the oscillation marks. Depending at the
intensity of the oscillation marks, regionally decreased shell thickness, breakouts or transverse
floor cracks can also additionally appear. The pitch of the oscillation marks at the floor of the
strand is connected to the frequency of the oscillation cycle.
The inward taper of the moulds, which compensates for the shrinkage of the solidifying shell,
varies with out a taper to unmarried taper and double taper. In a few plants, there has been not
unusualplace exercise now no longer simplest to apply untapered mold however additionally to
opposite the mildew tubes after a sure quantity of wear and tear to increase the tube life.
However, it's been visible now that there's a sturdy have an impact on of mold taper at the
intensity and uniformity of the oscillation marks and, as a result, on off-squareness and off-nook
inner cracks. It has additionally been visible that mold taper on the meniscus has a huge impact
at the neighborhood and ordinary warmness elimination from metallic, with effects for mold
distortion, oil lubrication and billet floor first-rate. Calculations primarily based totally on axial
profiles of measured warmness elimination, shrinkage of the cooling strong metallic and mold
distortion  have proven that a double taper is appropriate and is much less extreme for an
extremely low C warmness (, 0.16 %) than a excessive C warmness.
Mould distortion calculations advocate that the minimal wall thickness is to be around thirteen
mm for billet sections from a hundred mm to one hundred fifty mm and growth to more or less
20 mm for two hundred mm square. Wall thickness more than 20 mm can motive issues of
sticking, if the mildew is lubricated with oil, for the reason that thicker wall can also additionally
lead to mold warm face temperatures close to the meniscus that exceed the boiling variety of the
oil that's commonly 220 deg C to 350 deg C. As regards to inside nook radii, working revel in
has proven that a price of approximately three mm to four mm is useful in minimizing of the
longitudinal cracks.
The meniscus degree (from the pinnacle of the Cu mold tube) is to be optimally a hundred mm to
one hundred fifty mm. A shallow meniscus reasons the sector of most thermal enlargement of the
mold tube to be near the keeper plates, which commonly keep the tube in place. The resistance of
the keeper plates to the outward mold tube movement generates plastic traces and unwanted
everlasting tube distortion. Excessively deep meniscus ranges unnecessarily lessen the house
time of the solidifying shell withinside the mold.
It is appropriate to hold a excessive water velocity, commonly above 10-eleven meter/sec due to
the reasons (i) the water cooled face of the Cu tube should be sufficiently bloodless relative to
the boiling factor of water to suppress nucleate boiling, (ii) the recent face of the Cu tube should
now no longer exceed the boiling variety of the lubricating oil close to the meniscus, and (iii) the
temperature of the Cu should now no longer exceed the softening characteristics, dictated by the
point at temperature, of a specific Cu grade seeing that this ends in everlasting distortion of the
mildew.
There are 3 sorts of mold helps which might be used. They are (i) assist through keeper plates
equipped into slots on all 4 facets, (ii) keeper plates on facets close to the pinnacle of the mildew
tube, and (iii) assist at the pinnacle and bottom of the mildew tube. The 2nd assist in aggregate
with the shallow metallic ranges yields non-uniform mold distribution across the outer edge of
the tube. This, in turn, is conducive to off-squareness, as compared with first and third sort of
assist.
Quality of the cooling water has a very important. Even a 20-micrometer deposit is a devastating
influence on the mold tube temperature Hence This is because the deposit and relative to Cu,
introduces a large thermal resistance to heat flow from the tube to the cooling water. The most
immediate outcome of the poor water quality is permanent mold distortion. And it is often seen
that the severity of the deposits is not the same on all four faces of the mold tube.and This is
because the cooling water velocity changes around the outside periphery of the mold due to the
variation in the water channel dimensions At the root of the problem are the tolerances of the
components such as water jacket, mold tube, mold housing, and other assembly parts which
determine the dimensions of the cooling water channel.
Secondary cooling
Under the shape of the billet casting machine, the moving steel strand is cooled by the water
sprinkler banks. The purpose of secondary cooling is to continue the heat dissipation and
solidification initiated in the mold without creating tensile stresses of sufficient magnitude to
cause defects in shape, surface cracks, etc. or internal cracks. Spray nozzles are typically
attached to a vertical head or riser which is typically located in the center of each stage.Most
often, the spray nozzles used in billet casting machines create a full cone pattern (round or
square), although hollow cone nozzles are sometimes used. The length of the spray chamber can
vary from at least 0.5 m to 5 m.Principle of pressure atomization, ie water is pressed through a
hole or nozzle under pressure and breaks up into drops. The design of the secondary cooling
system for a billet caster depends primarily on quality aspects and requires knowledge of the
factors that influence the heat transfer through water sterilization cooling. The design of the
secondary cooling depends on three important aspects, namely (i) the effects of the spray cooling
on the formation of defects in the billets (ii) the heat dissipation by spraying, which is caused by
theVariables such as water pressure, distance, nozzle type, strand surface temperature and water
flow and (iii) the distribution of the water over the spray surface as a function of the spray
parameters mentioned in (ii). Billets are intermediate cracks, rhomboid cracks and diagonal
cracks. The influence of spray cooling on defect formation is described below.Overheating of the
billets after the spray chamber is the cause of intermediate cracks. The intensity of the spray
cooling influences the local temperature distribution over the shell, which in turn changes the
mechanical high-temperature properties of the shell. Steel and the shell's ability to resist buckling
due to the ferrostatic pressure of the liquid core.Spraying can influence the precipitation of
phases such as aluminum nitride (AlN), which can reduce ductility at high temperatures. If the
carcass is exposed to high tensile stresses in this state, for example during straightening, defects
such as transverse cracks can occur. There is a relationship between the rate of heat removal by
water sprays and the spray variables. The heat transfer coefficients of the spray are influenced by
a number of variables, such as: B. Type of nozzle, distance from nozzle to strand, water.The
pressure, the water temperature and the surface temperature of the steel. Outside of the nozzle
type, the distance from the nozzle to the strand and the water pressure influence the spray water
flow (liters / m2 sec.), Which is the most important spray variable. On the other hand, the
temperature and the water surface of the hand affect the temperature of the steel directly on the
heat transfer. Under normal continuous casting conditions, where the surface temperature varies
between 1200 ° C and 700 ° C, the surface temperature has little influence on the heat transfer
coefficient, while thegreater effect on the heat transfer coefficient. The molten billet after
secondary cooling is moved to the cutting section where the molten billet is cut to the desired
length with the hydraulic shear or cutting torches.
Here the defects in Continous cast steels are written below:
Defects in Continuous Cast Steels Continuous casting is process which converted liquid steel into a
solid product and mainly in the form of slab (either thick or thin), bloom or billets. It has one of
progressive steel making technologies which produced a cast product of a desired cross section in
indefinite length. The Continuous Cast Steels Continuous casting process required strict observance of
operating procedures, technological norms, and advanced production and control techniques. Despited
these measures, the occurrence of defects in the CC product cannot be fully ruled out.
 Longitudinal cracks – They are formed in the direction of extraction of the steel. The presence of this
defect causes rejection of the CC product. Longitudinal cracks occurs mainly due to (i) uneven primary
cooling in the mould, (ii) turbulent flow of liquid steel and a meniscus level variation in the mould, (iii)
non uniform or very intensive secondary cooling, (iv) variance in thermal conductivity coefficient along
the mould length causing unequal, advanced wear of the mould, (v) casting of liquid steel with high
superheat, (vi) (vi) high speed of casting, and (vii) (vii) use of the casting powder with improper
characteristics.  Transverse cracks – These cracks usually appear due to the tensions on the longitudinal
direction of strand. Normally these cracks are ground within the permissible prescribed limits provided
they are not deep. Transverse cracks appear due to (i) the thermal stresses, (ii) variation in the meniscus
level variation, (iii) presence of segregation at the bottom of oscillation mark, and (iv) friction of the
strand in the mould.  Corner cracks – These are cracks present in the edge of the cast steel product. They
appear due to (i) high temperature variations in the liquid steel, (ii) higher aluminum content in the steel,
(iii) higher sulphur level in the steel, (iv) non uniform edge temperature, (v) excess friction in the edges
during casting because of non uniform distribution of casting powder, and (vi) lower superheat of the
steel.  Star cracks – These cracks are very fine and caused by fragile nature of the strand at high
temperatures. They are visible only on scale free surface. The surface is usually ground locally to remove
the defect. Intense local cooling and presence of copper at the austenitic grain boundary cause star cracks.
To avoid the star cracks in the cast product it is necessary to have (i) correct correlation between the spray
flow and the casting speed, (ii) a uniform layer of melted casting powder between the strand and the
mould, (iii) moderate secondary cooling of the strand for avoiding increase of the thermal stress. 
Depressions – These are local deformations in the cast surface. Depressions can be longitudinal or
transverse. Longitudinal depressions appear like the shallow ditches oriented along the length of the cast
product. They occur due to the uneven heat transfer 6 in the mould. These depressions can be controlled
by uniform cooling in the mould, by centering of the liquid steel jet in the mould, by controlling the
fluctuations of the mould steel level, use of a casting powder with suitable viscosity and melting
characteristics, and by regularly monitoring the degree and uniformity of the mould wear. Transverse
depressions may occur cyclically along the strand length. The peritectic steels with low carbon and high
manganese contents and the stainless steels are sensitive to this defect. The transverse depressions can be
caused by the fluctuations in the mould level, large quantity of casting powder, and by the turbulence of
steel the sub-meniscus level. These depressions are controlled by controlling the mould steel level, having
proper mould taper, use of a casting powder with suitable viscosity and melting characteristics, and
proper positioning of the input nozzle and its support.  Blowholes – These are cavities in the outer
surface of the cast product and are often associated with inclusions. They are caused by presence of gases
in the steel, humidity and quality of the casting powder, variation in the mould level, presence of moisture
in the tundish refractory lining. Blowholes are controlled by sufficient de-oxidation of steel, use of dry
casting powder, use of casting powder compatible with the grade of steel grade, temperature and casting
speed, control of mould level fluctuations, control of nozzle immersion depth, avoiding the high superheat
and avoiding slag foaming around the nozzle.  Interruptions in the physical continuity of the cast product
– This defect occurs when there is a pause in the casting process. It often occurs when there is a change of
heat during sequence mode of operation. This defect is caused by a short interruption of the casting
process and occurs when there is sudden change in casting speed caused by the variations of steel
temperature in the tundish, by the variations of steel level in the mould, cogging of the nozzle due to high
alumina levels, or by the variations of casting mode. The corrective measures are maintenance of a
constant casting speed, a narrow range of temperature variation in the tundish, and steel level in the
tundish within the prescribed limits.  Slag spots defects -This defect is caused by the penetration of
tundish slag in the cast product. It is caused by high level of slag in the tundish, rise in the active oxygen
percentage in the steel, lowering of steel level in the tundish resulting in slag to enter the mould, and high
viscosity of casting powder.

NEW SHALIMAR STEEL

New Shalimar Steel Industries Pvt Ltd is one of the oldest and largest manufacturers and
stockists of rolled steel profiles; which is serving the nation for over three decades The company
was initially established as New Shalimar Steel Re-Rolling Mills in 1969 as a partnership
concern and was later upgraded to New Shalimar Steel Industries Pvt Ltd in the year 1986 under
the company’s ordinance of 1984
In the beginning; the mills mainly dealt in the production of mild steel; but with the passage of
time; included many new categories in the product line like medium carbon steel and alloy steel
Today; as a result of this expansion; we are not only serving private but also semi-government
and government institutions in their automobile; engineering; chemical; agricultural;
construction and numerous other fields New Shalimar steel Industries Pvt Ltd is a group of steel
concerns that begins at importing raw materials including scrap and chemicals from different
countries of the world The company not only manufactures and sells its own finished products
but also stocks steel profiles manufactured by other organizations in order to meet the
requirements of our valued customers The quality policy of company can be seen from the fact
that it has achieved International Standard of ISO 9002
PROCESS
MELTING PROCESS
Purchase of Raw Material (Scrap and Chemicals)
A separate department continuously keeps in touch with local and international markets to have a
comprehensive picture of basic raw materials (scrap and chemicals) Once the demand is raised;
inquiries from different companies in both local and international markets are collected for the
most competitive rates for the purchase of products
A separate department continuously keeps in touch with local and international markets to have a
comprehensive picture of basic raw materials (scrap and chemicals) Once the demand is raised;
inquiries from different companies in both local and international markets are collected for the
most competitive rates for the purchase of products
After the delivery of material it is analyzed in a laboratory for a set standard of quality after
which it is approved for consumption
Furnace Melting Process
The melting process is done according to the demand or at regular grades Both the Arc and
Induction furnaces mostly make low carbon steel grades like ASTM A36 and as the temperature
reaches to the desired degree; molten steel of Arc furnace is cast in moulds made of pig iron;
where as the molten steel from the induction furnace is taken to Continuous Casting plant
CASTING PROCESS
Continuous Casting Process
Molten steel from both furnaces (Arc and Induction) of required chemistry and at a
predetermined temperature is taken in a Ladle fitted with Slide Gate Mechanism with the help of
electric crane This ladle is kept above the Tundish from where molten steel is passed in copper
molds that are in mould jacket assemblies at a predetermined speed Mold Oscillators that vibrate
according to production size; determine the speed The red-hot billet is passed through
withdrawal rolls; where it is also cooled by spray of water at a very high pressure at the same
time This billet is then straightened by motor operated straighteners and then taken on to cooling
bed through run out tablets; after cutting into required lengths 
Billet Analysis and Color Coding: 
Once billets are made; a random sample of each is taken to the laboratory for chemical and
mechanical analysis Once the samples are up to the standards; the billets are then colour coded in
order to distinguish grade from grade The billets are then either sold out or sent to the mills for
the rolling process
ROLLING PROCESS
  Purchase of Billet and Slabs
Currently; New Shalimar Steel is using both steel slabs and billets for the production of hot-
rolled steel profiles There are four main sources from where purchase of raw material is made
These are:
Pakistan Steel Mills: which gives priority in the provision of products as New Shalimar Steel is
a potential consumer and one of its downstream industry 
Peoples Steel Mills Ltd: is another government-concern under the supervision of the world-
famous Pakistan scientist; Dr Abdul Qadir Khan 
Import: we are also using billet and ship plate imported from different countries The main
source for this is local market 
New Shalimar Unit 3: The process of this unit has been already discussed in detail This unit is
also fulfilling a large quantity of our raw material demand for rolling purposes
  Storage and Cutting of Billets and Slabs Storage and Cutting of Billets and Slabs
In open storage yard; various types of steel billets and slabs according to their respective
chemical properties are stocked These various grades are color-coded in order to facilitate quick
sorting as well as avoiding any mixingBefore the cutting; both billets and slabs are put separately
according to their sizes and grades After this; these are cut with the help of huge Mechanical
Cutting Machines and Gas cutters 
 Heating and Rolling
After cutting; exact sizes are then lifted with the help of electric cranes to the conveyers This is
the most important phase of the whole procedure When cut pieces reach at the specified
temperature they are rolled according to required sizes A heated piece is sent to different rolling
beds that change it into exact sizes automatically and/or manually The useless pieces are sold as
steel scrap 
MECHANICAL WORKSHOP
In Mechanical Workshops a roll is in a raw shape but has eminent strength and toughness This
place is then sent for hammer forging; which can also be used to cast any shape of steel into
specified size and shape Hammers are air drop-type that is supplemented with mechanical
presses; re-heating and heat treatment furnaces After forging; the steel becomes circular in shape
with two round shoulders This is then sent to the mechanical workshop for further process like;
converting this raw piece into rolls of different sizes
PRODUCTS
New Shalimar steel Pvt Ltd has the largest variety of the hot-rolled profiles in its industry The
company is not only producing residential but also industrial sections The quality and the
standards of these products are not only to local but also international standards These
include American AISI; SAE and ASTM; British (BSS); German (DIN); and Japanese (JIS) and
ISO International Standard Along with this; sizes and grades can be varied according to customer
needs and requirements In order to meet the needs and requirements of our valued customers we
also deal sections manufactured by other companies and imported sections
SIZE AND RANGE (INCHES)
Description Min Size ~ Max Size
I-Beam 4x2 ~ 24 x 8
H-Beam 4x4 ~ 12 x 12
Channel 3x1½ ~ 12 x 4
Girder 5x3 ~ 9x4
Angle 3/4 x 1/8 ~ 8x1
T-Iron 500gms ~ 1500gms
Flat 1 ½ x 1/8 ~ 10 x 1
Round Bar 3/8 ~ 12
Square Bar 3/8 ~ 9
Cold Twisted Bar 3/8 ~ 1½
Deformed Bar 3/8 ~ 1½
SIDDIQUI STEEL
From the commencement of its Steel operations in 1986; SGI has become one of the most
renowned brand in the steel industry of Pakistan We are geared to make high quality rolled
products with good tolerance levels conforming to all international production standards
including ASTM; BSI; and AASHTO Customer satisfaction is one of our core value and the
quality of our production needs no acknowledgement
PRODUCTION PROCESSES
INDUCTION MELTING FURNANCE
SGI has installed an Induction Melting Furnace based on American technology (Inductotherm
Group) with a capacity to produce 36;000 Metric Tons of quality billets annually Named
Siddiqui Steel Furnace the 7 Tons Melting Furnace ensures the provision of quality billets to the
Re-Rolling line in order to guarantee the steel bars conform to the set standards
CLASSIC STEEL RE-ROLLING MILLS
The unit was taken over in 2010; an 85 inch mill it was upgraded and modified to produce a
special size; 10mm (3/8 inch) of Steel Bars for the group The production ability of Classic Steel
Re-Rolling Mills currently stands at 36;000 Metric Tons per annum

SIDDIQUI STEEL RE-ROLLING MILLS

The plant acquired in 1990 has twice been upgraded to upscale its size to 9 inch Certain
improvements over this time have been made in the plant to keep it competent with modern
plants and enable it to produce quality bars The production capacity of the Mill stands at 42;000
Metric Tons of Steel Bars annually

PRODUCTS
BILLETS
The Billets are currently being manufactured according to the demands of Rolling Mills for
different qualities mainly ASTM 615-A Gr 40 and Gr 60 Siddiqui Steel Furnace is currently
manufacturing billets of 75mm × 75mm and 100mm × 100mm to suit the demand of billets for
various sizes of Steel Bars
COLD TWISTED BARS (TOR)
SGI has years of experience in manufacturing Cold Twisted TOR Bars for several civil works all
over the country The Bars conform to the prescribed Yield Strength ie 60;000 PSI and serve as a
great source for concrete reinforcement in structures The high strength and high bond value of
these bars make them a popular choice among numerous contractors seeking TOR Bars for their
unique aspects
COLD TWISTED (TOR) BARS                         3/8" – 15" OR 9mm – 40mm 
ASTM A 615/A 615M                                                 GRADE 40 – 60 – 75 – 80
(American Standards Testing & Materials)                             
The most popular and in-demand Steel Bar grades; (Grade 60 & Grade 40) lie in the category of
ASTM 615-A The company manufactures and holds ample amount of Grade 60 & Grade 40
Steel Bar in standard size enabling it to deliver these bars in the minimum possible time period to
the clients
BSI 4449                                                                           GRADE 250 – 460 – 500
(British Standard Institute)
BSI 4449 is one of the most commonly used standards in the steel industry worldwide The
company manufactures bars according to the BSI 4449 for several projects all over the
country These products are manufactured in several sizes and according to the grades specified
under BS 4449 by the clients
DEFORMED STEEL BARS – GRADE 250                                        2/8" OR 8mm
DEFORMED STEEL BARS – GRADE 460                                        9mm – 40mm
DEFORMED STEEL BARS – GRADE 500                                       9mm – 40mm
PLAIN ROUND BARS
SGI is one of the very few Rolling Mills capable of producing Plain Round Steel Bars and has
done so successfully for major multinational companies in the recent past The Bars are generally
produced according to International Standards ie ASTM; BSI; AASHTO etc but can also be
produced according to any requirements specified by the client PLAIN ROUND STEEL
BARS                          3/8" – 15" OR 9mm – 40mm
https://www.ispatguru.com/continuous-casting-of-steel-billets/
file:///C:/Users/muham/Downloads/Defects%20in%20Continuous%20Cast%20Steels.pdf
http://www.siddiquisteel.com/bsi-4449/
http://www.newshalimar.com/Rolling-Process.html