Sepction - 3
Sepction - 3
Sepction - 3
(2) Manufacture: The steel used for ingots shall be fully killed and homogenous. Ingots should be
adequately cropped so as to be free from pipes, segregation, and other harmful
defects. The material shall be fine grained. The forgings shall not be manufactured
from continuously cast blooms/billets/bars.
(3) Chemical Composition: The chemical composition by weight method should be as follows:
Steel International Superseded %C % Si % Mn *%P *%S % Cr % Mo % Ni
designation Designation Designation Max. Max
---
0.36 0.10 0.50 --- 0.50 0.40 2.30
EN-26
FU1 ---
(BS 970) 0.44 0.35 0.70 0.035 0.035 0.80 0.70 2.80
*Al=0.015 / 0.025, O2=0.002 max (20 ppm), N2=0.009 max (90 ppm), H2=0.0002 max (2ppm).
% S & %P are generally 0.035% max. However, when suffix 'L' is mentioned the limit of S and P are
0.015 & 0.020 respectively.
(4) Grain Size: Austenitic grain size of the items supplied should be tested according to
ASTM-E-112, 1988.The grain size should be within (5-8) and uniformly sized.
(5) Degree of purity (Non metallic inclusion): The steel shall have lesser inclusion rating than no.3
as per ASTM E-45 or IS : 4163-1982 or K4≤40 as per DIN 50602 specification for
oxides, sulfides alumina and silicates inclusions.
(6) Reduction Ratio: All the Rolled or forged/proof machined bar/cake must confirmed to forging/rolling
quality steel and must have undergone a reduction of at least 2:1 from bloom to
forgings and 4:1 from ingot to individual forging.
(7) Step Forging: If difference between major O.D. and minor O.D. is more than 2.0 inch, component
(pinion shaft) is to be step forged (length of holding is 200mm min.). No step forging
is required in case of plain/spline shaft (Mining group).
Prepared by Checked By
(HOD, LAB) (QA) Approved By
VULCAN INDUSTRIAL ENGINEERING CO. PVT. LTD.
Survey No.1091, Sunav-Kasor road, Piplav-388 460 Dist. Anand,
Gujarat, India.Tel: +91 2697 235812
Prepared by Checked By
(HOD, LAB) (QA) Approved By
VULCAN INDUSTRIAL ENGINEERING CO. PVT. LTD.
Survey No.1091, Sunav-Kasor road, Piplav-388 460 Dist. Anand,
Gujarat, India.Tel: +91 2697 235812
(11) Ultrasonic Testing: All the forgings or forged/rolled round bars/blooms should be ultrasonically
tested both axially and radially and should not contain any harmful defects like
shrinkage, cavities, piping, inclusions, flakes or excessive segregation. Any
indication with a defect echo more than 3.0 mm flat bottom hole (FBH) equivalent on
DGS (Distance, gain, amplitude scale) would be cause of rejection. U.T. should be
carried out as per ASTM-388. The surface of the forgings, rolled/forged round bars
should be free from surface defects like seams/laps cracks, and deep scale.
(12) Example: FU W indicates chemical composition given in FU row in para 3 with heat- Treatment
condition 'W' given in para 10.
(13) Documents, Test Certificates and Test Pieces: The test certificates indicating the results of all
the tests carried out as below shall be supplied mentioning the heat number of the
melt. The heat no. shall be clearly punched on all forgings.
(i) Chemical composition with mill TC
(ii) Grain size
(iii) Inclusion content
(iv) Recorded strip chart for Heat treatment cycle (including Annealing)
(v) Mechanical properties
(vi) NDT Test (UT / DP / MPI)
(vii) Calculation of Reduction Ratio and input R.M./Billet size.
(viii) Jominy Hardenability test
Note: A test piece as per BOM having extra length in to be sent for each heat along with the job as per
terms of PO.
Separate forged test piece of same ruling section to be provided along with job (Gear blanks).
No welding is permitted
Proof machining will be as per drawing attached with PO.
Number of test pieces depends on the no. of HT batches to be carried out.
Prepared by Checked By
(HOD, LAB) (QA) Approved By