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CHAPTER 9
INDONESIAN INDUSTRIAL
STANDARD
Classification of Iron scrap and
steel
IRON SCRAP
Iron scrap is molding product from another iron products and
commonly used to be melted back
CLASSIFICATION


Classification by quality
Class I Iron scrap which consist of former instrument of
machines, former machine tools, etc.
Class II Iron scrap which consist of former household
tools,etc.
Classification by size
Type A Group of scrap with weight between 1 kg-20 kg, per
piece.
Type B Scrap that easily can be A type scrap by beating or
cutting
Type C Salt and flakes with weight under 1 kg ( The remaining
of machine work without another foreign objects
STEEL SCRAP
Steel scrap is steel product that IS unable to function again and used to melted
back into new molding product
CLASSIFICATION
 Classification by the use
Steel scrap divided into three big parts by the purpose of its use to be
melted,molded, and for another usage
 Classification of steel scrap by quality and size
Steel scrap to be melted back divided into classess by quality and size
1. Classification by quality
Class I. Carbon steel scrap with maximum content of chemical
elements, as the followings:
Ni
0,45 %
Cr
0,20 %
Sn
0,06 %
Cu
0,20 %
P
0,05 %
S
0,05 %
Class II. Scrap steel alloys
Class III. Variety scrap steel
2 Classification by size
Type A
No.1 Thickness >6mm , length in all direction between 100-600 mm
No.2 Thickness between 3mm- 6mm , length in all direction 100-600 mm
No.3 Thickness >6mm, length in all direction over 600 mm and < 1200 mm
No.4 Thickness between 3mm - 6mm , length in all direction over 600 mm and < 1200 mm
No.5 Thickness <3 mm, length in all direction over 600 mm and < 1200 mm
If the sent scrap consist of some numbers from type A to define sub, that type using density as a rule
with this following condition :
Type A
No.1
Rj above 1500kg/m3
No.2
Rj above 1000kg/m3
No.3
Rj above 570kg/m3 and lower than 1000kg/m3
No.4
Rj above 400kg/m3 and lower than 570kg/m3
Type B
Steel scrap that easily can be change into one of the shapes above with cutting process.
Type C
Stainless scrap with maximum weight of 125 kg.
No.1
Cutting of thin plates
No.2
The remains of thin plates lead which the lead already eliminated
No.3
Steel scrap that does not include No.2 and no.2
•
Steel alloy scrap classified as these following :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Chrome steel scrap
Vanadium chrome steel scrap
Molybden chrome steel scrap
Alumunium-chrome-molybden chrome steel scrap
Nickel-chrome steel scrap
Nickel steel scrap
Nickel-chrome-molybden steel scrap
Chrome-molybden steel scrap
Chrome-wolfrang-vanadium steel scrap
Fast lathe steel scrap (HSS)
Rust-resistant chrome steel scrap
Rust-resistant nickel-chrome steel scrap
Rust-resistant titanium containing steel scrap
Rust-resistant molybden containing steel scrap
Rust-resistant copper containing steel scrap
Rust-resistant chrome molybden steel scrap
Heat-resistant steel scrap
Chrome-molybden heat-resistant steel scrap
Nickel-chrome-wolfrang heat resistant steel scrap
Nickel-chrome heat-resistant steel scrap
Matrix steel scrap
Matrix-chrome-wolfrang steel scrap
Silicon scrap
Sumber:………………………………………………………………….
GRAY CAST IRON
Mechanical characteristics of cast iron not only depends on chemical
elements only, but also from the speed of cooling off during
solidification. Because of that, classification of cast iron is not based on
chemical composition
Chemical composition of gray cast iron
Table above states that chemical composition of gray cast iron
which the use depends on material demand that suitable with
mechanical characteristic from cast objects that will be produced.
CLASSIFICATION
Gray cast iron classified based on the strong lure states on Table I.
Table I : Classification gray iron cast
Quality condition
• Chemical composition
Chemical composition of gray cast iron depends on producer’s policy. For
30-40 gray cast iron, maximum phospor content can be set based on
approval between producer and consumer. Gray cast iron product must
having an uniform properties and also free from defective such as
reduction cavity or porous and the field of fault have to gray coloring
• Tensile strength
Tensile strength of gray cast iron have to fulfill the requirements on Table I
Table II : Size of test-rad
Iron pellet-shape sponge
DEFINITION : Iron sponge is pellet of iron ore which directly have been reduced with H2 gas and
CO at some circumstances for reducing oxides which contain on it. Iron sponge use
for basic materials making of iron and steel. Pellet is iron concentrate that shaped
into round through some sort of process
Quality Condition
3.1 Dimension
maximum
3.2 Bulb density
3.3 Apparent density
3.4 Tensile strength
3.5 Chemical elements
Fe total
Fe metal
Metalisation
C
P
S
: Size between 5 until 16 mm, lower than 5 mm, 5%
: Minimum 1,65 ton/m3
: minimum 2.82 ton
: Minimum average 80 kg/ item
:Minimum 88%
: Minimum 75%
: Minimum 85%
: 1,5-3 %
: Maximum 0,03%
: Maximum 0,03%
Sampling steps
1. Sample of iron sponge took with automatical sampler tools by setting up
the periodic of taking/swinging sampling (Referred to Table 1), which
influenced by :
- Velocity of conveyor
- Shipping amount
- Number of retrieval
2. Semi-automatic way retrieval
If the time period is performed manually following table 1.
Calculation example for :
a) Set 1 times sampling
b) Amount of Iron sponge sampling earned
If automatically return and semi-automatic can not be done, then iron
sponge’s example is taken from the mound with applied SII methods.
Simple Way to Produce Cast Iron for Maleabel
DEFINITION
Simple way means the iron maker pour white, after we do heat it,
we can get maleabel cast iron.
RAW MATERIAL
The raw material that can be used such as raw iron for foundry
that applied on SII.0991-84 or iron sekrap. To get the
composition we want , we can use iron sekrap.
All raw materials must be choosen well know its composition,
and also free-polluter that able to impact heating process and
the final result.
SAND PRINTING
Pattern
Pattern can be made of wood, metal and resin depends on quantity,
shape and style that we want.
Printing and Core
Printing can be made from natural sand that applied on SIII, Silica
Sand is allowed on SII and the other sand which is fit for foundry.
Printing maker can make fastener material such as bentoit, clay,
water, glass water, resin,etc so able to fulfill conditions.
Core is made of sand that fit with its use.
Silica sand is one of variants sands that can be used for
metalfoundry that applied on SII. We use bentonit, clay , vegetable
oil and so on for the fastener raw that will be used for core sand to
fulfill conditions.
Planning
Spore runner and gate
Commonly, the material of cast iron for maleabel have short power flow,
fast frosting , and big depreciation. In that case , casting must be done by
considering those characteristics. In order flawed object cast which is
caused by the motion that distract printing can be prevented, the filter
which is made of fireproof material or ceramic able to be installed .
Addition
The function of this addition is to balancing the depreciation during
smelting casting in order to decelerate the casting of frosting.
Printing process
Wet molding process
For wet printing we use the mixture of silica sand, bentonit, and water in
sufficient ratio so we will get the quality of printing sand that according what is required.
We use mixer machine or sand grinder to process the sand in order to get perfect mixture.
The printing itself using printing machine and can be practiced in casting industry.
CO2 Process
Carbon oncret process is way of hardening mold or silica sand mixture of core with water
glass binder material (sodium silica Na2OsiO2 x H2O) then blow with CO2. The result of this
process is more precision, but it is oncrete easily .
Shell Printing Process
Sand print shell is made of silica sand mixture with 4-7 % of resin fenoldan and little of
oncr alcohol. Mold or core is made of metal which is already heated about 2500C . Into the
mold that has been heated is inserted about one minute sand which stick to the surface
of the mold hardens itself. For longer periods are left in the mold will continue thick.
The demolition of the casting is easy and the surface itself is good and smooth
MELTING PROCESS
Chemical Composition
Cast iron for maleabel made of white cast iron in chemical composition such
on this table I .
Table I
The Chemical Composition of Cast Iron for Maleabel
Crucibal Furnace
All kinds of crucibal furnace are able to be used in these certain
conditions:
1) Able to reach the temperature of molten iron
2) Able to produce cast iron with composition such on table I
Smelting Equipments
The addition tools of casting is kowi scale , degree temperature ,
the composition controller to analyze quickly, etc .
Smelting
The raw materials are put into the furnace and weighed
according to chemical composition. Class of maleabel cast iron
which is wanted, degree of melted metal in furnace must
reach about 1525o C – 1600o C.
Added Material
Added material can be used for :
• Bismuth is added according the composition and the thickness of
cast object to prevent primer graphite , in making of black maleabel
cast iron
• Boron is added for :
1.
2.
3.
Increase flow ability
Made up the temperature graphite
Offset the presence of chromium in cast iron that is about 0.0001 %
in every 0.01 % chrom.
Cleaning of the casting
Cast object must be clean , free from defect pouring which is
caused by inherent sand, perforated, or another defect that is
caused by cutting channel pour. The use of spray machine or such
that kind with purpose to clean cast surface can be done.
Steel Reinforcement for Construction of Prestressing
Concrete
1.Steel Reinforcement for Construction of Prestressing Concrete is
steel shaped bar circular cross section for concrete construction
material and processed from billet raw material steel which is killed
steel. It has been done with canai heat the do pulling process or
stretching process and also heating process.
2.Steel Reinforcement for Construction of Prestressing Concrete
consist of two types, they are plain type and deform.
3. Classification and Symbol
Classification and symbol of steel reinforcement of prestressing concrete
such on table I below
Table I
Classification
• Note :
1. Bj TPP :Plain steel Reinforcement for Construction of Prestressing
Concrete
2. Bj TPD : deform steel Reinforcement for Construction of Prestressing
Concrete
QUALITY REQUIREMENT
1. Nature seem
1.1
Wire should be free of the voltage
1.2
Surface should not, containing splinters folds cracks, light
waves manner or wire
1.3
Wire surface should not coated by oil or gemuk?
2. Dimension and Tolerance
Dimension and tolerance of steel wire have free voltage without layer for
the concrete construction prestressed as a table below :
Table II. Dimension and Tolerance
3. Deform Wire
Deform wire should have indent round, all are same, continous, and have a
same distance.
4. Mechanic Character
Mechanic character of free voltage steel wire for concrete construction
prestressed with low relaction like table IV
SIGN REQUIREMENT
Each flat zink steel wire for wire protection should given by label
which have sign :
-Factory name
-Wire size
-Netto weight
-Symbol (example : Bj, Kp, Pk)
Bj = Baja (Steel)
Kp =Kawat Pipih(Flat wire)
Pk = Pelindung Kabel (Wire protection)
STEEL WIRE FLATTENED ZINC PROTECTIVE OF ELECTRICAL CABLES
1.DEFINITION
Steel wire flattened zinc protective of electrical cables is steel wire a cross section
flattened coated with zinc that is use as cover of electrical cables.
2.QUALITY REQUIREMENT
1.Appearance
– The surface should be clean, slick and not disability- other defects that can
reduce usability in use.
– In one cannot roll or coil guiler connection
2. Size and Tolerance
3.Machanic Character
1. Pull Strong
Strong pull steel wire flattened layer zinc 35-15 kg. / mm2
2. Strain
Strain zinc minimum 10 % at length measuring instrument 200 mm
• \
Notes : KPNB = Kawat pratekan Normal Baji (Wire Pratekan Normal Wedge)
KPRK = Kawat Pratekan Rendah Kancing (Prestressing Wire With Low Studs)
9.7.
STEEL WIRE FREE VOLTAGE WITHOUT LAYER FOR PRESS CONCRETE
CONSTRUCTION
1. DEFINITION
The meaning of steel wire free voltage without layer for press concrete
construction is steel for oncrete construction or for the another construction
shaped wire with high carbon cross-section round which is processed in the
manner of cold drawing then conducted the process of stress relived with the
continuous heat treatment to obtain the desired mechanical properties.
SYMBOL CLASSIFICATION
Classification and embossed steel wire voltage-free layer of planting for
construction of concrete prestressing
Notes :
KPNB = Kawat pratekan Normal Baji (Wire Pratekan Normal Wedge)
KPRK = Kawat Pratekan Rendah Kancing (Prestressing Wire With Low Studs)
CARBON STEEL PLATES FOR PRESSURE VESSELS AND STREAM KATEL
DEFINITION
– Stream Boiler
Stream boiler is a plane to produce steam that is used by the air pressure outside
the aircraft.
– Pressure Vessel
Vessel is a pressure vessel to contain the emergence of both from within and from
outside. This pressure can come from outside or inside by using a heat source
directly or indirectly or a combination of both.
CLASSIFICATION AND SYMBOL
•
Carbon steel plate for boilers and pressure vessel are classified by symbols
as in Table I.
•
Notes:
Bj. KB = Abbreviation of steel plates for boilers and pressure vessels. Number
behind Bj. KB minimum tensile strength shows hinted at Mpa.
PROCESS
Steel for boiler plate is the result of a process tenur Sismens Martin (Open Hearth
Furnace), electric furnace and allowed the new processes and have another full
(fully killed). Boiler plate is hot rolled and must be normalized (normalized) or the
temperature control process at the time of the achievement.
QUALITY REQUIREMENTS
1. Looks Beyond
– Plate with surface defects after grinding resulted in thickness less than
the minimum thickness allowed, otherwise rejected (reject). Thick
translation grinded parts is less than the minimum thickness allowed,
allowed patched by welding in accordance with clause 4.1.6 but the
rest of the slab thickness should be a minimum of 80% of the nominal
thickness.
– Lamination defects on the side of the plate can be seen with the naked
eye or with a long test with 25mm magnetografi still allowed.
– For assessment lamination defects that are longer than 25mm, are
listed in Table II below.
Table II
Lamination defects on the side of the plate, more or less parallel to the
rolled surface.
—Addition of the defects that have been grinded by means of welding
must be in accordance with welding procedure qualification and must
be done by a qualified welder (qualified) under the terms..
—In the welding procedure qualification shall be held at the notch
Charpy test on weld, heat affected regions and parent material.
—In the welding procedure qualification weld test specimen and the
plates were repaired by welding heat treatment must be carried out,
in accordance with the implied.
2. Defects in the plate
The whole plate should be tested ultrasonically. Based on the results of ultrasonic
testing, the flaw in the plate is still allowed if the defect is less than half the
diameter of thick plates and for plates with 150mm thickness ,defects in the plates
still allowed if the defect diameter less than 75mm.
3. Dimensions, mass and vareasi
– Unless a special tolerance for thick plate used for boilers and pressure
vessels listed in point 4.3.1 dimensions, mass and vareasi based SII No. 018-80
“Dimensions, mass and vareasi for rolled steel sheet and hot rolled strip.”
–
Thickness Tolerance
Table III: Thickness Tolerance in mm
4.Chemical Composition
Chemical composition (ladle analysis) of carbon steel plates for boilers and
pressure vessels as in Table IV.
Table IV : Chemical Composition, % weight
5. Mechanical Properties
Mechanical properties of carbon steel for boilers and pressure vessels as in Table