PSM INTERNSHIP 2

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PEOPLES STEEL MILLS LTD.
KARACHI-PAKISTAN
INTERNSHIP REPORT
(27-july-2015 to 7-aug-2015)
ISO 9001 -2000 CERTIFIED

PEOPLES STEEL MILLS. ltd INTERNSHIP REPORT
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SUBMITTED TO:
MR. GHULAM RAZA
SUBMITTED BY:
Students of “DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY” and
“INSTITUTE OF SPACE TECHNOLOGY”.
GROUP MEMBERS:
 Mr. Muhammad Asim Aslam (D-13-IN-06)
(Department of “Industrial Engg & Mgmt from DUET)
 Mr. Muhammad Abeer Kamal (D-13-MT-07)
(Department of “Metallurgy and materials” from
DUET)
 Ms. Raheela Rasheed (130301016)
(Department of “Material science” from IST)
Internship Duration
Start Date: 27-july-2015
End Date: 07-august-2015

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CONTENTS
INTRODUCTION TO PSM………………………………………………………….……………….……… ….….…………………05
processflow diagram............................................................................................................….……….06
Scrap……………………………………………………………………………………………………………………………………………………..07
Refractorydevelopmentcenter…………………………………………………………………………………………………………….08
Electricarc furnace………………………………………………………………………………………………………………….…………….09
Ladle furnace…………………………………………………………………………………………………………………………………….…..11
Vacuumdegassing………………………………………………………………………………………………………………………………..12
Ingotcasting…………………………………………………………………………………………………………………………………………14
Continuouscasting………………………………………………………………………………………………………………………….…...16
Bloomingandslabbingmill (N-shop)……………………………….………………………………………………………………...…19
Bar rollingmill (Q-shop)…………………………………………..……………………………………………………………………………21
Forgingshops(R1, P2, R3)…………………………………………………………………………………………………………………….23
QAD LABS…………………………………………………….……………………………………………………………………………………..27

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PREFACE
This reportdocuments the work doneduring the summer internship at PEOPLES
STEEL MILLS Limited under the guidance of PSM staff. The report firstshall give
an overview of the learning during the period of internship with technical details.
We have tried our bestto keep reportsimple yet technically correct. We hope we
succeed in our attempt.
Students of Dawood University of Engineering andTechnology and Institute of
Space and Technology

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ACKNOWLEDGMENTS
Simply put, we could not have done this work withoutthe lots of help we
received cheerfully fromthe whole PSM. The work culturein PSM really
motivates. Everybody is such a friendly and cheerfulcompanion here that works
stress is never comes in way.
I would special like to thank MR. GHULAM RAZA for providing us a chance to get
this great experience.

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INTRODUCTION OF PSM
Peoples Steel Mills Ltd is a world class alloy and special steel manufacturer plant located in
Karachi, Pakistan. It was set-up by the Government of Pakistan in 1975 with Japanese
assistance.
The plant was upgraded in 1996 through a comprehensive balancing & modernization
programme with the technical assistance of VAIS, INTECO and Bohler of Austria. The plant is
now equipped with modern melting, refining, degassing, electro slag re-melting and necessary
casting, rolling and forging facilities with an annual capacity of 70,000 Mt. Product quality is
assured through modern material testing facilities and well trained staff.
The plant has the capability to produce steels according to all major international quality
standards and to date has manufactured more than 300 steel grades and now a days approx.
250 grade of steel manufactured.
Peoples Steel enjoys the highest market share in the alloy and special steel market of Pakistan.
A diversified base of customers includes high profile illustrious end users in automotive,
defense, machinery construction, special/high rise buildings, transportation and engineering
sectors. Components manufactured from our steels are supplied by our customers to renowned
European & Japanese automobile manufactures.
To meet the diversified requirements of quality conscious customers pertaining to automobiles,
agriculture, railway and sophisticated engg sectors, PSM have so far manufactured /supplied
more than 200steel grades of international quality standard, bradly classified as follows:
 Special carbon steels
 Free/semi free cutting steels
 Case hardening steels
 Spring steels
 Heat resisting steels
 Ball bearing steels
 Armour steels
 Steels for special applications and many others…

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PROCESS FLOW DIAGRAM OF PEOPLES STEEL MILLS ltd:

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SCRAP:
Scrap consists of recyclable materials left over from product
manufacturing and consumption, such as parts of vehicles,
building supplies, and surplus materials.
There are two types of metal scrap in all over the world
1. Ferrous
2. Non-ferrous.
 Ferrous scrap is scrap of iron and steel and PSM deals with ferrous scrap.
 Scrap selection depends upon three main factors:
1. Cost.
2. Size.
3. Weight.
 PSM mostly scrap import from Dubai and England.
TYPES OF SCRAP:
 There are five types of scrap which deals by PSM scrap dept.
1. Heavy Metal Scrap (HMS 1, HMS2).
2. Bundling scrap.
3. Shredded scrap.(ISRI2010,ISRI2011)
4. Rail scrap.(R45.R65)
5. Shop return scrap.(chips, endcuts)
OVERHEAD CRANES:
 Four overhead cranes use in scrap department.
1. IHI magnetic (5 ton capacity) (use for filling buckets)
2. Morres England (16ton capacity) (use for filling and charging bucket)
3. IHI (16 ton capacity) (use for charging).
4. Morres (16 ton capacity) (use for charging).

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REFRACTORY DEVELOPMENTCENTRE:
Refractories are heat-resistant materials that constitute the linings for high-
temperature furnaces and reactors and other processing units. In addition
to being resistant to thermal stress and other physical phenomena induced
by heat, refractories must also withstand physical wear and corrosion by
chemical agents.
The main purpose of RDC is to development in refractories and making new type of
refractory.
PURPOSE OF REFRACTORY LINNING:
There are following purpose to use refractory linning :
1. To protect ladle, tundish, furnace shell from molten metal.
2. To reduce wastage of temperature.
NATURE OF REFRACTORY:
There are three types of refractory:
1. Acidic.
2. Basic.
3. Neutral.
PHYSICAL FORMS OF REFRACTORY:
There are two types of physical forms:
1. Shaped refractory
2. Monolithic refractory.
PROCESS OF PREPARATION OF REFRACTORY:
1. Mining of raw material.
2. Primary and secondary crashing.
3. Calcination (heating process), in which 3 zones, preheating (500degree centigrade) ,
heating(1400-1450degree centigrade, cooling zone.
4. Post calcination.
5. Making recipe and mixing.
6. Then pressing.
7. After pressing brick formed then sintering process to hardening(1350 degree
centigrade)

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ELECTRIC ARC FURNACE(EAF):
This furnace can be described as a furnace heating
charged materials by the way of an electric arc. The
first electric furnaces came into being in 1907, at the
hands of Paul Heroult of French origin. The commercial
part of these furnaces was established in the USA.
CAPACITY of these furnaces exist in all the sizes-right,
from the smallest one having a capacity of around 1
ton to the largest one having a capacity of 400 tons
(approx.) and in PSM furnace capacity 15 tons.
PURPOSE:
There are two main purpose of EAF:
1. Melting
2. Dephosphorizarion
PLANT CAPABILITY:
1. Two EF in PSM use for working.
2. 11KV power received from K.E then using step down transformer reduce to min
230 and max 550 volts/ton.
3. Furnace capacity 15ton.
4. Tap to tap time 120min.
5. In Lancing Oxygen pressure 5 to 8bar. And average lancing time 20 to 25 min.
6. To remove slag from furnace tilt furnace 15 degree and slag automatically out
from slag door
7. If composition correct as per requirement then remove slag and tapping in ladle
and tilt furnace 45 degree for taping
8. During taping add some alloys.
9. Diameter of furnace without refractory 3.8m, diameter of furnace with
refractory 2.8m.
10. In EF oxidizing atmosphere.
11. Take three time temp and two time sample.
12. Electrode diameter 305mm.
13. Shell diameter3150mm.

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 PROCESSING:
 OXYGEN LANCING:
Uses of Oxygen lancing are:
 Use to making slag.
 Use to reduce the consumption of electricity
 Reduce time consumption.
 FURNACE REACTION:
1. We use oxygen lancing to reduce carbon composition in steel and prepare CO
gas which flow in the air.
C +O2 CO
2. Oxygen also used for Dephosphorization , when we use oxygen it reacts with
phosphorous and prepared phosphorous penta oxide(P2O5)
P + O2 P2O5
3. It’s a reversible reaction after 1620 degree centigrade then we add lime, CaO
react with P2O5 prepared CaP2O5.
Ca + P2O5 CaP2O5
 Now Phosphorous mixed in slag and remove with slag.
 Magnesia carbon powder form used for foamy slag, benefit of foamy is that foamy slag
safe furnace refractory.
 If oxygen increase boiling from furnace then to reduce oxygen Ferro silicon used.
 When desired temperature achieved in furnace then sample collect and check
composition.
 For properly addition of alloy composition calculate through standard formula.
 Basicity of slag more than 1.5
FORMULA FOR THECALCULATION OF ADDITION OF ALLOY:
 FORMULA of amount of addition of alloy in molten metal
= (required % of alloy – given % of alloy)/recovery rate*capacity of furnace

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LADLE FURNACE (LF):
A Ladle Furnace is used to relieve the primary
melter of most secondary refining operations
 Its primary functions are:
1. Reheating of liquid steel
through electric power
conducted by graphite
electrodes.
2. Homogenization of steel
temperature and chemistry
through inert gas stirring.
3. Formation of a slag layer that protects refractory from arc damage, concentrates
and transfers heat to the liquid steel, trap inclusions and metal oxides, and
provide the means for desulfurization.
 Secondary functions that can be included with a ladle furnace are:
1. Alloy additions to provide bulk or trim chemical control
2. Provide a means for deep desulfurization
3. Provide a means for dephosphorization
4. Act as a buffer for downstream steelmaking equipment
PURPOSE:
1. Alloy addition
2. Desulfurization
PARAMETER:
1. Temperature control.
2. Refining.
3. Composition of alloy control.
PLANT CAPABILITY:
1. Two LF use in PSM
 LF1 working slow
 LF2 working speed greater than LF1
2. 30 to 35 min process time in ladle furnace station
3. 8mm diameter of graphite electrode used in Ladle furnace station.
4. 8.5mm transformer used.

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5. Ring size in ladle 200mm.
6. 1.5kg to 2kg/ton consumable rate of electrode at this work station.
7. 1630 to 1640 degree centigrade holding temperature at L.F.
8. In ladle furnace reducing atmosphere.
9. Ladle weight=5570kg
10. Ladle height=2880mm
PROCESSING:
1. Slag making using lime
2. CaO react with sulphur and desulfurization and make slag.
3. In ladle furnace purging through purge plug, Argon or nitrogen gas used for purging.
4. Mostly purging through argon gas when special steel.
5. CalciumFluoride make fluidity in Slag.
6. At this station heat molten metal as requirement for VD and C.C temperature
ALLOY ADDITION:
 Alloy addition in this station like FeCr, FeV, SiCr, Ni,Al these all alloy and
other alloys add as per requirement in furnace .
DEOXIDIZER:
There are following deoxidizer used in L.F:
Si,mn,Al,Cr,Sn
VACUUM DEGASSING:
A Vacuum Tank Degasser (“VTD”) is used to reduce the concentrations of dissolved
gases (H2, N2, O2) in the liquid steel; Homogenize
the liquid steel composition and bath temperature;
remove oxide inclusion materials from the liquid
steel; and, provide the means and technical
conditions that are favorable for final
desulfurization
 The fundamental requirements for the ladle
degassing process include:
1. Sufficient freeboard in the ladle to contain
the vacuum-induced slag and steel boil.

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2. An inert gas percolating through the steel bath for stirring, inclusion separation,
and enhancement of vacuum degassing performance.
3. Sufficient superheat in the steel to avoid skull formation
4. Means to deliver additives while the ladle is inside the vacuum tank.
PURPOSE:
1. To remove gases from molten metal.
2. Making final steel composition.
PLANT CAPABILITY:
1. Two types of pump use to reduce pressure:
 Watering pump.
 Stream ejecting pump.
2. Two watering and four stream ejector pump.
3. At a time two pump work.
4. Whole process of vacuum degassing 20 to 25 min.
PARAMETER:
1. Purging plug work properly.
2. To hold metal at particular pressure.
3. Plant and pumps proper working.
PROCESSING:
1. Dolomite use to make heavy slag.
2. Fire clay use for sealed Ladle from outer side.
3. Rubber material use for joining.
4. Initial use both watering pump
5. For vacuuming must reduce pressure, 1 atmospheric =760torr and When pressure
comes to 3 to 4torr stop both pump.
6. Argon gas use at this station also for purging again.
7. Ca+si wire use for desulfurization if needed
8. If boiling create then use “Al” bar to reduce boiling.
9. When require low carbon composition in metal then after VD metal send to
VOD(vacuum oxygen decarburization) then for reduce oxygen send to VCD station
(Vacuum carbon deoxidization)
10. When to reduce oxygen direct after VD our metal send to VCD station to reduce oxygen.

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INGOT CASTING:
An ingot is a piece of material, usually metal,
that is cast into a shape suitable for further
processing. In steelmaking, it is the first step
among semi-finished casting products. Ingots
usually require a second procedure of shaping,
such as cold/hot working, cutting, or milling to
produce a useful final product. Non-metallic
and semiconductor materials prepared in bulk
form may also be referred to as ingots,
particularly when cast by mold based methods.
PLANT CAPABIITIES:
 In ingot casting bottom pouring.
 Use cast iron molds.
 Ingot casting provide feed stock to other shop with in the industry.
 Neutral refractories of Aluminia based.
 Prepared these types of products through ingot casting:
1. SQ 1100.
2. SQ1250.
3. SQ700.
4. FL2000.
5. FL1600.
6. FL1200.
7. FL1000.
8. FL600.
9. R2000.
10. R600.
11. OCT12ton.
12. OCT8ton.
13. OCT5ton.
14. OCT2ton.
 Ingot casting prepared :
1. High Alloy steel.
2. Tool steel.
3. Stainless steel.

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 Ingot casting products:
1. For making E.S.R electrode
2. Slap casting
3. Forging parts cast
4. When power failure then use ingot casting station
TYPES OF CASTING POWDER
Three types of Casting powder but used at different time:
1. High carbon powder (use when low and medium alloy).
2. Low carbon powder (use when stainless steel).
3. Medium carbon powder (use when tool steel).
 Casting powder dip in the mold it works as a Lubricant and remove contact with air.
 Cover powder and anti pipping powder are exothermic that cause burning thus use for
filling cavity.
 Feeder head use in mold to remove cavity.
 Before filling from ladle heat mold and increase temperature of mold 50 to 60degree
centigrade.
 Arrangements of mold and refractories in ingot casting :
PROCESSING:
First heat mold 50 to 60 degree centigrade then produce cloud from argon gas to
prevent contact of molten metal with air then through ladle bottom poring and these
labeling for refractory in dumbit .In Ingot casting bottom pouring. casting powder hang
in mold and cover powder and anti pipping powder use to fill cavity because when metal
solidify some space empty remaining then these powder are exothermic burn and
produce heat and cavity filled. Through slight ladle gate control the flow of molten
metal.
Mold
Drum bit
Trumped tube
Funnel
Runner bricks

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CONTINUOUSCASTING:
Continuous casting, also called strand casting, is the process whereby molten metal is
solidified into a "semi-finished" billet, bloom, or slab for subsequent rolling in the finishing
mills. Prior to the introduction of continuous casting in the 1950s
 "Continuous casting" has evolved to achieve improved yield, quality, and productivity
and cost efficiency. It allows lower-cost production of metal sections with better
quality, due to the inherently lower costs of continuous.
PURPOSE:
1. Making billets and bloom from molten metal for other industries.
2. Molten metal solidified into semi-finished billets bloom for rolling and forging in
downstream shop.
PARAMETER:
There are three main parameters are:
1. Casting temperature.
2. Casting speed.
3. Cooling system.
PLANT CAPABILITY:
 Three main departments of Continuous casting area:
1. Tundish area.
2. Casting area.
3. Runout area.

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 Tundish area purpose:
1. Act as a buffer between ladle and mold.
2. Flow rate control.
3. Act as a reservoir
4. Multiple stream supply easily.
5. Inclusion flotation.
 6 ton tundish capacity.
 Secondary cooling have 3 zones with different length but total length 6m.
1. Zone 1 (0.3 m)
2. Zone 2(2.7)
3. Zone 3(3m)
 Parabolic plant of continuous casting.
 Metallurgical length from mold to where molten metal freeze approx. 9mm.
 Copper Molds used in continuous casting.
 Mold length 800mm.
 Diameter of mold 7mm.
 Temp of heat liquidize +50 degree centigrade.
 Billet mold size 110*110mm, 125*125mm, 150*150mm.
 Bloom size 230*230mm
TUNDHISH REFRACTORY:
 In tundish refractory consist of:
1. Insulation sheet.
2. Silica bricks.
3. Fire clay bricks.
4. High alumina bricks.
POWDERS:
 Casting Powder use in mold for three main purpose:
1. Remove contact with air.
2. Inclusion.
3. As a lubricant.
 Covering powder use in tundish for three main purpose:
1. Temperature drop.
2. Remove contact with Environment.
3. Inclusion not come.

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PROCESSING:
The main processes at Continuous casting:
1. First drying tundish and remove moisture and pre heat tundish at 1200 degree
centigrade for 90 min before ladle come.
2. Then place shroud at bottom of ladle.
3. Then molten metal flow from shroud to tundish and shroud submerged in
tundish this is called submerged entry shroud (SES).
4. Then control flow from slight gate and stopper system.
5. Use cating and covering powder.
6. Then molten metal flow in copper mold and dummy bar pulled molten metal
7. When molten metal come from mold through dummy bar water and gas shower
cooled outer surface of molten metal.
8. Further molten metal cooled in three cooling zones.
9. Billet or bullet cut accurate size through shearing machine.
10. Then store and leave for proper cooling.
DEFECTS:
There are two types of inspection to check defects:
1. Online inspection.
2. Final inspection.
Final inspection further divided in two sub division:
1. Surface inspection.
2. Internal inspection.
SURFACE INSPECTION:
 There are following defects which shown in surface inspection:
1. Pin hole
2. Crack
3. Commodity
4. Bulging
5. Depression.
INTERNAL INSPECTION:
 There are few defect which shown in internal surface:
1. Macro etching.
2. Blow hole.

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BLOMMING AND SLABBING MILL (N-SHOP)
 Every shop have some inputs and outputs.
INPUTS:
1. Flat ingot.
2. Square-ingot.
3. Cast slab (Import) (M.s material).
4. Bloom (SQ-230*230mm).
5. Billet (SQ-150mm).
OUTPUTS:
1. Plate (10mm to 80mm thickness).
2. Blooms (SQ-230*230mm), these blooms also called rolled bloom.
3. Plate (10mm to 80mm) (M.s material).
4. Round bar & billets (angle 110mm, 130mm) (SQ-100mm).
5. Gothic bar (SQ-76mm).
PLANT CAPABILITIES:
1. Re-heating furnaces use.
2. 2-HI Reversible mill
3. Furnace temperature 1250degree centigrade.
4. 9ton/hr. capacity of furnace.
5. Plate leveler.
6. 1000KV nozzle.
7. Pressure (air and water) =145kg/cm2.
8. Diameter of roller=820mm.
9. Roll length=1800mm.
10. Max plate width pass through roller 1500mm.
11. Soaking time 8hr.
PROCESS OF PLATE PREPARATION:
1. First cast slab heated in re-hearing furnace.
2. Then slab pass through furnace three zone:
.Top zone (pre heating zone) (S.T=1240degree centigrade).
.Bottom (heating zone) (S.T=1220 degree centigrade).
.soaking (temp hold and uniform heat in all part) (S.T=1280 degree centigrade)

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3. After soaking then slab rolled in 2HI reversible mill but before starting rolling de-
scaling.
4. Then through rolling process plate make and roll up and down through the
adjustment of dialer.
5. Then hot shearing machine cuts plates end cuts
6. Then plate pass through leveler to straight the plate.
INSPECTION:
1. Online inspection (100%).
2. Final inspection (100% and sometimes 50% or 70%).
FINAL INSPECTION further divided in two sub division:
1. Visual
2. Dimensional.
 In both visual and dimension inspection NON- DESTRUCTIVE TEST (NDT).
INSPECTION INSTRUMENT:
1. Vernier caliper.
2. Micrometer.
3. Hot plate measuring gauge.
4. Ultrasonic thickness gauge.
DEFECTS:
Every material have different defect in which some defect shown below:
PLATE:
1. Pitting.
2. Cracks.
3. Edge cracks
4. Waviness.
ROUND BAR AND BILLETS:
1. Seam.
2. Folding.
3. Cracks.
4. Fin.

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BLOOM:
1. Folding
2. Cracks.
GAUTHIC BAR:
1. Cracks.
2. Seam.
BAR ROLLING MILL (Q-SHOP):
PURPOSE:
1. Reduction of diameter.
2. Increase length.
3. To remove casting structure because casting structure
weak in strength.
INPUT:
Input of bar rolling shop “billet (110,125,150)”.
OUTPUT:
1. Round bar (18mm to 80mm).
2. Deform bar.
3. Flat bar (SUP9, 5140).
PLANT CAPABILITIES:
1. Entry and delivery guide box and guide.
2. One Rough mill
3. Cast steel rolls for rough mill
4. Five Finish limit/stand (F1 to F4 3 rolls, at F5 2 rolls.)
5. Guide material cast iron.
6. Finish mill roll material cast iron.
7. One delivery guide.
8. Cooling bed.
9. Hot shearing machine
10. Flying shearing machine.

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PROCESS FOR MAKING FLAT BAR:
1. First billet heat in re heating furnace.
2. Then after heating and soaking material pass seven times through rough mill
roller, in rough mill 50% reduction thus we use cast steel rolls, in rough mill 3
roller top and bottom roller move clockwise direction and middle roller move in
anticlockwise direction, continuous water showering to cooling roller inside and
outside.
3. Then divided piece in 2 equal length through hot shearing machine.
4. Then material pass through finish mill roller and then at F5 our required
dimension guides through F5 roll pass, in finish mill roller cooled through outside
water showering.
5. Through delivery guide material forward to cooling bed.
6. Then cut in three equal parts through flying shearing machine.
INSPECTION:
Inspection process same as N-SHOP.
DEFECTS:
Every material have different defect in which some defect shown below:
1. ROUND BAR:
Crack, rolled out, Fin, Guide mark, Size variation (under/over), Seam,
Folding/lamination, Ovality.
2. DEFORM BAR:
Bending, Size variation (under/over), DE shaping.
3. FLAT BAR:
Roll mark/pass mark, size variation (under/over), guide mark, deep scratches, bending,
twisting.

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FORGING SHOP:
Forging is a manufacturing process involving the shaping
of metal using localized compressive forces. The forging
process is superior to casting in that the parts formed have
denser microstructures, more defined grain patterns, and less
porosity, making such parts much stronger than a casting.
TYPES OF FORGING SHOP:
1. R1 (Die forging).
2. R3 (press forging).
3. P2 (Long forging machine).
TYPES OF FORRGING EQUIPMENT:
1. Hammer.
2. Press.
TYPES OF FORGING:
1. Open die forging.
2. Closed die forging.
R1 SHOP (DIE FORGING):
INPUTS:
1. Round bars (dia38mm,
60mm).
2. Flat.
3. Square.
OUTPUT:
1. Gear blank
2. dummy bars
3. Round bars (12mm to 50mm).
4. Square (12 to 50mm).
5. Crown wheel.
6. Chisel.

24 | P A G E
PLANT CAPABILITY:
1. Four re-heating furnaces.
2. Band saw machine.
3. Peersing and trimming machine.
4. Counter blow hammer.
5. Heat treatment furnace (normalizing).
6. Hammer forging machines.
7. Open die forging machines.
8. Closed die forging machine.
9. Furnace temp 1200 degree centigrade.
10. 350kg/batch capacity of furnace.
PROCESSES:
 CLOSED DIE FORGING:
1. Feed stock cutting ,here some allowances
like
.additional weight cutting
.burning allowance
2. Feed stock charged in furnace and heating
one hour and 90 mins.
3. 500kg loading capacity of hammer in
hammer forging for preform.
4. Die forging hammer pressure 3.15ton
5. Flash remove though trimming
6. Inside hold making through peersing.
7. Heat treatment (normalizing process)
8. Short blasting.
 OPEN DIE FORGING:
1. Feed stock cutting through band saw
machine.
2. Feed stock charged in furnace.
3. Hammer forging.
4. Now forging only through hammer
without die, only die use in round bar.
5. Heat treatment(annealing)
6. Short blasting.

25 | P A G E
R3 SHOP (PRESS FORGING):
INPUT:
1. Ingot casting(SQ700, SQ1250, OCT
2000,OCT3000, OCT5000,
OCT8000,OCT12000)
2. ESR material (dia 400mm, 600mm, 750mm).
OUTPUT:
1. Round bars(dia min 200mm, max 500mm)
2. SQ block /bars (max450mm)
3. Rectangular (min 150mm, max 400mm)
4. Forging shapes:
.disk (max dia 200mm)
.rectangular block.
.ring (min dia 1500mm and max dia 2000mm) (length 300mm)
PLANT CAPABIITIES:
1. BAND SAW MACHINE:
. Double column band saw machine.
. model =UMSO 2000HF full automatic.
.max height= 2000mm
. max width=2200mm
. Products: rings, round bar, rectangular block.
. HSS (high speed steel) blade used.
2. Furnace capacity 40Mton
3. Soaking time= 1mm/min.
4. Manipulator =15ton capacity
5. Forging press machine 1700ton capacity.
6. 2Mton furnace.
7. 4Mton furnace.
8. Manipulator use to charge in furnace capacity 3 ton.
9. Water (capacity 30000litre) and oil tank (capacity 50000litres) for quenching
10. Head electrical furnace 1500kg capacity

26 | P A G E
P2 SHOP (LONG FORGING
MACHINE):
INPUT:
1. Bloom ( 230*230mm)
2. Billet (110,125,150mm)
3. Oct 230.
OUTPUT:
1. Round bar (dia50mm)
2. SQ (50*50mm)
3. Rectangular (30*50mm)
PROCESS:
1. Material heat in walking re-furnace (3 zones ) (6 ton per hour)
2. After furnace material placed in Long furnace machine.
3. Two chuck head in LFM and four hammer, material fixed in chuck head A.
4. Hammer angle changed according to our material.
5. Hard material pass 10mm in one time.
6. Soft material pass 30mm in one time.
7. After forging in LFM then heat treatment process.
8. Two heat treatment furnaces:
 Austeria:
 15ton capacity.
 14burner.
 Gas fired.
 PLC control.
 China :
 10ton capacity.
 6burner.
 Gas fired.
 Auto.
9. Annealing, normalizing quenching, tempering every process in these two furnaces.
10. Then straighten material through straighten machine
11. Then finish by machining and peeling process on material.

27 | P A G E
FORGING DEFECTS:
1. Crack
2. Seam
3. Forging mark
4. Folding
INSPECTION:
1. ONLINE INSPECTION:
 Reduction ratio 6 for I.C and 8 for C.C.
 Forging start temp 1200 degree centigrade
 Optical pyrometer
 Soaking time check (1hr=25mm)
 Forging finish temp=850 degree centigrade.
 Dimensional inspection
2. FINAL INSPECTION:
 Dimensional inspection.
 Visual inspection.
 Ultrasonic test.
 NDT (non-destructive test)
QAD LAB:
There are two types of testing:
1. Destructive testing
2. Non-destructive testing
DESTRUCTIVE TESTING:
In destructive testing, or (Destructive Physical Analysis DPA) tests are carried out to the
specimen's failure, in order to understand a specimen's structural performance or material
behavior under different loads. These tests are generally much easier to carry out, yield more
information, and are easier to interpret than nondestructive testing
There are two types of destructive testing:
1. Analytical testing.
2. Mechanical testing.

28 | P A G E
ANALYTICAL TESTING:
There are various type of analytical testing:
1. Metallography
2. Spectro lab.
3. Rapid analysis.
4. Wet chemical test
5. XRF (X-ray fluorescence).
 METALLOGRAPHY:
Metallography or metallographic analysis is the study of a materials microstructure and
can be considered an integral branch for metallurgical testing or for the field of
materials science.
There are various steps in metallography:
 SAMPLING:
Cut the sample through micro cutting machine.
 MOUNTING:
Mounting through mounting machine using plastic material like bakelite,
mounting machine temperature max 180 to 200 degree centigrade. Mounting
machine pressure 150kg.
 GRINDING:
Grinding through rough and fine grinding paper, grinding starts with
rough paper then grade of grinding paper increase unless the surface becomes
flat.
 POLISHING:
After grinding specimen is polished through polished clothes and mirror
like surface is obtained.
 ETCHING:
The purpose of etching is to make visible the many structural characteristics
of the metal or alloy. The selection of appropriate etching reagent is determined by the
metal or alloy and specific structure desired for viewing.
 Then optical microscope is used to see the structure, in PSM two microscope is
used, the magnification of microscope is 50x and 100x

29 | P A G E
 SPECTRO LAB:
In spectro lab online testing of material composition, all M-shop sample check in spectro
lab, first sample collect from M-shop then cutting the sample and then sample polished
then check the composition of sample through OES (Optical Emission Spectrometer).
OPTICAL EMISSION SPECTROMETER:
In the optical emission spectroscopy (OES)
technology, atoms in a sample are excited by energy
that comes from a spark formed between sample
and electrode. The energy of the spark causes the
electrons in the sample to emit light which is
converted into a spectral pattern. By measuring the
intensity of the peaks in this spectrum, OES analyzers
identify the quality and quantity of the material
composition with uncompromising accuracy. They
are ideal for high performance analysis of alloyed
and trace elements, nitrogen analysis in duplex steel.
In PSM tungsten electrode is used, argon purging is
used, 22 detector for 22 elements, 22 focus, and 22
separator.
 RAPID ANALYZER:
In rapid analyzer quick analysis of composition of material mostly oxygen, nitrogen, carbon,
sulfur.
CS444 machine:
 CS444 machine is used to analyze the carbon and sulfur, analyze extra high carbon (6%)
and extra low carbon (0.001) and sulfur (0.35%).
 First material weight (1gm)
 3 cell (1.High carbon, 2. Low carbon, 3.sulfur).
 2 parts (1.induction furnace, 2.detector part).
 Ceramic crucible used and tungsten powder used in crucible.
 Sample use in chips form (chips cut through lathe or drill machine).
 18 Mhertz induction frequency.
 Pure oxygen is used to remove other gases.
 Chemical reagent used as filter (magnesium per chloride, sodium hydroxide).
 Minimum 3 readings collect.

30 | P A G E
OXYEGEN NITROGEN HYDROGEN MACHINE:
 ONH2000 machine used in analyze nitrogen, oxygen, hydrogen.
 Impulse furnace is used.
 Graphite crucible is used.
 Lower and upper electrode
 Crucible material placed between upper and lower electrode.
 Current pass through electrode then graphite crucible due to resistance heat up and
melt the sample.
 Helium and argon purging, helium purging for “ON”, argon purging for OH.
 O and N result upto 2000PPM (part per million)
 H result upto 1000PPM (part per million).
 To remove moisture NaOH and magnesium per chloride.
 Schutz reagent us to concert CO to CO2.
 IR cell is used to detect Oxygen, and TC cell is used to detect Nitrogen and Hydrogen.
 800A current is used.
 Temperature 3000 degree centigrade
 Quartz wool is used to remove dust.
WET CHEMICAL TEST:
In wet chemical test analyze chemically the composition of metals and alloy and non-metals.
RAW MATERIAL OF FERRO ALLOY: Ferro silicon, ferro magnese, ferro nickel and ferro
vanadium etc
Analyzer: Si, Mn , P, Ni, Cd, V, Ti, W etc
RAW MATERIAL OF FERROUS: cast iron, pig iron, high carbon steel, low carbon steel,
medium carbon steel, stainless steel, tool steel.
RAW MATERIAL OF NON FERROUS: brass, bronze, tin, nickel chrome.
INGREDENT:Cr,Pb,Sn,Al,Fe,Cd,C,Ca
RAW MATERIAL OF REFRACTORY:
 Fire clay
 Dolomite.
 Fluorspar.
 Chrome magnese.

31 | P A G E
INGREDENTS: SiO2, Al2O3, CaO , P2O5,MnO2, ZrO2 MgO2.
WATER ANALYSIS: Total hardness, PH, TH, Tds, S.S.
CHEMICAL ANALYSIS STANDARD:
 ASTM (mostly follow)
 British
 ISO
 Japanese
 Chinese
LAB CAPABILITIES:
 2oven for dryer.
 PH meter
 Shaker balance
 Run operator.
 Muffer furnace
 Max temp 1100 degree centigrade.
 S.V 1000 degree centigrade P.V=998 degree centigrade.
 Bulk desity operator.
 Spectro photo meter
 U.V spectroscopy.
 Lower range 0.1 to 2PPM.
 Si, Mn, Cr, Ni, P analyze.
 ATOMIC ABSORTION SPECTROMETER
 Use lamp of that element which we want to analyze.
 Hollow cathode lamp used.
 Four lamp used but analyze one element at a time.
 Minimum current 10A.
 One Burner is used.
XRF (X-RAY FLUORESCENCE SPECTROSCOPY):
X-ray fluorescence (XRF) is the emission of characteristic
fluorescent X-rays from a material that has been excited by
bombarding with high-energy X-rays. The phenomenon is
widely used for elemental analysis and chemical analysis,
particularly in the investigation of metals, glass, ceramics.

32 | P A G E
The wavelength obtained is given by the Bragg Equation:
XRF (A PHYSICAL DESCRIPTION):
Step 1: When an X-ray photon of sufficient energy strikes an atom, it dislodges an electron from
one of its inner shells (K in this case)
Step 2a: The atom fills the vacant K shell with an electron from the L shell; as the electron drops
to the lower energy state, excess energy is released as a Kα X-ray
Step 2b: The atom fills the vacant K shell with an electron from the M shell; as the electron
drops to the lower energy state, excess energy is released as a Kβ X-ray
MECHANICAL TESTING:
There are five basic test :
1. Hardness.
2. Ultimate tensile test
3. Toughness.
4. Ductility
5. Compressive.
HARDNESS TEST:
1. Brinell hardness test.
 Tungsten carbide ball use in intender
 Force 3000kg
 We use brinell when sample width double the sheet.
 We hold 10 to 15 sec to resis elasticity.
2. Rockwell hardness test.
 Start minor force then HRB 100kg ,HRC 150kg force
 HRB=ball intender use, HRC diamond cone intender use.
 Size limitation in brinell we use Rockwell because in brinell thin sample not test.

33 | P A G E
ULTIMATE TENSILE MACHINE:
Tensile strength is defined as a stress, which is measured as force per
unit area. ultimate strength, is the maximum stress that a material can
withstand while being stretched or pulled before failing or breaking
UTS machine used to measure:
 Tensile strength
 Yield strength
 Breaking and fracture point
 Ductility
 Compressive.
 % elongation.
BASIC PRINCIPLE:
 Strain stress curve
 Load displacement curve
TWO TYPES OF TENSILE MACHINE:
 Instron :
 60ton force
 Engliand based
 Wedge type Gripping system
 Hydraulic
 PAEKYUNG TECH:
 100ton force
 Korean based
 Two types of specimen:
 Round
 flat
TOUGHNESS: (charpy impact test)
In materials science and metallurgy, toughness is the
ability of a material to absorb energy and plastically
deform without fracturing. One definition of
material toughness is the amount of energy per unit
volume that a material can absorb before rupturing.

34 | P A G E
TYPES OF NOTCHES:
 V notch (angle 45 degree , depth 2mm, 0.255mm +_ tolerance )
 U notch (5mm radius, 5 mm depth)
 Hammer lift angle 139 degree centigrade
 Sample shape 10*10mm length 25mm
 Energy 500 Joule.
 Striker radius 2mm, 8mm
 Cos alpha(angle) when hammer lift and move freely
 Cos beta (angle) when sample used.
 Toughness= cos alpha – cos beta *hammer height, hammer length.
NON – DESTRUCTIVE TEST:
In which sample not damage or destroy.
 ULTRASONIC
 MPI (Magnetic particle inspection)
 DPT (dye penetrating test)
ULTRA SONIC TEST:
The use of ultrasonic waves to evaluate the
condition of a material. • Anomalies absorb
or deflect the sound waves, which are then
detected as changes in the waves. – holes,
delaminations, voids – damage, de bonds –
resin-rich, -poor areas
MAGNETIC PARTICLE INSPECTION (MPI):
The part is magnetized. Finely milled iron
particles coated with a dye pigment are
then applied to the specimen. These
particles are attracted to magnetic flux
leakage fields and will cluster to form an
indication directly over the discontinuity.
This indication can be visually detected
under proper lighting conditions.

35 | P A G E
DYE PENETRATING TEST (DPT):
Dye penetrant inspection (DPI), also called liquid
penetrant inspection (LPI) or penetrant testing (PT), is a
widely applied and low-cost inspection method used to
locate surface-breaking defects in all non-porous
materials (metals, plastics, or ceramics). The penetrant
may be applied to all non-ferrous materials and ferrous
materials, although for ferrous components magnetic-
particle inspection is often used instead for its subsurface detection capability. LPI is used to
detect casting, forging and welding surface defects such as hairline cracks, surface porosity,
leaks in new products, and fatigue cracks on in-service components

PSM INTERNSHIP 2

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