2. Pre- Treatment process to be performed
before liquid Coating or Power Coating
Why PT
To Clean and remove impurities .
Objective:
Remove impurities such as Oil,
Scale, soil, Grease, metal filings/
burr etc.
Converting the surface for
optimum adhesion of coating.
Properties:
Adhesion, impact etc.
Resistance of corrosion , humidity
etc.
Two Method
Mechanical and Chemical PT
Mechanical treatment: Emery
Sanding, Wire Brushing, Grit/Shot
Blasting.
Chemical Treatment: Remove
impurities, and Enhancing
surface.
Thumb Rule:
Mechanical Pre-treatment: hot
rolled steel and casting.
Chemical PT : CR & HR Pickled
m/t.
Chemical PT
Chemical PT: enrichment generated
by adding a thin layer of Phosphate
on MS Surface.
7 Tank Process:
Degreasing
Water rinse
Derusting
Water rinse
Phosphate
Water rinse
Passivation
3. Pre- Treatment process to be performed
before liquid Coating or Power Coating
Concentration of Reaction
Bath.
Water Quality.
pH of Water.
Conductivity of Water.
Temperature of Bath.
Dip Timings.
Improper Degreasing.
Water break phenomenon is
observed on the component.
Degreasing bath
concentration, temperature
lower to specification.
Higher oil content in bath.
This will lead to poor phosphating,
adhesion failures, delamination
etc. resulting easily corrosion.
Coating appearance: Uniform
Grey compact fine coating
Coating WT: 2.0-3.5 gm /m2.
Crystal Size: <10 µm.
Crystal Shape: Columnar
Crystalls.
Phosphating Monitor Pt Issues/ Problem PT
4. Issues/ Problem PT
Yellow/ Rusty Phosphate after
drying
Rusted surface, inadequate derusting
Ineffective surface condition.
Phosphate bath- higher free acid,
lower total acid.
Coating over rusted surface would lead to
early corrosion
Powdery phosphate coating
White powdery phosphate coating is
observed.
Inadequate phosphate bath, removal
of sludge not proper.
Higher bath temperature.
This would result in adhesion failure
5. Issues/ Problem PT
Incomplete phosphate coating
Improper degreasing
Improper surface condition.
Drying in a inter- stage zone
This would lead in adhesion failure and
corrosion.
Blisters
It observed on painted article when
stored or during water immersion test
or humid condition.
The water soluble salt on substrate
would attract humidity and dissolve
the salt solution, will attract more
water to osmosis to form Blisters.
This lead to early corrosion
6. Why Galvanizing
Why Zinc
Application
Monopole
TLT
Cable Tray
Solar Panel
Bridges
Crash Barrier
Batch Hot Dip Galvanizing of Steel
by Rhishikwsh Mane & Deepak Deshpande
7. Batch Hot Dip Galvanizing of Steel
by Rhishikwsh Mane & Deepak Deshpande
Degressing
Obj- to remove Oil & Dirt
Parameter:
Alkali Conc. –E.g KOH, NaOH,
• Builder- good soiling carrier &
complex Builder- dispersion of
pigment.
• Surfactants
HIGH Ph value
Temperature- 80 C
Soil load
Rinsing
Obj- To remove Alkali carryover
or acid & free Fe residue.
Parameter- pH- 6.5 to 7.5 , Temp-
80 C.
Use- hot water, two tanks of
cascade, Agitation-in case of
single tank.
Picking
Obj- To remove scales on steel.
HCL/H2SO2- HCL is use more
effective.
Process Parameter- Acid Conc.( 8
to 10%), Fe conc., Temperature,
Inhibitor Conc.,Agitation.
Inhibitor:- use te reduce Fe
generation & acid utilization.
Inspection in post pickling:- check
dry spot, causes of coated in
angled products.
PROCESS/ STEPS
8. Fluxing
Obj- remove flash scales,
protective film of flux to prevent
re-oxidation.
Flux conc.- 200-300 gm/lit.
Flux temp-60-80 deg C.
pH - 4-5
Flux ratio- ZnCl2 to NH4Cl- 0.85 for
wet galv.
Fe in bath- 5 gm/lit.
Flux additive- Detergents.
Drying
Use hot air to dry the flux. Temp-80 deg
C.
Benefit:
• Less Splashing of Zinc.
• Reduce ash formation
• Higher productivity.
• Distortion decreases.
• Decreases hydrogen embrittlement
in high strength steels.
Galvanizing
Obj- to coat the Zn
Parameter:
• Bath temp
• Bath Chemistry
• Dipping time
• Withdrawal speed.
• Angels of dipping and
Withdrawal.
Batch Hot Dip Galvanizing of Steel
by Rhishikwsh Mane & Deepak Deshpande
9. Galvanizing : Process Parameter
Bath Temp
Temp- 450 deg C.
Temp range - 480 – 530 deg C
Increase Temp- inc. in fluidity of
Zn, Fe in bath, this cause Dross
generation.
Recommendation:
• Re-active steel- temp 440-450
C, coating thk low & improve
appearance.
• Less re-active steel – temp 450-
460 C inc coating thk.
• Bath Chemistry
Al:
• 0.002 to 0.005% - improve shine
& dec detrimental Fe in bath.
• It inc coating adherence &
improve corrosion rate.
• Defect- Black Spot.
Nickel:
• 0.05 tp 0.06%, - improve shine &
smoothness of coating
• Improve fluidity & Zn
consumption 5-15%
• Defect- reduce grey patches.
• Bath Chemistry
Lead & Bismuth:
• Pb : to improve fluidity- 0.6-0.8%
• Avoid eating of welded kettle in
Znliquid.
• Pb is replace by Bi due to RONS norm.
• Bi below 0.1%. To maintain bath fluidity.
Fe: 0.1%
• High Fe – Dull part
• Low Fe – Shiny part
• It Inc. coating formation rate, mainly
alloys layer which form grey patches.
Batch Hot Dip Galvanizing of Steel
by Rhishikwsh Mane & Deepak Deshpande
10. Process – Galv.
Withdrawal Process-
• higher withdrawal rate higher
coating.
• Alloys layer not depend on
withdrawal rate. But on dipping
time.
• Withdrawal Speed VS Coating
Wt-- 1.5m/min dipping time.
Quenching; after Galv. & reduce in
Grey patches
Post Treatment (Passivation) -
prevent from white rust. Conc- 0.1
to 1.5% . Temp- 70deg C. (higher
causes green- yellow patches).
Defects
1. Black Spot / Bare Spot.
2. Zinc Flow Mark.
3. Ash Lump & Streaks.
4. Dross Pimples
5. Coating Peel Off.
6. Grey coating
7. Storage strains.
Effect Of Steel
Chemistry
Silicon- Sandelin Curve- 0.15-0.25%
Phosphorous
Sulphur- > 0.1%
Si Eq- Si + 2.5 X P> 0.09%
Coating Thk :-
1. Low- 45-75µm – Class A –
Si<0.04%
2. Middle - 85-130µm- Class B – Si =
0.15-0.25%
3. High- >150µm- Class D –
Si>0.25%
Batch Hot Dip Galvanizing of Steel
by Rhishikwsh Mane & Deepak Deshpande
11. The Path To Achievement
By Prof. Amol Muley
I Shall now begin the discipline of yoga.
Yoga is the overcoming of the vruttis
(attitudes) that the Chitta (Subconsious) goes
through.
You can attain your ‘Swarp’ by overcoming
the Vruttis (attitudes/ disposition).
Otherwise the person becomes just like his
attitude / disposition.
Vruttis- 5 types person
1) Pramaan 2) Viparyaya
3) Vikalpa 4)eedra
5) Smruti
Facts myths- when a person starts believing
that his gold real knowledge when in fact he
has only begun the journey.
Lack of action. Lack of initiative & lack of
proactive step towards ones goals in nidra.
‘Smruti’ means memory
Proactive of all thing that take you closer to
yours goals & the ability to keep away from
anything that defers you from your goals .
Abhyaass Strengthens your resolve.
Only abhyaas that is done respectfully & with
affection can become firm in your mind.
The state of disinterest in pleasure of the eyes
& ears.
When you start realizing the true form of the
existence, you begin experiencing a certain
disinterest in worldly pleasures.
When you rein in the vruttis that control your
1) Viitark 2) vichaar 3) anand 4) Asmita
Nirbeej Samaadhi
Videha- Experiencing a body-less State,
Prakrutilay- One with nature
Shraddha : Belief in goals / in the Journey
Veerya – Enterprise
Smruti – Memory
Samaadhi – The Ability to Focus
Pradnyaa – The intellect needed.
Greater the practice, higher the speed of
achievement.
12. What is PEB?
It is a prefabricated
structure of a building
designed over a structural
concept of primary and
secondary member and
so on.
Application:
• Commercial office
• Indoors & energy
• Metro & Railway Station
• Mall & City centres
• Ind. & processing plant
Advantage:
• Economical & Robust
Const.
• Fast Constr. Time
• Low maintenance cost
• Ease of future
expansion
Steel For Pre-engineering Building(PEB)
Segment And Evolving Market Trends
by Abhishek P. Singh + 1
13. Steel Grade HR
Plate for PEB
• ASTM A572 Gr50 (Type 1) :
HG62, HG67,HG69, HG75 ….
• ASTM A572 Gr50 (Type 2):
HH18, HH17 ……
• IS2062E250BR : HR05, HR20,
HR19, HU13, HU14, HO67,
HU12…
• IS2060EE350BR, C : HT03, HR21,
HR22, HR29
• IS2062E450BR / ASTM S572Gr65:
HR81, HT82, HJ67, HJ68..
HR Plate Processing
& TPR
• Process:- cutting- Detail- SAW
PHI- Pitment-Manual Welding-
Clearing- Surface Finish- Ship.
• Gas torch Cutting- Tag Welding-
Submerged- Arc Welding-
Piercing-Short Blasting-Quality
Check & Dispatch.
• Critical parameter for steel:
• Flatness after Plasma/ gas torch
cut
• Dimension, thickness Tol. Y.S,
CEq as per IS std for welding.
Tech Process
Requirement
Critical Shape related parameter:
• Cross Bow: 3mm/meter (i.e 6mm
max for 2m width plate).
• Camber: 1 mm/m in mill edge
supplied sheets.
• Flatness: 10mm max over 1.0m
length (in Slit- Bow test).
• Longitudinal Bow: 10mm/meter.
• Out of Squareness: 1mm max per
100mm width.
• After gas torch cutting/Plasma
cutting: Bow after cutting is critical.
Steel For Pre-engineering Building(PEB)
Segment And Evolving Market Trends
by Abhishek P. Singh + 1
14. Critical Quality
Check for SPC
• Slit bow test ( to check flatness
/ bow in sheets).
• Leveller calibration from time
to time to ensure processing
minimal residual Stress.
• Crown kill roll in CTL m/c.
• Packing ( min 700mm dist.
Between wooden dunnages).
Critical Customer
Req.
• Thickness: -0.3mm & for thicker
plate >12 mm +0.3mm.
• Cross Bow: 6mm max. & length
10 mm max after plasma cutting.
• Chamber: 1.5mm/m in mill edge
sheets
• Min. residual stress after levelling.
• Defect:
• Cross Bow: Curve In The Width
Direction.
• Warpage: req. 75% plasticity in
CTL leveller
CASE STUDY
Poor Edge Condition After Cutting:
• Clearance = S/T
• S = Dist. Bet. Cutting edge.
• T = M/T thickness
• Clearance: 10-15% of m/t
thickness.
Steel For Pre-engineering Building(PEB)
Segment And Evolving Market Trends
by Abhishek P. Singh + 1
15. Engaging with you Spouse
by Sriram Iyar
Three Cs in a relationship: Care, Communication, Compatibility
9 Mantras
Leaning mind-sets
Improving communication
Becoming independent / interdependent
Labour roles / rules
Financials
Working on common ground / interests
Having little ‘my space’
Minimizing ‘silent zone’ times
Agreeing to disagree
16. Executive Presence and personal Mastery
by Amit Lala
Power of seven
Confidence
Brand – you
Influential patterns
Authenticity
Driven from within
Rapport
Humour
Quadrant
Activities towards goals
Distracted
Mastery
Decay
Development
Converting Q3 to Q4
Challenge Vs Skill
Monitored thr. Traction maps
Ingredient of Happiness
Physiology
Focus
Language
The iceberg model
-ve thought
+ve thought
17. Art of negotiation
by Pradeep V
Objectives
How to plan Negotiation
Diff. between Bargaining &
Negotiation
Bargaining – Costing- only price-
Win
Negotiation – Win-Win relationship
SKILL
Effective Speaking
Effective Listening
Sense of Humour
A positive Attitude
Respect
Self confidence
Persistence
Emotional intelligence
Patience
Creativity
Plan of Negotiation
Goals
Trade off
Alternative
Relationship
Expectation
Consequences
Power
Solution
18. Self Love
by vasundhara Talware’s
Thought lead to Feeling
Two type:- RAGA AND DWESHA
SWADHARMA- duty to your self
YOGA
Self Love = Selfish
Known yours Values
Saying No
Meditate
19. Communicate with your Money
by Priyanka acharya
I-R-R-R
• Life Style Inflation
• Spender
• Saver
• Investor
• Risk- asset Allocation :- Stock,
Bond, Real Estate, Cash.
• A=P*(1+R/100)N
• N= no of yrs
• 3 pillar financial lie
• Growth
• Preservation
• Security
• Investment:- types
20. TLS Technique
TOC- Global Optimization
Lean- Waste Reduction
Six Sigma- Reduce Variation
Problem:
Higher Cost
Poor Quality
Delayed Delivery
8 Type Waste
(DOWNTIME)
Defect
Over Production
Waiting
Unused Talent
Transportation
Inventory
Motion
Extra Processing
VSM Key Metrics
TAKT time (Demand rate)
Cycle time (Production Rate)
Change over time
Up time
First Pass Yield
Inventory Turnover
Lead time
To identify the process problem that makes you products costlier than your
competitors.
Value Stream Mapping For Cost Competitiveness
by A N Singh
21. 22 Steps To Develop Improvement Plan
1. Form a VSM Team
2. Draw a Process map
3. Collect Process Information
4. Collect Process Date
5. Customer Information- Demand
6. Draw Process Boxes
7. Draw Data Boxes
8. Collect inventory Data
9. Collect Supplier Data
10. Calculate Lead Time & draw
information flow
11. Draw current Stata VSM
12. Cal. Demand Rate—TAKT time
13. Current State Problem- identification
14. TAKT time & Cycle time Analysis
15. Problem identification
16. set improvement target
17. Cycle time improvement
18. Future state Pull System
19. Create Super Market
20. Future State VSM
21. Identify the GAP
22. VS improvement Plan- Kaizen Project, JIT &
Kanban System
Improvement
Project – Tools used
Kaizen project
JIT
Kaban System- Pull
A visual representation of every process in the Material and Information Flow
of a product’s path for Customer to Supplier.
Value Stream Mapping For Cost Competitiveness
by A N Singh
22. Steel for Automotive Applications
Standard – different international VS Indian
STD
Formability – no fracture/ wrinkles & no spring
back (Deep- Drawing, Stretching, Bending,
Stretch- Flanging
GI Vs GA - Corrosion Resistance, Stamping,
Weld ability, Painting
TATA ASTRUM
FLAT product application/ grades- long / short
member, Automotive wheels, Brakes, Truck
body, Tube & Pipe., etc., medium carbon-
C30 etc.
Changing trend:
Perforation Corrosion- CRCA TO GA/GI M/T in
car body.
Load Body Development=D Grade>HSLA340,
Gr A>E34/SPFH590, HSS M/T
Tripper Body = Gr A, E350 TO HSS-
BSK46,HS700/800.
Long member of CV- BSK 46 TO HS800
BS4 to BS6 transition
Case Study:
Stretch Flange: Ca treated m/t-SAPH440
EDD M/T Cracking - R- bar MIN 1.65 req.
