MAKING OF MILD STEEL

Have you ever wondered how mild steel is made? Mild steel is an alloy created from iron and carbon, and it’s one of the most common materials used in manufacturing. It is strong, durable, and relatively inexpensive to produce. In this blog post, we will take a look at the process of making mild steel so that you can better understand what goes into creating this versatile material. The Process of Making Mild Steel: Making mild steel begins with a process called smelting. Smelting requires heat and a fuel source to break down the ore into its component parts. The ore used in making mild steel is typically iron ore which contains a high concentration of iron and varying amounts of other elements like silicon, sulphur, manganese, phosphorus, and oxygen. To make mild steel, these ingredients are heated in a furnace until they form molten metal, known as pig iron. Next comes the refining process, which removes impurities from the pig iron, such as carbon monoxide. This is done by blowing hot air through the melted metal, which causes oxygen to combine with the carbon monoxide molecules in order to create carbon dioxide; this process also raises the temperature of the metal to over 2000° F (1093°C). Once all impurities have been eliminated from the metal, it can be cooled and formed into shapes for use in construction or manufacturing projects. Finally, adding more carbon to the molten metal creates what is known as wrought iron or mild steel; this increases its strength and makes it more suitable for building structures that need additional support, such as bridges or large buildings. The amount of carbon added determines exactly how strong or hard the resulting material will be, so careful consideration must be taken when deciding how much should be added during this process. The process of making mild steel begins with the mining of iron ore. The iron ore is then crushed and screened to size. The crushed iron ore is then mixed with coke and limestone and placed in a blast furnace. The blast furnace heats the iron ore to a high temperature, causing it to react with the coke and limestone to form molten steel. The molten steel is then poured into molds to create various shapes and sizes of mild steel. Conclusion: Mild steel is an incredibly common material due to its strength and affordability. It has countless uses across many industries, including construction, automotive manufacturing, shipbuilding, toolmaking, and many others. By understanding how mild steel is made, you can better appreciate just what goes into creating this versatile material that plays such an important role in our everyday lives! Knowing more about its production can help you make informed decisions when selecting materials for your next project!

OUR INFRASTRUCTURE

01. RAW MATERIAL STOCKYARD
Inflow of raw material
02. STEEL MELTING SHOP
Sponge iron charging
03. STEEL MELTING SHOP
Hot liquid metal being made
06. CONTINUOUS CASTING MACHINE
Ready billets
05. QUALITY CONTROL ROOM AT CCM
Billets quality check
04. CONTINUOUS CASTING MACHINE
Casting into billets
07. ROLLING MILL
Materials being rolled
08. ROLLING MILL
Automatic cooling bed for best quality straight materials
09. ROLLING MILL
Cutting machine
12. QUALITY CONTROL CHEMICAL LAB
Checking of chemical composition of C, Mn, S, P, Si
11. QUALITY CONTROL PHYSICAL LAB
Finished goods quality check
10. ROLLING MILL
Straightening Machine
13. GERMAN GI UNIT
Checked & passed materials get transferred to Galvanized Unit
14. GERMAN GI UNIT
1st layer coating - materials get galvanized through German GI coating
15. GERMAN GI UNIT
2nd layer coating - materials get coated and becomes ‘passive’ i.e. less readily affected or corroded by the environment through passivation
18. BUNDLING UNIT
Bundling
17. QUALITY CONTROL LAB (GI UNIT)
Micron testing
Salt spray testing
16. GERMAN GI UNIT
3rd layer coating – materials get a transparent & translucent coat applied over the underlying material as a sealer through the top coating.
19. PACKAGING UNIT
Packaging
20. STOCKYARD
Finished goods
21. DISPATCH UNIT
Ready for loading and dispatch
23. DELIVERY
Doorstep delivery at dealer point
22. WEIGH UNIT
Weighing of the loaded truck

01. RAW MATERIAL STOCKYARD
Inflow of raw material
02. STEEL MELTING SHOP
Sponge iron charging
03. STEEL MELTING SHOP
Hot liquid metal being made
04. CONTINUOUS CASTING MACHINE
Casting into billets
05. QUALITY CONTROL ROOM AT CCM
Billets quality check
06. CONTINUOUS CASTING MACHINE
Ready billets
07. ROLLING MILL
Materials being rolled
08. ROLLING MILL
Automatic cooling bed for best quality straight materials
09. ROLLING MILL
Cutting machine
10. ROLLING MILL
Straightening Machine
11. QUALITY CONTROL PHYSICAL LAB
Finished goods quality check
12. QUALITY CONTROL CHEMICAL LAB
Checking of chemical composition of C, Mn, S, P, Si
13. GERMAN GI UNIT
Checked & passed materials get transferred to Galvanized Unit
14. GERMAN GI UNIT
1st layer coating - materials get galvanized through German GI coating
15. GERMAN GI UNIT
2nd layer coating - materials get coated and becomes ‘passive’ i.e. less readily affected or corroded by the environment through passivation
16. GERMAN GI UNIT
3rd layer coating – materials get a transparent & translucent coat applied over the underlying material as a sealer through the top coating.
17. QUALITY CONTROL LAB (GI UNIT)
Micron testing
Salt spray testing
18. BUNDLING UNIT
Bundling
19. PACKAGING UNIT
Packaging
20. STOCKYARD
Finished goods
21. DISPATCH UNIT
Ready for loading and dispatch
22. WEIGH UNIT
Weighing of the loaded truck
23. DELIVERY
Doorstep delivery at dealer point

German GI (Galvanised Iron) Process: Definition, How It Works & Applications

GI Coating is one finishing process that has applications in a wide range of Industries. This process improves parts' appearance and properties. Initially, metals can only be electroplated with other metals, but with the recent technological advancement, galvanised improving non-metals with this process is available too.

Besides, galvanised can combine the desirable properties of certain metals with other materials. These properties often include strength, abrasion, appearance, resistance, and electrical conductivity. Moreover, this process aims to boost or improve the material's properties. The material could be metals, plastic, or even wood.

What Is GI Coating?

GI Coating is a coating process that has been around since the early 19th century. Although there has been advancement in the technology used, the basic process remains the same.

There are four primary components of this process:

Anode: This is the positively charged electrode used in the circuit. The anode holds the metal used for the coating process.

Cathode: This is the negatively charged electrode used in the circuit. It holds the material you want to coat, also called the substrate.

Coating Solution: This is one of the most important metal finishing solutions. It serves as a catalyst facilitating the flow of electricity in the circuit. The coating solution usually contains copper sulphate and one or more metal salts.

Power Source: The power supply adds current to the circuit. The power source introduces electricity to the system when connected to the anode.

Advantages of GI Coating

Offers Substrate Material Protection: Protecting objects from corrosion and tarnishing is one of the major advantages. Furthermore, it also improves object shock protection and heat resistance.

Reduces friction: Electroplating objects minimizes the friction on metals when rubbed together. Hence, reducing scraping and heat generated. Moreover, less friction also translates to less wear and tear, allowing you to use objects for a long period.

Improving object properties: this process imbues objects with extra properties such as thickness, magnetism, and conductivity. This gives the process application producing electronics and other products that require materials with such proper.

Environmental Pollution: when not properly done, this process can produce hazardous waste that is detrimental to the environment. However, you can avoid this with proper waste management.

Expensive to set up: A complete setup for this process is quite expensive as you would have to get metals, chemicals, and other expensive equipment before it is up and running.

Takes time: Metal deposition occurs very slowly, which takes a lot of time. It even consumes more time when the material requires more than one layer.

SALT SPRAY TESTING MACHINE

What is the purpose of salt spray test?

A salt spray test is a corrosion testing method that uses high-saline environments to measure the corrosion resistance of products, paintings and coatings over extended periods.

How do you conduct a salt spray test?

Salt spray tests are conducted in a closed testing chamber. A salt water solution is applied to a sample via a spray nozzle. This dense salt water fog is used to imitate a corrosive experiment. After a period of time, which is dependent on the corrosion resistance of a product, the appearance of oxides is evaluated.

What is the standard for salt spray testing?

Salt spray testing is usually carried out to most widely used standard ASTM B117 neutral salt spray test for between 24 and 1000 hours, however this may be specified.

How many hours of salt spray test for zinc plating?

A set of the as plated and zinc Trivalent chromated parts were tested along with parts, which were zinc Trivalent chromated and sealed. Both sets met the 240-hour salt spray requirement; however, the Zinc Trivalent sealed parts performed better.

MAKING OF MILD STEEL

OUR INFRASTRUCTURE

GI UNIT

QUALITY CONTROL

TESTIMONIALS