CHAPTER 9INDONESIAN INDUSTRIAL

STANDARD

CHAPTER 9INDONESIAN INDUSTRIAL

STANDARD

Classification of Iron scrap and steel

IRON SCRAPIron 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 sizeType 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 SCRAPSteel 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• Classification by qualityClass 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 alloysClass III. Variety scrap steel

2 Classification by sizeType ANo.1 Thickness >6mm , length in all direction between 100-600 mmNo.2 Thickness between 3mm- 6mm , length in all direction 100-600 mmNo.3 Thickness >6mm, length in all direction over 600 mm and < 1200 mmNo.4 Thickness between 3mm - 6mm , length in all direction over 600 mm and < 1200 mmNo.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 ANo.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 BSteel scrap that easily can be change into one of the shapes above with cutting process.

Type CStainless scrap with maximum weight of 125 kg.No.1 Cutting of thin platesNo.2 The remains of thin plates lead which the lead already eliminatedNo.3 Steel scrap that does not include No.2 and no.2

• Steel alloy scrap classified as these following :

• 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 IRONMechanical 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 spongeDEFINITION : 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 Condition3.1 Dimension : Size between 5 until 16 mm, lower than 5 mm, 5%

maximum3.2 Bulb density : Minimum 1,65 ton/m3

3.3 Apparent density : minimum 2.82 ton3.4 Tensile strength : Minimum average 80 kg/ item3.5 Chemical elements

Fe total :Minimum 88%Fe metal : Minimum 75%

Metalisation : Minimum 85%C : 1,5-3 %P : Maximum 0,03%S : Maximum 0,03%

Sampling steps1. 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 retrievalIf the time period is performed manually following table 1.Calculation example for :• Set 1 times sampling• Amount of Iron sponge sampling earnedIf 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 MaleabelDEFINITIONSimple way means the iron maker pour white, after we do heat it,

we can get maleabel cast iron. RAW MATERIALThe 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 CorePrinting 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.

PlanningSpore runner and gateCommonly, 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 .

AdditionThe function of this addition is to balancing the depreciation during smelting casting in order to decelerate the casting of frosting.

Printing process

Wet molding processFor 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 ProcessCarbon oncret process is way of hardening mold or silica sand mixture of core with waterglass binder material (sodium silica Na2OsiO2 x H2O) then blow with CO2. The result of thisprocess is more precision, but it is oncrete easily . Shell Printing ProcessSand print shell is made of silica sand mixture with 4-7 % of resin fenoldan and little ofoncr alcohol. Mold or core is made of metal which is already heated about 2500C . Into themold 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 CompositionCast iron for maleabel made of white cast iron in chemical composition such on this table I .

Table IThe Chemical Composition of Cast Iron for Maleabel

Crucibal FurnaceAll 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 EquipmentsThe 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. Increase flow ability2. Made up the temperature graphite3. 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 SymbolClassification and symbol of steel reinforcement of prestressing concrete such on table I below

Table I Classification

• Note : • Bj TPP :Plain steel Reinforcement for Construction of Prestressing

Concrete• Bj TPD : deform steel Reinforcement for Construction of Prestressing

Concrete

QUALITY REQUIREMENT1. Nature seem

1.1 Wire should be free of the voltage1.2 Surface should not, containing splinters folds cracks,

light waves manner or wire1.3 Wire surface should not coated by oil or gemuk?

2. Dimension and ToleranceDimension 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 WireDeform wire should have indent round, all are same, continous, and have a same distance.

4. Mechanic CharacterMechanic character of free voltage steel wire for concrete construction prestressed with low relaction like table IV

SIGN REQUIREMENTEach 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 CABLES1.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 REQUIREMENT1.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 Character1. Pull StrongStrong pull steel wire flattened layer zinc 35-15 kg. / mm22. StrainStrain zinc minimum 10 % at length measuring instrument 200 mm

• \

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 CLASSIFICATIONClassification 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)

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 BoilerStream 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.

PROCESSSteel 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 plateThe 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 PropertiesMechanical properties of carbon steel for boilers and pressure vessels as in Table