Conversion

Vacuum Induction Melting (VIM)

• Single furnace: 24-ton/15-ton box sizes

EAF/AOD

• 35-ton electric arc furnace (2)
• 38-ton argon-oxygen-decarburization vessel

Vacuum Arc Remelting (VAR)

• 5 furnaces; crucible sizes ranging from 18" to 36" in diameter

Primary Mill Rolling Equipment

• 110" Mill capable of rolling plate, rounds and slabs

Steckel Mill

• Capable of rolling Hotbands up to 52" wide

Press Forge

• 5,000-ton capacity forging press; diameter: 4" min./45" max.; 50,000 lbs. maximum weight; upset opening: 99", die width: 60"

Plate Finishing

• Key equipment includes: plate annealing furnaces, roller leveler, stretcher leveler, shot blaster, shear, abrasive saws, and plasma-cutting equipment

Bar & Wire

• Wire mill: product size ranging from .217" to 1.031" in diameter in coil form
• Rod mill: product size ranging from .50" to 5.250" in diameter in straight lengths.

Cold Draw Finishing

• Key equipment includes: Cold Pilger mills, tubing draw benches, roller hearth annealing furnaces, pickle tanks, straighteners, cutters, centerless grinders and batch wire annealer
• Tubing: product size ranging from 1/2" to 9-1/2" in diameter, up to 86' in length

Machine Shop

• Key equipment includes: rRod turners, peelers, saws and milling machines

Sheet & Strip

• Key equipment: Coil Build-up, Continuous Anneal and Pickle; Bright Anneal, cold reduction mills, coil grinder, slit/cut-to-length line and slitters
• Max coil weight: 30,000 lbs
• Max coil width: 52.000"
• Max coil starting ga.: 0.4"
• Min coil gauge: .006"

COIL PREP

• MAX O.D. : 63"
• MIN I.D. : 20" - 24"
• MAX WT. : 20,000 LBS
• MAD WIDTH: 50"
• MIN WIDTH: 24"
• MAX THICKNESS: 0.16
• MIN THICKNESS: 0.049 (note: .050 for surface critical)

NOTES

• Paper or plastic interleave recommended due to less tension - looser wrap.
• Can increase weight by 10%.
• Incoming coils of 63" would have to be cut in half for further processing.
• Minimum slit required for .120 to .160 is .75 inch each side.

Z-MILL

• MAX O.D.: 57"
• MIN I.D.: 24"
• MAX WT.: 20,000 LBS
• MAD WIDTH: 51"
• MIN WIDTH: 24"
• MAX THICKNESS: 0.225
• MIN THICKNESS: 0.009

NOTES:

• Paper interleave down to .012 under .012 receives no paper interleave due to crease transfer to surface.
• Thickness less than .030 will be on a 2" mill core.
• Generally, a rolling session will reduce the width by 1/8".
• Minimum width of 24 is okay for .012 or thicker - less than .012 has to be approved by Production Supervisor.

BRIGHT ANNEAL

• MAX O.D.: 58"
• MIN I.D.: 24"
• MAX WT.: 20,000 LBS
• MAD WIDTH: 38"
• MIN WIDTH: 24"
• MAX THICKNESS: 0.06
• MIN THICKNESS: 0.015

NOTES:

• Maximum anneal temperature is 2000 degrees f. Minimum line speed is 4 FPM.
• Paper interleave recommended due to less tension - looser wrap.

HV SLITTER

• MAX O.D.: 60"
• MIN I.D.: 16-20-24"
• MAX WT.: 25,000 LBS
• MAD WIDTH: 52"
• MIN WIDTH: 18"
• MAX THICKNESS: 0.06
• MIN THICKNESS: 0.008

NOTES:

• Minimum slit size is .75 inch.
• Paper interleave available for wide coils only. Multi cuts are not paper interleaved.
• Incoming thickness less than .030 going to the mill for rolling will be put on a 2" mill core at HV line.
• Edge trim requires 1/4 inch per side (1/2) inch total) if there is no major edge defect or damage.
• Intermediate edge trim between rolling sessions on a double session process is 1/4 inch per side.
• An edge trim and rolling session will reduce the width of the coil by 5/8 inch.
• A Double session process will reduce the width twice for a total reduction of 1 1/4 inch.

OD Grinding service also available:

• Slitter Knives: I.D 7.5 10” OD min to 12” max OD
• Work Rolls: 55” to 70” long 2.3” min OD to 2.6” max OD
• Roller wipes 55” – 70” long 1” min OD to 2” max OD
• 1st intermediates 57” long 3.8” min OD to 3.94” max OD
• 2nd Intermediates 60” to 63” long 6.8” min OD to 6.94” max OD
• Surface Roughness RA: 5 and courser

Air Induction Melting (AIM)

• furnace: 31,500 lbs. capacity

Electroslag Remelting

• Eight furnaces

Tube Extrusion

• 6,000-ton Extrusion Press, Wean Tube Reducer, Trepanning equipment, pickling facility

Saw Cutting

• 14" to 4" diameter billet

Homogenization

Furnaces

• 2200F max, natural gas-fired
• General condition "A" type heat treatment

Press forge (one open die hydraulic press, 4.5K ton)

• Large press (4500 ton)
• 10 ton capacity
• Daylight for upsetting =100"
• Ingot/billet diameter = 6" min/40" max
• Max slab width = 34"
• Max billet length =29.5 ft (finish); 19 ft (reheat)
• Max moment app. 300,000 ft-lbs (or 30,000?) (contact Dunkirk for details)

Rotary forge (GFM SX-55)

• 4 hammers, 200 strokes/min
• 1000 metric tons per hammer forging force
• 12,000 lb Capacity
• Output Shapes: Rounds, Round-Cornered-Squares and Flats (Rectangles)
• Max input diameter = 550 mm
• Min input diameter = 125 mm
• Max input length = 5000 mm
• Min input length = 1500 mm
• Max output length = 10,000 mm (250 mm F or less)
• Min output diameter = 100 mm*
• Max Slab width = 305 mm
• Min Slab width = 102 mm
• Min Slab thickness = 75 mm
• CNC control

VIM Melting

• 40,000 lb and 12,000 lb furnaces
• Mold diameters 14, 17, 21, 27, 30, 34

VAR Melting

• Ingot sizes 17, 20, 24, 30

ESR Melting

• Ingot sizes 17, 20, 24, 30, 36

Rolling

• 22" hand mill can roll 2.25" round up to 5" round
• 16" hand mill can roll 0.406" round up to 2" round

Vacuum Induction Melting (VIM)

• Computer-controlled processing available.
• High-frequency melting, refining, and casting with a nominal capacity of 8 tonnes.
• Typical ingot sizes, 320, 345, 420, 440 and 540 mm diameter.

Electroslag Remelting (ESR)

• Computer-controlled processing.
• Nominal capacity up to 5.8 tonnes depending on the product diameter.
• Mould sizes, 460, 540 and 665 mm diameter.

Vacuum Arc Remelting (VAR)

• Computer-controlled processing available.
• Nominal capacity up to 5.8 tonnes depending on the product diameter.
• Mould sizes, 380, 520 and 610 mm diameter.

Forging

• A computer-controlled hydraulically operated 1750 tonne press.
• Maximum billet size, 700 mm diameter. Smallest size typically 100 mm diameter, round or square with rectangles down to 50 X 140 mm.
• Mobile manipulator has 360° jaw rotation and a capacity of 17 tonnes at 2.5 m.
• Maximum workpiece size, 1400 mm diameter.
• Railbound manipulator has 360° jaw rotation and a capacity of 18 tonnes at 6 m.
• Maximum workpiece size, 1300 mm diameter.

Homogenized Heat Treatment

• A natural gas–fired furnace with an oxidizing atmosphere operating in the range of 550–1250°C.
• Controlled to a +10°C/-20°C at 750°C.
• Bar length, 3.5 m max. Load weight, 20 tonnes max. Maximum piece weight, 7 tonnes X 2.5 m X 1400 mm diameter.

Cold Rolling (General Guidelines) - Sheet

• Maximum length, 3200 mm. Maximum width, 1220 mm. Minimum gauge, 0.50 mm.

Heat Treatment (Temperatures up to 750°C)

• Maximum length, 3900 mm. Maximum width, 1020 mm.

Shears

• Maximum length, 3000 mm. Maximum width, 2000 mm. Maximum gauge, 20 mm.

Extrusion

• The extrusion press at SMW (Hereford) is available for hire work activity subject to inquiry to Production Management.
• The press is rated at 5650 tons maximum press force and can accommodate billet parameters of 175 mm, 225 mm, 275 mm, 300 mm and 343 mm, up to a maximum of 750 mm.
• Product forms available are solid bar (round or profile) and tube ( not 175 mm billet).
• Preheating is via gas-fired batch furnaces and temperature range available is 400°C to 1250°C (+ or - 15°C at 400°C to 600°C; + or - 10°C at above 800°C to 1250°C).

Rod Rolling

• 5 Stand Rod / Bar Mill incorporating:
• 1 Reversing Stand
• 4 Finishing Stands
• Induction Preheat Furnace
• Fully Automated Operation
• Air Cooling and Water Quench Facilities

Feedstock Straight Lengths:

• 65mm round 1.8m length
• Alternative, 42.5mm to 32mm.

Finished Sizes

• Straight Lengths - 12.5 mm to 32 mm.

Preheating Temperature Range

• 750°C to 1250°C.

Products

• Bar in as-rolled, peeled, or ground finish.

Types of Heat Treatment

• Annealing
• Softening
• Stress Relieving
• Solution Treatment
• Precipitation Treatment

Methods of Cooling

• Air Cool
• Water Quenching
• Air Blast Cooling
• Furnace Cooling

All types of heat treatments are conducted in air atmospheres.

Temperatures are controlled on multi-point recorders within tolerances of:

• +/- 5°C for treatments up to 750°C.
• +/- 10°C for treatments above 750°C.

Fur

• Water quench from gas furnace only 4 in. dia. or 12.5 sq. in.
• Cross-sectional area, with 185 kg max piece weight.