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Carbon, Alloy and Bearing Steel for Various Industries Application.

KFIL is an established market leader in the production of special engineering steels. We produce carbon, alloy and martensitic stainless steel bars with a special emphasis on ultra-clean steels, free machining steels, bearing steels, and on other specially engineered steel grades. With over 15 years of experience in the manufacture of special steels our strength lies in our ability to produce very clean steels consistently and cost effectively; to produce hard to manufacture free machining steels; to develop and custom produce steels that meet specific mechanical or metallurgical requirements; and to deliver small lots of steels.

Modern Equipment and Methods

We operate one of the most modern alloy steel plants in the country located at Jejuri, near Pune. All our steel is produced through the electric arc furnace (EAF) route, is ladle refined, vacuum degassed, continuous cast and rolled. These primary equipments are supplemented by best in class quality enhancing devices such as an automatic mould level controller, non-sinusoidal tundish oscillators, electro-magnetic stirrers etc., with the singular objective of producing the best steel

Carefully Chosen Inputs

The quality of inputs used for melting has a direct bearing on the quality of the output. For this reason, we melt a very carefully chosen mix of virgin metal (pig iron and DRI) and clean scrap so as to control the appearance of tramp elements. We have a trusted set of suppliers all of whom are periodically audited to ensure adherence to our standards. In addition, we test all incoming material for radiation and other hazardous contaminants

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Clean Steel Process

KFIL prides itself on manufacturing the cleanest steel in the country, on par with the best worldwide this is entirely attributable to our steel making practices. While good equipment is a prerequisite for making Clean Steel, at KFIL, we believe that good practices are even more vital. While modern equipment may be procured at a cost, good practices are much more difficult to develop, and institutionalize it takes determination, time and painstaking effort. For this reason, throughout our 15 years of steel making history, we have focused on developing process knowhow, training people, and creating a committed quality culture. We are proud to say that our processes and practices are second to none. We follow a strict de-oxidation practice to ensure that macro inclusions of Alumina and Silica are floated out quickly from the molten metal. We ensure that the slag in the LRF is synthesized quickly and that the slag volume and chemistry are appropriate for complete slag killing. Similarly, low re-oxidation at the caster is ensured by controlling the superheat, achieving free opening consistently, and by adhering to proper tundish and mould practice.

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Application Based Steel Making

At KFIL, we like to understand where our steel is used. Where possible, our Technology Process Group (TPG) interacts with customers at the shop floor and at the R&D level to translate the customer's product requirement into a steel specification and a steel making process specification. This "Application Based" approach enables to deliver the most suitable and cost effective product. Today, given our history and our approach, we have developed an understanding of hundreds of applications that use our steels and we can use that experience to help you either select a steel or to develop a new grade appropriate to your requirements.

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PROCESS FLOW FACILITY MAJOR ACTIVITIES/
PROCESS CONTROL
CHECK POINTS
Scrap / Metallics
 
Primary Melting
 
 
 
 
SECOUNDARY REFINING
AND FERRO ALLOY ADDITION
 
 
 
 
VACCUUM DEGASSING
 
 
 
CONTINUOUS CASTING OF
160/180/200/225 MM ROUNDS
 
 
INSPECTION OF BLOOMS
 
AS COST
DESPATCH
ROLLING
 
 
 
FINISHING OPERATIONS
AND INSPECTION
 
METALLURGICAL
TESTING
 
 
 
HEAT TREATMENT
 
DISPATCH
 
 
50 MT ultra high power (36 MVA)electric arc furnace with eccentric bottom tapping system. Facility for continuous charging. Consists of auto melt control unit.
 
50 MT refining furnace.
Ladle with free board of 500 mm (8MVA-transformer capacity).
Auto feeding arrangement for ferro alloys and cored wire.
 
Five stage steam ejector.
Facility for addition under vacuum.
Auto feeding arrangement for ferro alloys and cored wire.
 
Two strand round caster.
In mould electro-magnetic stirring.
Double radius 12/18 m. PLC controlled spray-cooling zones.
Auto mould level controller(AMLC). Argon shrounding during casting. 
 
Walking hearth reheating furnace.
On line descaler.
Twelve strand, Two- high continuous rolling mill. 
 
Band saw machine.
Straightening machine
 
Vacuum emission spectrometer.
Carbon sulphur determinator.
Hydrogen, oxygen, nitrogen gas determinators.
Tensile testing machine.
Impact testing machine.
Hardness tester.
Magnetic crack detector.
Mobile spectrometer.
Metascope.
Metallurgical microscope. 
 
Electrically operated bogie hearth furnace for: annealing, normalising, spheroidised annealing. 
 
 
1.1 Checking of charge mix as per standard.
   
2.1 Addition of fluxes for early slag formation.
   
2.2 Check for chemistry.
   
2.3 Process observation and monitoring.
   
3.1 Addition of fluxes for early slag formation of desired chemistry for achieving a high degree of cleanliness.
   
3.2 Addition of alloying elements.
   
3.3 Check for chemistry.
   
3.4 Process observation and monitoring.
   
3.5 Superheat control.
   
4.1 Check for chemistry before trimming addition
   
4.2 Process observation and monitoring.
   
5.1 Check for as cast macro and chemistry.
   
5.2 Control of parameters with respect to casting speed, mould oscillation ,EMS frequency and current and tundish temperature.
   
6.1 Macro routine check.
   
7.1 Monitoring of reheating furnace controls.
   
7.2 Checking of dimension and surface quality during rolling.
   
8.1 MPI/pickling and inspection, eddy current testing.
   
8.2 Ultrasonic testing.
   
8.3 Cut to length.
   
8.4 Colour coding.
   
8.5 Straightning of bars.
   
8.6 Spark / spectral testing of the lot for mix-up detection by the mobile spectrometer / metascope.
   
8.7 Bundling and tagging.
   
9.1 Metallurgical tests like chemistry, macro, micro inclusions, grain size, decarb, step down, gas analysis, blue fracture, mechanical properties and other required test.
   
9.2 Testing and certification as per technical delivery conditions.
   
10.1 Monitoring of heat treatment cycle.
   
10.2 Checking of hardness, micro structure and mechanical properties.
   
Installed Capacity 350000 MT/annum
Process Route EAF - LRF - VD - CCM - RM
Heat size 45 MT
Products As Cast Rounds
Rolled Round Corned Square (RCS)
Bright Bars (Peeled / Turned) Cold Drawn / Cold Finished)
Size Range
    As Cast Rounds
    Rolled Rounds
    Round Corned Square(RCS)		 160,180,200 And 225 mm dia.
25.4 to 115 mm dia for all application 125 to 170 mm dia for seamless tube industry
45 to 75 mm and 125 mm
Standard Hot Rolled Sizes
    Rounds

    RCS		 25.4,26,26.4,27,28.3,30,32,34,36,38,40,42,45,48,50,52,
56,60,63,65,70,75,80,85,90,95,,100,105,115,125,137,150,
170MM AND AS CAST - 160,180,200& 225MM
45,50,52,55,60,63,65,70,75 MM AND 125 MM

   Additional size/ shapes upon specific request/agreement.
Supply Lengths Standard 3 to 6 m with 10% shorts down to 1 m or user defined.
Straightness Tolerance
   Hot Rolled
   Hot Rolled and Machine Straightened
   Cast Product		 3.0 mm per meter
1.5 mm per meter
5.0 mm per meter
Length Tolerance for fixed Length Supply + 50, -0.00mm
Condition of Ends Standard Gas Cut / Hot Sheared (as per customer requirements)
Standard Size Tolerance for Hot Rolled Bars / Billets
 
Nominal Size (mm RCS)
Over Upto and
including		 Tolerance
on size		 Ovality
25.4 28 +0.25 0.40
28 31 +0.28 0.45
31 34 +0.30 0.50
34 38 +0.36 0.60
38 50 +0.40 0.60
50 64 +0.8,-0 0.80
64 89 +1.2,-0 0.80
89 114 +1.6, -0 1.20
114 139 +2.0,-0 1.50
Nominal Size (mm RCS)
Over Upto and
including		 Tolerance
on size		 Ovality
- 50 +0.6 0.60
50 64 +1.2,-0 0.80
64 89 +1.8,-0 1.30
89 100 +2.4, -0 1.80
       
Tolerance on weight Kg per meter shall be +4%, -0%
 
For cast rounds size tolerance shall be +3mm and Ovality 2.5% of dia.
Alternative tolerance upon specific request / agreement.
 
Grades (lllustrative)
Plain Carbon Steels SAE 1008,SAE 1010, SAE 1012, SAE 1019, SAE 1026, SAE 1035, SAE 1035, SAE 1040, SAE 1045,
SAE 1518, 070M20, 080M40, 080M46, 070M55, CK35, CK45, CK55, CK60 etc.., and equivalent.
Case Hardening Steels 665M23, 635M15, 637M17, 815M17, 820M17, 822M17, SAE8617, SAE8620, 15Cr3, 16MiCr5,
20MnCr5, 15CrNi6, SCM415, SCM420, SCM421 etc., and equivalent.
Spring Steels 55Si7, 60Si7, 37MnSi5, 50CrV4, 38xc, 50Cr4V2, 51CrMov4, 52Cr4Mo2v etc.,and equivalent.
Free Cutting Steels SAE 1117,SAE 1137, SAE 1140, SAE 1141, 216M36, SAE 1144, EN-8M, EN-1A etc., and equivalent.
Ball Bearing Steels SAE 52100, 103Cr2, 100Cr6, SUJ2 etc., and equivalent.
Micro Alloyed Steels HMnV, 38MnSiVS5, 49MnVS3, C7056 etc., and equivalent.
Other Alloy Steels SAE 4130, SAE 4135, SAE 4140, SAE 4340, 817M40, 34Cr4, 37Cr4, 41Cr4, 25CrMo4, 42CrMo4, 40NiCrMo4,
40NiCrMo15, SCM435, SCM435, SCM440, SA182-F11, SA 182-F12, SA 181F11, T-5, T-9, T-23, T-91 etc., and equivalent.
Ferritic Stainless Steels AISI-410, AISI-420
Tool Steels H-11 and H-13
 
Control Chemistry Tramp Elements(max.)
Carbon 03 points Tin 0.02%
Manganese 05 points Copper 0.15%
Sulphur 10 points Nickel 0.20%
Chromium 05 points Molybdenum 0.05%
Molybdenum 05 points Boron 4 ppm max
 
Grain Size Guarantee ASTM 5 to 8 Alternative grain size upon specific request / agreement.
 
Inclusion Rating Guarantee
Carbon & Alloy Steels Thin series ABCD - 2max. Thick series ABCD - 1,5 max or as per cusotmer requirements.
SAE 52100 Thin and Thick series A - 1.0 max., B - 0.5 max., c - nil, D - 0.5 max.
Resulphurised Steels Thin and Thick series A - 3.0 max., BCD - 2.0 max.
  Alternative inclusion rating upon specification request / agreement.
 
Oxygen Level
Carbon   Alloy Steels 25 ppm max.
Bearing Steels 15 ppm max.
  Alternative Oxygen level upon specification request / agreement.
 
Hydrogen Level 2 ppm max.
 
Nitrogen Level 80 ppm max.
 
Titanium Level 30 ppm max. in Ball Bearing Steel.
 
Calcium Level 10 ppm max. in Ball Bearing Steel.
 
NDT Facilities Ultrasonic testing, Spark, Spectral, Mobile spectrometer, MPL testing
Finish Supply Condition As Rolled Bright Bars
Annealed Drawn
Normalised Peeled
Spheroidised Anealed Ground
Quench & Tempered