Bisalloy Tech Guide 2012-2013(1)

BISPLATEtechnical guide

For more information regarding BISPLATE refer to the technical information pdf documents provided on the Bisalloy Steels website at www.bisalloy.com.au

1BISPLATEtechnical guide

2ConTEnTS

Introduction 3

HowtoContactUs 4

ProcessRoute 5

RangeofGrades 6

BISPLATESizeRange 30

ManufacturingTolerances 31

CuttingBISPLATE 35

WeldingBISPLATE 45

Bending,Rolling,ShearingandPunchingBISPLATE 64

Drilling,Countersinking&TappingBISPLATE 69

TurningandMillingBISPLATE 76

BISPLATEIdentificationMarkingandColourCoding 81

TestingandCertification 83

HardnessTestingBISPLATE 85

3InTroduCTIon

BisalloySteelsPtyLtd,locatedatUnanderra,NSWisAustraliasonlymanufacturerofhighstrength,wearresistantandarmourgradesteelplateproducedbythecontinuousrollerquenchingandtemperingprocess.

Quenchingandtempering,definedasacombinationofheatingandcoolingofametaloralloy,changesthemicrostructureofthesteelandimprovesthestrength,hardnessandtoughnessofthematerialsbeingtreated.

Utilisingthemostadvancedheattreatmenttechnology,furnacetemperaturesandquenchingratesarescientificallycontrolledusingPLCstoobtaintheoptimumqualitygradesofsteelwithlowalloycontent.Theresultingproductsoflowalloyquenchedandtemperedsteelofferdesignersthestrengthtoweightadvantagesandwearresistantpropertiesnotavailableinconventionalsteels.

Highstrengthsteelhasastrengthtoweightratioofapproximatelythreetimesthatofmildsteel.Principalapplicationsareinminingequipment,transport,telescopiccranes,materialshandlingequipment,highriseconstructionandforestry.Highhardnessgradesofferimprovedwearlifemakingitidealforapplicationssuchaslinersforchutes,buckets,dumptrucksetc.BISPLATEarmourgradesaresuitableforarmouredpersonnelcarriersandballisticprotectionofmilitaryandcivilianfixedplantandtransportequipment.

BISPLATEgradescanbereadilycut,welded,formedanddrilledusingsimilartechniquestomildsteel.

BisalloySteelsoperatesanapprovedmechanicaltestinglaboratoryregisteredandmonitoredbytheAustralianNationalAssociationofTestingAuthorities(NATA).ThecompanysqualitycontrolandmanagementsystemisassessedbyLloydsandaccreditedtoISO9001.

Thecapacity,qualityandversatilityofourheattreatmentlineenablesustocompeteinbothdomesticandinternationalmarkets;includingNorthandSouthAmerica,Asia,NewZealandandAfrica.

4How To ConTACT uS BISALLoy STEELS PTy LTd 18ResolutionDriveUnanderra POBox1246UnanderraNSW2526Australia TelSwitch+61242720444 Fax+61242720456 WebSitewww.bisalloy.com.au

SALES & MArkETIng MAnAgEr MichaelSampson Tel+61242720412 Mob0418603852 [email protected]

TECHnICAL MAnAgEr Tel+61242720470 [email protected]

ExPorT MAnAgEr WillyPang Tel+61242720418 Mob+61419280765 [email protected]

nATIonAL SALES MAnAgEr TerryMcDermott Tel+61242720432 Mob0406398421 [email protected]

For STATE By STATE EnQuIrIES PLEASE ConTACT

our MAIn oFFICE on o2 4272 0444

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InTroduCTIon

BisalloySteelsgradesareworldclass,ourstructuralgradescomplyingwithmanyoftheworldsquenchedandtemperedsteelplatestandards.

Eachofthegradescoveredbythisbrochurehasspecificmechanicalandchemicalpropertiesdetailed.TheprocessinformationdetailedbelowisapplicabletoallBISPLATEproductmanufacturedbyBisalloySteels.

BISALLoyS FEEd PLATE

ThetechnologyusedinthemanufactureofBISPLATEisnotonlyworldclass,butthedemandsofhighstrengthandhighhardnesssteelsdictatetheneedforoneofthemoststringentprocessroutesutilisedinthemanufactureofsteelplate,anywhereintheworld.

Hotmetaldesulphurisationensureslowlevelsofsulphurandotherimpuritiesinsteelmaking.VacuumdegassingiscarriedouttoreducetheHydrogencontentofthesteel,whilstalsodecreasingtheamountofundesirableOxygenandNitrogeninthesteel.ControlofimpuritiesisadditionallyassistedthroughtheuseofhotmetalinjectionandconditioningoftheslagduringtheBasicOxygenSteelmakingprocess.

ClosecontrolofchemicalcompositionandfinalmicrostructureismaintainedthroughtheuseofladlerefiningwithCalciuminjection,Argonbubblingthroughtheheatduringsteelmakingandalloyingadditionsmadeundervacuum.

Followingsteelmaking,integrityofslabproductisensuredbytheuseofelectromagneticstirring,continuouscastingandcontrolledcoolingofslabspriortoplaterolling.

Finally,platerollingiscarriedoutinacomputercontrolledfourhighrollingmill,inwhicheachdraftismodifiedduringrollingforoptimisationoffinalproperties.

Thenetresultissteelthatprovidesimprovedtoughness,structuralintegrityandfatigueresistance,providingconsistentproductperformanceinservice.

7BISALLoyS HEAT TrEATMEnT

Plateisheatedinournaturalgasfiredfurnace,priortoquenchingintheDreverrollerquenchunit.CompletePLCcontrolallowstightandconsistentcontrolofallfurnaceandquenchoperations,includingwaterflowratesandpressure,furnacetemperaturesandresidencetimes.

Preandpost-heattreatmentshotblastingremovesscaleandpresentsanattractiveplate.Thisresultsinimprovementsinproductproperties,weldingandcutting,aswellassimplificationduringfabrication.

ThefinaloperationatBisalloyisplatelevelling,throughourplateleveller,formaterialupto32mmthick.Thishasresultedinsignificantimprovementsinflatnessofplatetomarket,muchtighterthantheAustralianStandardandotherInternationalStandards.

Ourqualityassurancesystemensuresthatfulltraceabilityexistsfrominitialsteelmakingrightthroughtheprocesstothefinalplate.Eachplateisindividuallyhardstampedwithauniqueidentification,thislinkstotheoveralltraceability.

Allplatesaretestedforhardness,whilstallstructuralgradesaretestedinBisalloysNATAapprovedmechanicaltestinglaboratory.Platesofallgradesarecertified.TheentireprocessiscarriedoutincompliancewithISO9001,certifiedbyLloydsRegisterQualityAssurance(LRQA).

BISALLoyS TECHnICAL dEVELoPMEnT

EachofthegradesoutlinedinthisbrochurehavebeendevelopedtooptimisechemistryandmechanicalpropertiesinconjunctionwithBisalloysheattreatmentprocess.

Ourworldclasssteelgradesensurethatpropertiessuchasductility,weldabilityandtoughnessaremaximised,whilstcomplyingwiththerequisitehardnessandstrengthrequirements.

OngoingR&DatBisalloykeepsourproductrangeattheleadingedgeofavailablequenchedandtemperedsteels.Already,wearedevelopingsteelstomeettheemergingrequirementsforstillstrongerstructuralgradesandthesewillbereleasedtothemarketasdemanddictates.

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8BISPLATE 60

BISPLATE60isalowcarbon,lowalloy,highstrengthstructuralsteelthatexhibitsexcellentcoldformabilityandlowtemperaturefracturetoughness.

APPLICATIonS

ThecombinationofBISPLATE60mechanicalpropertiesandeaseoffabricationofferseconomicaladvantagesinmanystructuralapplications.Someexamplesofapplicationsforthisgradeinclude:

Storagetanks (Water/Oil/Gas)High-risebuildings (Columns/Transfer beams)Liftingequipment (Mobile/Overhead cranes)

FABrICATIon

BISPLATE60canbeweldedsuccessfullywithminimallevelsofpreheatandhasexcellentlowtemperaturefracturetoughness.

BISPLATE60hasbeendesignedsuchthatalowhardnesslevelisproducedintheheataffectedzone(HAZ).Asaresult,thissteelhasalowsusceptibilitytoHAZcracking.

ForfurtherdetailsonfabricationpleaserefertoBisalloystechnicalliterature.

9BISPLATE 60

MECHAnICAL ProPErTIES

PROPERTIES SPECIFICATION TYPICAL

0.2%ProofStress 500MPa(Min) 580MPa

TensileStrength 590-730MPa 640MPa

Elongationin50mmG.L. 20%(Min) 30%

CharpyImpact(Longitudinal)-20C(10mmx10mm)

80J(Min)* 200J

Hardness 210HB

*Dependentonplatethickness

CHEMICAL CoMPoSITIon

THICKNESS(mm) C P Mn Si S Cr Mo B CE(IIW)* CET*

5-80-100 Maximum 0.18 0.025 1.5 0.25 0.008 1.20 0.25 0.002 0.58 0.34

*Typicalaverage

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BISPLATE 70

BISPLATE70isalowcarbon,lowalloy,highstrengthstructuralsteel.Thisgradecanbeweldedwithminimalpreheatandhasexcellentlowtemperaturefracturetoughnesssuitableforstructuralapplications.

APPLICATIonS

ThecombinationofBISPLATE70mechanicalpropertiesandeaseoffabricationofferseconomicaladvantagesinmanystructuralapplications.Someexamplesofapplicationsforthisgradeinclude:

Transportequipment (Trays/Low loaders/Outriggers)Storagetanks (Water/Oil/Gas)High-risebuildings (Columns/Transfer beams)Liftingequipment (Mobile/Overhead cranes)Miningequipment (Dump truck trays/Structural applications)Longwallminingsupports

FABrICATIon

BISPLATE70exhibitsexcellentcoldformabilityandlowtemperaturefracturetoughness.

BISPLATE70hasbeendesignedsuchthatalowhardnesslevelisproducedintheheataffectedzone(HAZ).Asaresult,thissteelhasalowsusceptibilitytoHAZcracking.


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BISPLATE 70



0.2%ProofStress 600MPa(Min) 670MPa

TensileStrength 690-830MPa 760MPa

Elongationin50mmG.L. 20%(Min) 28%


75J(Min)* 180J

Hardness 230HB




5-80-100 Maximum 0.18 0.025 1.5 0.25 0.008 1.20 0.25 0.002 0.58 0.34

*Typicalaverage

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BISPLATE 80

BISPLATE80isahighstrength,lowalloysteelplatewithayieldstrengththreetimesthatofcarbonsteelandfeaturinglowcarbon,excellentnotchtoughness,goodweldabilityandformability.

APPLICATIonS

UtilisingthehighstrengthpropertiesofBISPLATE80allowsreductioninsectionthicknesswithoutlossofstructuralintegrity.Thefollowinglistssomeapplicationswherethestrengthadvantagehasbeenrealised:

Transportequipment (Low loaders)High-risebuildings (Columns)Miningequipment (Dump truck trays/Longwall roof supports)Liftingequipment (Mobile cranes/Container handling equipment)Bridges Storagetanks ExcavatorbucketsInduceddraftfans

FABrICATIon

BISPLATE80isahighstrengthsteelmanufacturedwithacontrolledcarbonequivalentforoptimumweldability.

BISPLATE80canbesuccessfullyweldedtoitselfandarangeofothersteels,providedlowhydrogenconsumablesareusedandattentionispaidtopreheat,interpasstemperature,heatinputandthedegreeofjointrestraint.Stressrelievingcanbeachievedat540C570C.Heatingabovethistemperatureshouldbeavoidedtominimiseanyadverseeffectsonmechanicalproperties.Coldformingcanbesuccessfullyconducted,provideddueaccountistakenoftheincreasedstrengthofthesteel.


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BISPLATE 80



0.2%ProofStress 690MPa(Min)* 750MPa

TensileStrength 790-930MPa* 830MPa

Elongationin50mmG.L. 18%(Min)* 26%


40J(Min)* 160J

Hardness 255HB




5-80-100 Maximum 0.18 0.025 1.5 0.25 0.008 1.20 0.25 0.002 0.58 0.34

*Typicalaverage

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BISPLATE 80PV

BISPLATE80PVisahighstrengthsteelalternativefordesignersofunfiredpressurevesselsthatmeetstherequirementsofAS1210andachievesalightweightstructure.

APPLICATIonS

BISPLATE80PVhasbeenapprovedbystatutoryauthoritiesandcomplieswiththerequirementsofAS1210forpressureapplicationsandissuppliedultrasonicallytestedtoAS1710-Level1.Itshighstrengthofferssubstantialweightreductionsinthefollowingareas:

TransportableroadtankersStoragetanks (Spherical and cylindrical)Railroadtankers (LPG/Liquid ammonia)Refineryandpetrochemicalequipment (Tube plates/Channel covers)

FABrICATIon

BISPLATE80PVisahighstrength,lowalloypressurevesselsteelwithacontrolledcarbonequivalentforoptimumweldability.

BISPLATE80PVcanbesuccessfullyweldedtoitselfandarangeofothersteels,providedlowhydrogenconsumablesareusedandattentionispaidtopreheat,interpasstemperature,heatinputandthedegreeofjointrestraint.Stressrelievingcanbeachievedat540C570C.Heatingabovethistemperatureshouldbeavoidedtominimiseanyadverseeffectsonmechanicalproperties.Coldformingcanbeconductedsuccessfully,provideddueaccountistakenoftheincreasedstrengthofthesteel.

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BISPLATE 80PV



0.2%ProofStress 690MPa(Min)* 750MPa

TensileStrength 790-930MPa* 830MPa

Elongationin50mmG.L. 18%(Min)* 26%

LateralExpansion 0.38mm(Min) 0.70mm

CharpyImpact 55J

Hardness 255HB




6-80 Maximum 0.20 0.025 1.5 0.25 0.008 0.30 0.25 0.002 0.50 0.35

>80-100 Maximum 0.18 0.025 1.5 0.25 0.008 1.20 0.25 0.002 0.58 0.34

*Lowheatinputbuttweldingrequiredtoensuretransverseweldtensilepropertiesareachieved.Alternatechemistrymaybespecifiedwhennecessary*Typicalaverage

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BISPLATE 320

BISPLATE320isathroughhardened,abrasionresistantsteelplate,offeringlonglifeexpectancyinhighimpactabrasionapplications.

APPLICATIonS

BISPLATE320offerstheoptimumcombinationofhardness,impactandformabilityforwearapplicationsthatrequireextensiveforming/drillingorfabrication,inimpactabrasiveapplicationssuchas:

DeflectorplatesChutesStoragebinsDumptrucklinersEarthmovingbuckets

FABrICATIon

BISPLATE320isahighhardness,abrasionresistantsteelwithacontrolledcarbonequivalentforoptimumweldability.Withappropriateattentiontoheatinput,preheatandconsumableselection,BISPLATE320canbereadilyweldedtoitselfandothersteels,usingconventionalprocesses.

ColdformingofBISPLATE320platesispossibleinallthicknesses,providedthehighstrengthofthissteelistakenintoaccount.Adequateallowancemustbemadeforincreasedspringbackrelativetomildsteel.Heatingabove400Cshouldbeavoided,otherwisethemechanicalpropertiesmightbeaffected.

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BISPLATE 320



0.2%ProofStress 970MPa

TensileStrength 1070MPa

Elongationin50mmG.L. 18%

CharpyImpact(Longitudinal)+20C(10mmx10mm)

60J

Hardness 320-360HB 340HB



5-80-100 Maximum 0.18 0.025 1.5 0.25 0.008 1.20 0.25 0.002 0.58 0.34

*Typicalaverage

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BISPLATE 400

BISPLATE400isathroughhardened,abrasionresistantsteelplate,offeringlonglifeexpectancyinhighimpactabrasionapplications.

APPLICATIonS

BISPLATE400offersexcellentwearandabrasionresistanceandimpacttoughnessinapplicationsthatinclude:

DumptruckwearlinersCyclonesScrewconveyorsDeflectorplatesChutesGroundengagingtoolsStoragebinsCuttingedgesEarthmovingbuckets

FABrICATIon

BISPLATE400isahighhardness,abrasionresistantsteelofferingverygoodimpacttoughnessproperties.BISPLATE400providesanoptimumcombinationofabrasionresistance,toughnessandweldability.Duetoitslowalloycontent,BISPLATE400canbereadilyweldedusingconventionalweldingprocessesandlowhydrogenconsumables.ColdformingofBISPLATE400isachievableonallthicknessesalthoughanallowanceforthehigherstrengthshouldbetakenintoaccount.Bendingmachinecapabilitiesshouldalsobetakenintoconsiderationpriortoanyformingoperation.Heatingabove250Cshouldbeavoided,otherwisemechanicalpropertiesmightbeaffected.

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BISPLATE 400







55J




5-80-100 Maximum 0.18 0.025 1.5 0.25 0.008 1.20 0.25 0.002 0.58 0.34

*Typicalaverage

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BISPLATE 450

BISPLATE450isathroughhardened,abrasionresistantsteelplate,withverygoodtoughness,weldabilityandformability,offeringlonglifeexpectancyinslidingandgougingabrasionapplications,withimpactloading.

APPLICATIonS

BISPLATE450offersexceptionallylonglifeinhighabrasionapplicationswithimpactloading.Applicationsinclude:

Dumptruckwearliners/bodiesMiningbucketsTipperbodiesCuttingedgesConstructionwastebinsLinerplates/chutes

FABrICATIon

BISPLATE450isalowcarbon,highhardness,abrasionresistantsteelwithguaranteedimpacttoughness.BISPLATE450canbesuccessfullyweldedtoitselfandarangeofothersteelsbyconventionaltechniques.Becauseofitshighhardness,coldformingofBISPLATE450requireshigherbendingandformingforcesandgreaterallowancesmustbemadeforspringback.Heatingabove200Cshouldbeavoided,otherwisemechanicalpropertiesmightbeaffected.

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BISPLATE 450







guArAnTEEd CHArPy-V IMPACT TougHnESS

THICKNESS(mm) TESTPIECE MIN.ENERGY,LONGITUDINAL@-40C

6-8 10x5 17J

10 10x7.5 21J

12-20 10x10 25J

>20-40 10x10 20J

>40-50 10x10 15J


THICKNESS(mm) C P Mn Si S Ni Cr Mo B CE(IIW)* CET*

6-20 Maximum 0.23 0.025 1.00 0.60 0.008 0.25 1.00 0.25 0.002 0.46 0.30

25-50 Maximum 0.25 0.025 1.20 0.60 0.008 0.25 1.20 0.35 0.002 0.58 0.36

*Typicalaverage

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BISPLATE 500

BISPLATE500isathroughhardened,abrasionresistantsteelplate,offeringlonglifeexpectancyinslidingandgougingabrasionapplications.

APPLICATIonS

BISPLATE500isthehardeststeelproducedbyBisalloySteelsandoffersexceptionallylonglifeinslidingabrasionapplicationssuchas:

DumptruckwearlinersChutesWearlinersEarthmovingbucketsCuttingedgesGroundengagingtools

FABrICATIon

BISPLATE500isamediumcarbon,highhardness,abrasionresistantsteel.Withappropriateattentiontoheatinput,preheatandconsumableselections,BISPLATE500canbesuccessfullyweldedtoitselfandarangeofothersteelsbyconventionaltechniques.Becauseofitshighhardness,coldformingofBISPLATE500isdifficult,requiringhigherbendingandformingforces,andgreaterallowancesmustbemadeforspringback.Ifheatingisnecessary,thisshouldnotexceed200C,otherwisemechanicalpropertiesmightbeaffected.

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BISPLATE 500







35J



THICKNESS(mm) C P Mn Si S Ni Cr Mo B CE(IIW)* CET*

8-100 Maximum 0.32 0.025 0.40 0.35 0.008 0.35 1.20 0.30 0.002 0.62 0.40

*Typicalaverage

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BISPLATE HIgH HArdnESS ArMour PLATE

InTroduCTIon

BISPLATEHighHardnessArmour(BISPLATEHHA)isaquenchedandtemperedsteelarmourplatesuitableforuseinbothmilitaryandcivilapplicationswherelightweightandresistancetoballisticprojectilesisrequired.

METHod oF MAnuFACTurE

BISPLATEHHAisahotrolledsteelproductthatissubsequentlyheattreatedtopromoteitshighstrengthandtoughness,highhardnessandballisticsproperties.

BrInELL HArdnESS

THICKNESS(mm) SPECIFICATION TYPICAL

5-50* 477-534HB 500HB

*Otherthicknessesmaybeavailableonrequest

TEnSILE ProPErTIES

PROPERTY TYPICAL




CHArPy IMPACT VALuES

THICKNESS(mm) TESTPIECE TESTTEMP MIN.ENERGY(TRANSVERSE) MIN.ENERGY(LONGITUDINAL)

5 10xThk -40C ByAgreement ByAgreement

6-

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BISPLATE HIgH HArdnESS ArMour PLATE

MECHAnICAL TEST FrEQuEnCIES

TEST FREQUENCY

Hardness PerPlate

Charpy(L) PerBatch

Charpy(T) PerBatch

TensileTesting ByAgreement

ThicknessTesting PerPlate

BallisticTesting ByAgreement

CHEMISTry

ThechemicalspecificationconformswiththerequirementsofMIL-DTL-46100,althoughitistighterthantherequirementsofthatspecificationsoastooptimisethematerialsperformance.Productchemicalanalysesaretakenonaper-heatbasis

Chemicalanalysisisasfollows:


THICKNESS(mm) C P Mn Si S Ni Cr Mo B CE(IIW)** CET**

5-501 Maximum 0.32 0.025 0.80 0.50 0.005 0.50 1.20 0.30 0.002 0.61 0.40

**Note:NickelandVanadiumareintentionallyadded**Typicalaverage1Otherthicknessesmaybeavailableonrequest

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BALLISTIC ProPErTIES

AS 2343 PArT 2 BuLLET rESISTAnT PAnELS For InTErIor: oPAQuE PAnELS

CLASS CALIBRE AMMUNITIONMEASUREDVELOCITY@DISTANCEFROM

MUZZLERANGE MINIMUMREQUIREDHHATHICKNESS

G2 44Magnum 15.6gLeadSemi-WadCutterBullet 48810m/[email protected] 3m 6mm2

S0 12Gauge(FullChoke)12Gauge70mmHigh

VelocityMagnum32gSGShot

40310m/[email protected] 3m 6mm2

S1 12Gauge(FullChoke) 12Gauge70mm24.8gSingleSlug 47710m/[email protected] 3m 6mm2

R1 5.56mm M1935.56mm3.6gFullMetalCaseBullet 98015m/s@5m 10m 10mm2

R2 7.62mmNatoStandard7.62mm9.3g

FullMetalCaseBullet85310m/s@5m 10m 6mm

2Standardthicknessesproduced.Minimumthicknessrequiredislessthanstatedthickness.PleasecontactBisalloyforfurtherinformation.

ClassGHandGun ClassSShotgun ClassRRifles

rESIduAL MAgnETISM

MaximumresidualmagnetismofBISPLATEarmourgradesis50Gausswhenplatesaredespatched.Specialarrangementcanbemadetolimitthemaximumresidualmagnetismto20Gauss.

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grAdE EQuIVALEnTS

GRADE COUNTRYOFORIGIN STEELSTANDARD COMMENTS

60 Australia AS3597Grade500 Min.yield500MPa

60 ISO ISO4950-3AMD1 Min.yield500MPa

60 Japan JISG3106SM570 Min.yield420MPa

60 USA ASTMA572/A537MGrade60 Min.yield415MPa

60 USA ASTMA537/A537M Min.yield485MPa

60 Europe EN10025S460 Min.yield460MPa



70 USA ASTMA533/A533MCI.1 Min.yield550MPa




80 USA ASTMA514/A514M Min.yield690MPa


80 Japan JISG3128 Min.yield685MPa

80PV Australia AS3597Grade700PV Min.yield690MPa

80PV USA ASTMA577/A517M Min.yield690MPa

80PV Europe EN10028P690 Min.yield690MPa

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SuMMAry TABLES STruCTurAL STEEL grAdES

STEELGRADE

PLATETHICKNESS

(mm)

CARBONEQUIVALENT

(IIW)

BRINELLHARDNESS(HB3000/10)

MECHANICALPROPERTIES

TENSILE CHARPYV-NOTCHIMPACT

PLATETHICKNESS

(mm)

0.2%PROOFSTRESS(MPa)Min

TENSILESTRENGTH

(MPa)

%ELONGATION(50mmG.L)

Min

PLATETHICKNESS

(mm)

ENERGY(J)(Min)

TESTTEMP.(C)

TESTDIRECTIONS

BISPLATE60

(AS3597Grade500)

5-80-100

0.40

0.50

0.58

210 5-100 500 590-730 20

5 ByAgmnt -20 L

6-9.5 45 -20 L

9.5-12 60 -20 L

13-100 80 -20 L

BISPLATE70

(AS3597Grade600)

5-80-100

0.40

0.50

0.58

230 5-100 600 690-830 20

5 ByAgmnt -20 L

6-9.5 40 -20 L

9.5-12 60 -20 L

13-100 75 -20 L

BISPLATE80

(AS3597Grade700)

5-80-100

0.40

0.50

0.58

255

5

6-65

70-100

650

690

620

750-900

790-930

720-900

18

18

16

5 ByAgmnt -20 L

6-9.5 20 -20 L

9.5-12 30 -20 L

13-100 40 -20 L

BISPLATE80PV

(AS3597Grade700PV)

6-80 0.50

2556-65

70-100

690

620

790-930

720-900

18

166-100

LateralExpansion0.38mmmin.

ByAgmntmax.0C T

>80-100 0.58

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SuMMAry TABLES HIgH HArdnESS STEEL grAdES

STEELGRADE PLATETHICKNESS(mm)CARBON

EQUIVALENT(IIW)

BRINELLHARDNESS(HB3000/10)

MECHANICALPROPERTIES

TENSILE CHARPYV-NOTCHIMPACT

0.2%PROOFSTRESS(MPa)

TENSILESTRENGTH

(MPa)

%ELONGATION(50mmG.L.)

ENERGY(J)* TESTTEMP.(C)TEST

DIRECTIONS

BISPLATE320

5-80-100 0.58

BISPLATE400

5-80-100 0.58

BISPLATE450

6-20 0.46

425-475 1150 1400 12

25

-40 L25-400.58

20

>40-50 15

BISPLATE500 6-100 0.62 477-534 1400 1640 10 35 +20 L

*Note:Charpyenergyvaluesarefor10x10mmspecimensizes

Legend:L LongitudinalT Transverse GuaranteedValues TypicalAverageValues(providedforreferenceinformationonly)

IIWCarbonEquivalentFormula:C.E.=C+Mn+Cr+Mo+V+Ni+Cu C.E.T=C+(Mn+Mo)+(Cr+Cu)+Ni 6515 10 2040

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BISPLATE SIzE rAngE

STAndArd SIzE SCHEduLE

Table1:PLATEMASSINTONNES

GRADE BISPLATE60,70,80,320,400 BISPLATE450 BISPLATE500WIDTH(mm) 1525 1900 2485 1525 2485 3100 2485 3100 1525 1900 2485 2485LENGTH(m) 6000 6000 6000 8000 8000 8000 8000

*85008000*8300**8800

6000 6000 6000 8000

Thickness(mm)5 0.4796 0.575 0.936 0.9368 1.248 1.248 1.24810 1.561 1.947 1.561 1.947 1.56112 1.873 2.336 1.873 2.336 1.87316 2.497 3.115 2.497 3.115 2.49720 3.121 3.894 3.121 *4.040 3.12125 3.901 4.867 3.901 **5.354 3.90132 4.994 *5.306 4.99440 6.242 6.242 6.24250 7.803 7.803 7.80360 7.023 7.02370 6.264 6.26475 6.712 5.38780 7.159 5.74690 6.464 6.464100 7.183 7.183

Platemass(tonnes)calculation=7.85xWxTxL(m)

non STAndArd SIzES

Available subject to sales enquiry Minimum order quantities may apply

EdgE CondITIon

All plate 1525 mm wide and 5 & 6 mm thick is supplied with untrimmed edge

All other plate is supplied with trimmed edge

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MAnuFACTurIng ToLErAnCES THICknESS ToLErAnCE

Table1:

WIDTH

THICKNESS(+/-mm)

6>68

>810

>1013

>1318

>1822

>2230

>3042

>4263

>63

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unTrIMMEd EdgE PLATE

Table3:

WIDTH(ALLTHICKNESS) PLUS MINUS

1500 40 0

Note:Alldimensionsareinmillimetres

LEngTH ToLErAnCE

Table4:

ALLTHICKNESS

33

CAMBEr EdgE CAMBEr ToLErAnCE

Table5:

SPECIFIEDWIDTH TRIMMEDEDGE UNTRIMMEDEDGE

ALL 4 6


Figure1:


EdgeCambershallbelimitedsothatitshallbepossibletoinscribethedimensionsoftheorderedplatewithinthedeliveredsize.

Measurementofflatnesstoleranceshouldbemadewhentheproduct,restingunderitsownmass,isplacedonaflathorizontalsurface.

Astraightedgeshallbeplacedontheplateandthemaximumverticaldistancefromtheplateshallbemeasured(H).

Figure2a: MeasurementofFlatness-Waviness

Figure2b:MeasurementofFlatness-Bowing

W = Width L = Length C = Edge Camber

L = Length H = Deviation

W = Width L = Length H = Deviation

Ma

nu

fac

tu

rin

g t

ole

ra

nc

es

34

BISALLoy MAnuFACTurIng ToLErAnCES

Table6:

SPECIFIEDTHICKNESSPLATE

(mm)

DISTANCEBETWEENPOINTSOFCONTACT

(mm)

SPECIFIEDWIDTHOFPLATE(mm)

35

CuTTIng BISPLATE

FLAME CuTTIng, PLASMA CuTTIng, LASEr CuTTIng, wATErJET CuTTIng And SAwIng rECoMMEndATIonS

AllgradesofBISPLATEquenchedandtemperedsteelcanbecutbyeitherthermalcutting,lasercutting,waterjetcuttingorpowersawoperations.Thecuttingoperationscanbecarriedouteitherintheworkshopor,inthecaseofflamecutting,infieldconditions.Boththehighstrengthstructuralgradesandthewearandabrasionresistantgradescanbecutusingthesametypeofequipmentemployedincuttingplaincarbonsteels.

Figure1a:

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LaserCut-Top

PlasmaCut-Top

FlameCut-Top

FlameCut-Bottom

Effects of flame, plasma and laser cutting on plate hardness for a 6 mm AS3597 Grade 700 steel (BiSPLATE 80). Hardness tests were conducted using the Vickers method and converted to Brinell hardness values (HB).

Distance from Cut Edge (mm)

0 1 2 3 4 5 6 7

450

400

350

300

250

200

150

Har

dne

ss (B

rinel

l)

36

10

Laser Cut

Plasma Cut

Flame Cut550

500

450

400

350

300

250

Har

dne

ss (B

rinel

l)

0 1 2 3 4 5

Distance from Cut Edge (mm)

CuTTIng oPErATIonS

Dependentonthegradeandthicknessbeingcut,thefollowingoperationscanbeusedonBISPLATEgrades:

FlameCutting(Oxy-LPG and Oxy-acetylene) PlasmaCuttingLaserCuttingWaterjetCuttingPowerSawing

Figure1b:

Effects of flame, plasma and laser cutting on plate hardness for a 6 mm BiSPLATE 500. Hardness tests were conducted using the Vickers method and converted to Brinell hardness values (HB).

Note: Some variations to the hardness profiles of figure: 1a and 1b will occur with changes to cutting speed and plate thickness.

37

FLAME CuTTIng

BothOxy-LPGandOxy-acetyleneprocessesareacceptableforsectioningallthicknessesofBISPLATE.Withtheseprocesses,thefollowingtechniquesarerecommended:

GaspressuretobethesameasforcuttingtheequivalentthicknessinplaincarbonsteelReducetravelspeedsby30%whencomparedtotheequivalentthicknessplaincarbonsteelswhenusingastandardcuttingnozzle

NozzlesizetobethesameasforequivalentthicknessplaincarbonsteelCorrectselectionofnozzlesizefortheplatethicknessbeingcutisimportanttoensureefficientcuttingandtominimisethewidthoftheheataffectedzone(HAZ)

Aswithallplatesteels,thesmoothnessofthecutisaffectedbysurfacescale.Ifthisispresent,itisadvisabletoremoveitpriortocutting(BISPLATEisnormallysuppliedintheshotblastedcondition).

UndernormalOxycuttingconditions,thetotalheataffectedzoneadjacenttotheflamecutedgewillextendintotheplateapproximately2-3mm,asshowninfigure1aforBISPLATE80.Itshouldbenotedthattheheataffectedzoneproducesahardlayeradjacenttotheflamecutedge,withasoftlayerinsidethis.Theoriginalplatehardnessreturnsafterthe2-3mmdistancefromthecutedge.ForBISPLATE500theHAZmayextendasmuchas4-5mmintotheplateasshowninfigure1b.

PreheatingBISPLATEsteelpriortoflamecuttingwillminimisethehardnessoftheflamecutedgeandalsoreducetheriskofdelayedcrackingfromthiscutedge.Thisisparticularlyimportantincoldenvironmentswhereplatetemperatureislessthan20CandforthehighhardenabilitygradesofBISPLATE500.

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38

Table1below,givesguidanceonthepreheatrequirements.Itisrecommendedthatthezonetobepreheatedshouldextendatleast75mmeithersideofthelineofcut,withthetemperaturebeingmeasuredontheoppositesurfaceandatadistanceof75mm,asshowninfigure2.

rECoMMEndEd MInIMuM PrEHEAT TEMPErATurES For FLAME CuTTIng oF BISPLATE grAdES

Table1:

BISPLATEGRADE PLATETHICKNESS(mm) MINIMUMPREHEATTEMPERATURE(C)

60,70 8-32 20

80,80PV5-31

32-1002050

320,4005-31

32-1002050

4506-2021-50

2050

5008-20

21-10050100

39

Figure2:Recommendedpreheatzoneandlocationofpreheatmeasurement.

Iftheflamecutsurfaceistobethefaceofaweldedjoint,theheataffectedzonefromtheflamecuttingneednotberemoved.However,allslagandloosescaleshouldberemovedbylightgrinding,andpriortowelding,thecutsurfaceshouldbedryandfreefromorganicmattersuchasoil,grease,etc(asdirectedbygoodworkshoppractice).

Whenstrippingplates,theuseofmultiplecuttingheadswillhelptominimisedistortionofthecutpieces.Correctnozzlesize,gaspressureandtravelspeedwillalsominimisedistortionduringcutting.Softeningonedgescanalsooccurwhenflamecuttingsmallstrips,eg.50mmwidex50mmthickplate.

QuenchcuttingofBISPLATEgradestominimisedistortionisnotrecommended,coolinginstillairispreferred.Thetechniqueofstackingplatesduringprofilecuttingshouldalsobeavoided.

Forcomponentcuttingand/orprofilingofsmallpartsanincreaseintemperaturecanoccurandmayaffectthemechanicalpropertiesofthesteel.

Measure preheat temperature here

75 mm 75 mm

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40

SuMMAry oF FLAME CuTTIng rECoMMEndATIonS

ForoxyprocessesusegaspressuresandnozzlesizesasforanequivalentthicknessofplaincarbonsteelForoxyprocessesusecuttingspeedstwothirdsofthatrecommendedforanequivalentthicknessofplaincarbonsteelFlamecuttingproducesaheataffectedzoneonallgrades.TheriskofdelayedcrackingisreducedbyusingpreheatespeciallyforthickplateandforBISPLATE500grade

UsemultiplecuttingheadswhenstrippingplatesStillaircoolingaftercuttingDonotstackcutDonotquenchcutplatesUsethermalcrayonsorsurfacethermometerstomeasurepreheattemperatures

rEFErEnCES/FurTHEr rEAdIng

WTIATechnicalNote5FlameCuttingofSteels.

PLASMA CuTTIng

PlasmacuttingisanacceptablemethodofsectioningallgradesofBISPLATE.Theprocessoffersparticularadvantagesofproductivityoverflamecuttinginthicknessesupto20mmusingcurrentlyavailableequipment.Forinstance,thecuttingspeedof6mmBISPLATE400maybeupto9timesthatrecommendedforconventionalflamecuttingtechniques.

Thecutqualitymaybeinferior,however,duetoroundingofthetopedgesanddifficultyinobtainingasquarecutfaceofbothedges.Guidanceontheoptimumsettingsfornozzlesize,gaspressure,gascompositionandcuttingspeedswillbeprovidedbytheequipmentmanufacturer.BISPLATEwithlowalloycontentsshouldbetreatedsimilarlytoconventionalstructuralsteels.

Theheataffectedzonefromaplasmacutisnarrowerthanthatproducedfromflamecuttingbutpeakhardnessesaregenerallyhigher.Generalrecommendationsfortheremovalofthishardenedzoneareoutlinedbelow.

41

HArdnESS ProFILE CHArACTErISTICS For PLASMA CuTTIng

Table2:

PLATETHICKNESS(mm)RECOMMENDEDDEPTHOF

REMOVAL(mm)PEAKHARDNESS(HB)

BISPLATE

60,70,80,320,400BISPLATE

450BISPLATE

500

5-8 0.4-0.5 430 480 540

>8-12 0.6-0.8 450 480 540

>12-20 1.0-1.2 450 480 540

TheplasmacutHAZtypicallyextends0.51.0mmintotheplateundernormalconditions.Asisthecaseforflamecutting,completeremovalbygrindingisrecommendedifcoldformingofthecutplateiscontemplated.

Allothercommentsforflamecuttingregardingpreheating,removaloftheHAZ,strippingandstackcuttingofplateswouldapplytoplasmacutting.

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42

LASEr CuTTIng

LasercuttingisaproductivemethodforsectioningallgradesofBISPLATEupto12mmthickness,particularlywherehighlevelsofaccuracyandminimaldistortionisrequired.Currently,withthicknessesabove12mm,productivitylevelsdropwhencomparedwithotherprocesses.

Thelasercuttingprocessisunlikeotherthermalcuttinginsofarasthematerialisessentiallyvapourisedfromthekerfratherthanmeltingandremovalbykineticenergy.

Thelaserconcentratesitsenergyintoafocusedbeamresultinginlowlevelsofexcessheat.ThisresultsinverysmallHAZareas(0.050.15mm)andsmallkerfs(0.3mm).

CoMPArISon oF FLAME, PLASMA And LASEr CuTTIng on 6 MM BISPLATE 400

Table3:

PROCESS KERFWIDTH(mm) HAZWIDTH(mm)

FlameCutting 0.9 1.5

PlasmaCutting 3.2 0.5

LaserCutting 0.3 0.2

Cuttingspeedsaretypically5000mm/minandtheedgeisgenerallysquare,burrfreeandminimaldross.

Peakhardnesslevelsarelowerthanthoseobtainedfromalternatecuttingmethodspreviouslydescribed.RemovaloftheHAZisgenerallynotconsiderednecessaryformostapplications,however,forformingoperationsitisadvisedthatBisalloySteelsarecontactedforguidance.

43

PowEr SAwIng

AllBISPLATEgradescanbecutwithpowersaws,providedlowerbladespeedsandbladepressuresupto50%higherthanthoseusedforcuttingplaincarbonsteelareused.Bestresultshavebeenachievedusingpowersawbladesnormallyrecommendedforcuttingstainlesssteel(generally,bladeshaving4-6teethper25mm).Sawingdirectlyontoaflamecutsurfaceshouldbeavoidedwherepossible.

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44

wATErJET CuTTIng

WaterjetcuttingcanbeperformedonallgradesofBISPLATE,althoughitswidespreaduseislimitedduetothecurrentmachinesavailableinAustraliaandtheirlowcuttingspeeds.

AkeyadvantageofwaterjetcuttingisthatitleavesthesurfacefreeofHAZ.Cuttingwithoutheatprotectsagainstmetallurgicalchangesintheplate,ensuringoriginalplatemechanicalpropertiesaremaintained.

RecenttestsperformedbytheCSIRODivisionofManufacturingTechnologyonwaterjetcutting8mmBISPLATE500at40mm/minresultinginnearperfectcutedges.Speedsto75mm/minarepossiblebutwithreducedsmoothnessofthecutedge.

Thewaterjetcutshowsnochangeinmaterialstructureattheedgeofthecut.Thelasercutedgeshowsadistinctchangeinstructuretoadepthof0.2mm.

Bothlasercuttingandwaterjetcuttingareindustrialprocesseswhichshouldbeconsideredbystructuraldesignersandfabricatorsasalternatemeanstoavoidingproblemsassociatedwithfitup,cutedgesquareness,shapeprecision,drossandgrossHAZswhichcanoccurwithconventionalthermalcuttingprocesses.

BisalloySteelswishtothanktheAustralianWeldingjournal,CSIRO-DMT,IanHenderson,CRCforMaterialsWeldingandjoiningandRoryThompson,CSIROIndustryLiasionManagerforinformationpertainingtolaserandwaterjetcuttingcontainedinthispublication.

45

wELdIng oF BISPLATE QuEnCHEd And TEMPErEd STEELS

gEnErAL InForMATIon

AllgradesofBISPLATEcanbereadilyweldedusinganyoftheconventionallowhydrogenweldingprocesses.

Theirlowcarboncontentandcarefullybalanced,butrelativelysmalladditionsofalloyingelements(Mn,Cr,Mo,Ni,B)ensuresgoodweldability,inadditiontotheadvantagesofhighstrength,impacttoughnessandhighhardness.

HydrogEn ConTroL

ToensureadequateweldingofBISPLATE,itisnecessarytobemoremindfulofthelevelsofhydrogen,preheattemperaturesandarcenergyinputsinordertominimisethehardeningandmaintainthepropertiesoftheweldHeatAffectedZone(HAZ).

ParticularattentionmustbepaidtothecontrolofhydrogencontenttominimisetheriskofweldandHAZcracking.

Weldhydrogencontentisminimisedbycarefulattentiontothecleanlinessanddrynessofthejointpreparationsandtheuseofhydrogencontrolledweldingconsumables.

Recommendationsonthecorrectstorageandhandlingofconsumablesmaybeobtainedfromweldingconsumablemanufacturers,forinstancetheuseofHotBoxesforstorageandreconditioningarerequiredwhenusingmanualmetalarcweldingelectrodes.ReferWTIATechNote3forfurtherguidance.

HEAT AFFECTEd zonE ProPErTy ConTroL

TheHAZ,aregiondirectlyadjacenttotheweld,experiencesathermalcyclerangingfromunaffectedparentplatetonearmeltingatthefusionboundary.

Thepropertiesofthiszonearedeterminedbythesteelcompositionaswellasthecoolingrate.

46

STEEL CoMPoSITIon

BISPLATEgradesandchemicalcompositionsmaybedividedintocategoriesbasedonCarbonEquivalentandCETasfollows:

Table1:

BISPLATEGRADE PLATETHICKNESS(mm)CARBONEQUIVALENT(IIW)

TYPICALAVERAGECET

TYPICALAVERAGE

60,70,80,320,400 5-12 0.40 0.29

60,70,80,320,400 13-80 0.50 0.35

60,70,80,320,400 81-100 0.58 0.34

4506-2025-50

0.460.58

0.300.36

500 8-100 0.62 0.42

Notes:1. C.E.(IIW)=C+Mn+Cr+Mo+V+Cu+Ni 6 5152. CET=C+Mn+Mo+Cr+Cu+Ni 10 2040 Thesecategoriesgiveanindicationofthedegreeofcarerequiredintheproperselectionofweldingpreheat/heatinputs.

47

CooLIng rATE

LimitationsonbothpreheatandheatinputarenecessarytoensurethattheHAZcoolsatanappropriaterateandthatthecorrecthardnessandmicrostructureareachieved.TooslowacoolingratecanresultinasoftHAZandthusalossoftensileandfracturetoughnessproperties.ToorapidacoolingrateproducesahardHAZwhichmaycauselossofductility.Coolingiscontrolledbyabalancebetweenpreheatandheatinputforaparticularplatethicknessandjointconfiguration.

PrEHEAT/HEAT InPuT

Thepreheat/heatinputrecommendationsoutlinedintables2and3willensurethatthecoolingrateoftheHAZissatisfactory.

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48

rECoMMEndEd PrEHEAT/InTErPASS TEMPErATurES (C) For BISPLATE

Table2:

BISPLATEGRADEJOINTCOMBINEDTHICKNESS(t1+t2+t3)(mm)

40

49

PErMISSIBLE HEAT InPuT (kJ/MM) For BISPLATE

Table3:

WELDINGPROCESSJOINTCOMBINEDTHICKNESS(t1+t2+t3)(mm)

40 >4060 >60100 >100

MMAW 1.25-2.5 1.25-3.5 1.5-4.5 1.5-5.0

GMAW 1.0-2.5 1.0-3.5 1.5-4.5 1.5-5.0

FCAW 0.8-2.5 0.8-3.5 1.5-4.5 1.5-5.0

SAW 1.0-2.5 1.0-3.5 1.5-4.5 1.5-5.0

Heatinput(kJ/mm)=VoltsxAmpsx0.06 TravelSpeed(mm/minute)

Note:Forthicknessesupto12mminstructuralgrades,themaximumarcenergymayneedtobelimitedto1.5KJ/mmmaximuminspecificapplications

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50

wELdIng BISPLATE

wELdIng ConSuMABLE SELECTIon guIdE For BISPLATE (AS CLASSIFICATIonS)

Table4a:

BISPLATE60

BISPLATE70

BISPLATE80

BISPLATE320,400,450,500

MMAWConsumables*Warning:OnlyuseHydrogenControlledconsumables

StrengthLevel Matching E55XX/E62XX+ E69XX~ E76XX N.R.Lower E49XX E55XX E55XX/E62XX+ E55XXLower E49XX E49XX E49XX E49XX

Hardness Matching N.R. N.R. N.R. 1430-AX,1855-AX^

GMAWConsumables**StrengthLevel Matching W55XX/W62XX+ W69XX+ W76XX N.R.

Lower W50XX W55XX W62XX/W69XX W55XXLower W50XX W50XX W55XX.X W50XX

Hardness Matching N.R. N.R. N.R. 1855-BX^

FCAWConsumables***StrengthLevel Matching BT55X/BT62X+ BT69X~ BT76X N.R.

Lower BT49X BT62X BT62X BT55XLower BT49X BT55X BT55X BT49X

Hardness Matching N.R. N.R. N.R. 1430-BX,1855-BX,1860-BX^

SAWConsumables****StrengthLevel Matching W55XX/W62XX+ W69XX~ W76XX N.R.

Lower W50XX W50XX W50XX W50XXLower W40XX W40XX W40XX W40XX


Table4acourtesyofWTIA(TechNote15)

51

Notes:* MMAW-AS/NZS4855consumableclassification** GMAW-AS2717.1consumableclassification*** FCAW-AS/NZS17632andAS/NZS18276consumableclassification**** SAW-AS1858.1andAS1858.2consumableclassificationX AVariable-anyvalueallowedbytherelevantstandardmaybeacceptableprovidedthattheconsumableishydrogen

controlled(ielowhydrogen)+ E62XXandW62XXtypeconsumablesovermatchthestrengthrequirementsbutmaybeused~ TheseConsumablesmaybedifficulttoobtain.InsomecasesE62XX,W62XXorBT62Xconsumablesmaybe

substituted,otherwiseuseE76XX,W76XXorBT76Xtypes^ AS2576andWTIATN4ClassificationsN.R.NotRecommended

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52

wELdIng ConSuMABLE SELECTIon guIdE For BISPLATE (AwS CLASSIFICATIonS)

Table4b:

BISPLATE60

BISPLATE70

BISPLATE80

BISPLATE320,400,450,500

MMAWConsumables*Warning:OnlyuseHydrogenControlledconsumables

StrengthLevel Matching E80XX/E90XX+ E100XX~ E110XX N.R.Lower E70XX E80XX E80XX/E90XX E80XXLower E70XX E70XX E70XX E70XX

Hardness Matching N.R. N.R. N.R. 1430-AX,1855-AX^

GMAWConsumables**StrengthLevel Matching ER80S-X/ER90S-X+ ER100S-X~ ER110S-X N.R.

Lower ER70S-X ER80S-X ER90S-X/ER100S-X ER80S-XLower ER70S-X ER70S-X ER80S-X ER70S-X


FCAWConsumables***StrengthLevel Matching E8XTX-X/E9XTX-X+ E10XTX-X~ E11XTX-X N.R.

Lower E7XTX-X E9XTX-X E9XTX-X E8XTX-XLower E7XTX-X E8XTX-X E8XTX-X E7XTX-X

Hardness Matching N.R. N.R. N.R. 1430-BX,1855-BX,1860-BX^

SAWConsumables****StrengthLevel Matching F8XX/F9XX+ F10XX~ F11XX N.R.

Lower F7XX F7XX F7XX F7XXLower F6XX F6XX F6XX F6XX


Table4bcourtesyofWTIA(TechNote15)

53

Notes:* MMAWAWSA5.1-2004andAWSA5.5consumableclassification** GMAWAWSA5.18-2005andAWSA5.28consumableclassification*** FCAWAWSA5.20-2005andAWSA5.29consumableclassification**** SAWAWSA5.17-1997andAWSA5.23consumableclassificationX AVariable-anyvalueallowedbytherelevantstandardmaybeacceptableprovidedthattheconsumableishydrogen

controlled(ielowhydrogen)+ E90XX,ER90S,E9XTXandF9XXtypeconsumablesovermatchthestrengthrequirementsbutmaybeused~ TheseConsumablesmaybedifficulttoobtain.InsomecasesE90XX,ER90S,E9XTXorF9XXtypeconsumablesmay

besubstituted,otherwiseuseE110XX,ER110S,E11XTXorF11XXtypes^ AS2576WTIATN4ClassificationsN.R.NotRecommended

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54

wELdIng ConSuMABLES For MAnuAL METAL ArC wELdIng (MMAw)

Table5:

BRANDS BISPLATE60 BISPLATE70 BISPLATE80 BISPLATE

320,400,450,500

CIGWELDM.S. Alloycraft90

Alloycraft90(under)Alloycraft110(over)

Alloycraft110 N.R.

L.S.Ferrocraft61

Ferrocraft16TwincoatFerrocraft61



Ferrocraft16Twincoat

M.H. N.R. N.R. N.R. Cobalarc350,650or750

Lincoln M.S. Conarc70G Conarc80+ Conarc80,Conarc85+ N.R.

L.S.Conarc49C,

Easyarc7018-1Conarc49C,



Easyarc7018-1

M.H. N.R. N.R. N.R. N.R.

W.I.A M.S. N.R. WeldwellPH118 WeldwellPH118 N.R.

L.S.Austarc16TC,18TCor

Austarc77Austarc16TC,18TC

Austarc77N.R.

Austarc16TC,18TCAustarc77

M.H. N.R. N.R. N.R. AbrasoCord350,700

SpecialisedWeldingProducts(SWP)

^WAG=WeldingAlloysGroup

M.S. MetrodeE9018-D1 MetrodeE10018-D2 MetrodeE11018-M N.R.

L.S.WAG^Speedarc7018-1-EWAG^Speedarc7016-E

WAG^Speedarc7018-1-EWAG^Speedarc7016-E

WAG^Speedarc7018-1-EWAG^Speedarc7016-E

N.R.

M.H. N.R. N.R. N.R.

MetrodeMethard350MetrodeMethard650WAG^Hardface400-EWAG^HardfaceL-E

MAnuFACTurErS wELdIng ConSuMABLES

WeldingConsumablessuitableformatchingstrength,lowerstrengthandmatchinghardnessarereadilyavailablefromarangeofconsumablemanufacturersasperfollowingtables5to8.

55

M.S.MatchingStrengthL.S.LowerStrengthM.H.MatchingHardnessN.R.NotRecommendedN.A.NotAvailableN.B.Consumablesinbracketswillmatchmechanicalpropertyrequirementsinthemajorityofinstancesaspermanufacturersrecommendationsandwheretheappropriateweldprocedureisapplied.WeldQualificationproceduresshouldbecarriedouttoestablishactualWeldmetalproperties.

+Overmatchingstrength**C02ormixedgas

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Table5:Continued

BRANDS BISPLATE60 BISPLATE70 BISPLATE80 BISPLATE

320,400,450,500

SMENCO/EutecticCastolin

M.S. N.A. N.A. N.A. N.R.

L.S. Eutectrode66*66 Eutectrode66*66 Eutectrode66*66 Eutectrode66*66

M.H. N.R. N.R. N.R. N.R.

ESAB M.S. OK74.70 OK74.86 OK75.75 N.A.

L.S. OK48.08,OK48.04 OK48.08,OK48.04 OK48.08,OK48.04 N.A.

M.H. N.R. N.R. N.R.OK83.28(30HRC)

OK83.50(50-60HRC)

56

wELdIng ConSuMABLES For gAS METAL ArC wELdIng (gMAw)

Table6:

BRANDS BISPLATE60 BISPLATE70 BISPLATE80BISPLATE

320,400,450,500CIGWELD/STOODY

ContactBisalloyorCigweldforshielding

gasinformation

M.S. AutocraftMnMoAutocraftMnMo(Under)AutocraftNiCrMo(Over)

AutocraftNiCrMo N.R.

L.S.AutocraftLW1orAutocraftLW1-6

AutocraftLW1orAutocraftLW1-6



M.H. N.R. N.R. N.R. AutocraftHF650Lincoln M.S. LNMNi1 LNMNi1(UM) LNMMoNiVa N.R.

L.S. UltraMagS4UltraMagS6**

UltraMagS4UltraMagS6**



M.H. N.R. N.R. N.R. N.R.W.I.A

M.S.AustmigESD2/CO2

orMixedGas AustmigNiCrMo+ AustmigNiCrMo N.R.

L.S.AustmigES6/CO2orMixedGas

AustmigES6/CO2orMixedGas



M.H. N.A. N.A. N.A. TD600/CO2orMixedGasSpecialisedWeldingProducts(SWP)

M.S. SWPD2 SWP110+ SWP110 N.R.

L.S. SWPS6 SWPS6 SWPS6 N.R.

M.H. N.R. N.R. N.R.SWPHF350SWPHF600

SMENCO/EutecticCastolin M.S.

AN45252+/CO2orMixedGas

AN45252+/CO2orMixedGas

AN45252/CO2orMixedGas

N.R.

L.S.DO*65/CO2orMixedGas

DO*65/CO2orMixedGas

DO*65/CO2orMixedGas

DO*65/CO2orMixedGas

57


+Overmatchingstrength**C02ormixedgas

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Table6:Continued


320,400,450,500ESAB

M.S.OKAristoRod13.09

MixedGasOKAristoRod55

MixedGasOKAristoRod69

MixedGasN.A.

L.S.OKAristoRod12.50CO2orMixedGas

OKAristoRod12.50CO2orMixedGas

OKAristoRod12.50CO2orMixedGas

N.A.

M.H. N.R. N.R. N.R.OKAutoRod13.89(30-40HRC)OKAutoRod13.90(50-60HRC)

58

wELdIng ConSuMABLES For FLux CorEd ArC wELdIng (FCAw)

Table7:


320,400,450,500CIGWELD/STOODY

ContactBisalloyorCigweldforshieldinggasinformation

M.S.Seamless Verticor91K2H4

Verticor91K2H4(Under)***Verticor111K3H4(Over)Tensicor110TXPH4(Over)Metalcor110H4(Over)

***Verticor111K3H4Tensicor110TXPH4Metalcor110H4

N.R.

L.S.Seamless(E6XT-X) VerticorXPLTH4 VerticorXPLTH4 VerticorXPLTH4 VerticorXPLTH4

L.S.Seamless

Verticor3XPH4Verticor5XPH4Metalcor5H4

Verticor81Ni1H4


Verticor81Ni1H4


Verticor81Ni1H4


Verticor81Ni1H4

L.S.Seamed

Verticor3XPSuprecor5MetalcorXP

Verticor81Ni181Ni2


Verticor81Ni181Ni2


Verticor81Ni181Ni2


Verticor81Ni1,81Ni2

L.S.SelfShielded

Shieldcor8XPShieldcor8Ni




M.H. N.R. N.R. N.R.StoodySuperBuild-Up-G

Stoody965-GStoody965AP-G

Lincoln M.S. Outershield91Ni1-HSR Outershield91Ni1-HSR(UM) Outershield690-H N.R.

L.S. Outershield81Ni1,71-MX,71-CXInnershieldNR-232,NR-233,NS-3MOutershield81Ni71-MX,71-CX

InnershieldNR-232,NR-233,NS-3MOutershield81Ni-H,71-MX,71-CXInnershieldNR-232,NR-233,NS-3M

Outershield81Ni1,71-MX,71-CXInnershieldNR-232,NR-233,NS-3M

M.H. N.R. N.R. N.R. Lincore33,Lincore36LS,Lincore55-G

W.I.A/HobartBrothers M.S.

Austfil81N1M/MixedGasTM-71HYD/CO2

TM-811N2/CO2orMixedGasFabCO110K3M/MixedGas FabCO110K3M/MixedGas N.R

L.S.

Austfil71T-1/CO2Austfil70C-6M,71T-1M/MixedGas

FormulaXL-525/MixedGasFabshield4,XLR-8

TM-991K2/CO2orMixedGasAustfil81N1M/MixedGas

TM-71HYD/CO2TM-811N2/CO2orMixedGasMetalloy80N1/MixedGas

TM-991K2/CO2orMixedGasAustfil81N1M/MixedGas

TM-71HYD/CO2TM-811N2/CO2orMixedGasMetalloy80N1/MixedGas

Austfil70C-6M,71T-1M,81N1M/MixedGas

Austfil71T-1,TM-71HYD/CO2

TM-811N2/CO2orMixedGasMetalloy80N1/MixedGasFormulaXL-525/MixedGas

Fabshield4,XLR-8

M.H. N.R. N.R. N.R. Vertiwear600/MixedGas

59

M.S.MatchingStrengthL.S.LowerStrengthM.H.MatchingHardnessN.R.NotRecommendedN.A.NotAvailableN.B.Consumablesinbracketswillmatchmechanicalpropertyrequirementsinthemajorityofinstancesaspermanufacturersrecommendationsandwheretheappropriateweldprocedureisapplied.WeldQualificationproceduresshouldbecarriedouttoestablishactualWeldmetalproperties.+Overmatchingstrength**C02ormixedgas***Verticor111K3H4notrecommendedforplatethicknessover20mm

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Table7continued:


320,400,450,500

SMENCO/EutecticCastolin

M.S. N.A. N.A. N.A. N.A.L.S. TeromatecOA2020 TeromatecOA2020 TeromatecOA2020 TeromatecOA2020M.H. N.R. N.R. N.R. N.R.

SpecialisedWeldingProducts

(SWP)^WAG=WeldingAlloysGroup

M.S.WAG^RobofilRNi1+WAG^RobofilMNi1WAG^RobofilBNi1

WAG^RobofilR690+WAG^RobofilM700WAG^RobofilB700


N.R.

L.S.WAG^RobofilR71+WAG^RobofilM71WAG^RobofilB71



N.R.

M.H. N.R. N.R. N.R.

WAG^RobodurK350-GWAG^RobodurK450-GWAG^RobodurK600-GWAG^HardfaceT-GWAG^HardfaceP-GWAG^HardfaceL-GWAG^HardfaceLP-G

ESAB M.S. DualshieldII80-Ni1H4MixedGas DualshieldT-100CO2ShieldingGas DualshieldT-115CO2orMixedGas N.A.

L.S. Dualshield7100UltraMixedGas DualshieldII80-Ni1H4MixedGasDualshield7100UltraMixedGasDualshieldII80-Ni1H4MixedGasDualshield7100UltraMixedGas N.A.

M.H. N.R. N.R. N.R.OKTubrodur15.40(30-40HRC)CO2OKTubrodur15.52(55-60HRC)

CO2orSelfShielded

60

wELdIng ConSuMABLES For SuBMErgEd ArC wELdIng (SAw)

Table8:


320,400,450,500

CIGWELDM.S. N.A. AutocraftNiCrMo(Over)/Satinarc4

AutocraftNiCrMo/Satinarc4 N.R.

L.S. AutocraftSA1SA2/Satinarc4or15AutocraftSA1SA2/Satinarc4or15

AutocraftSA1SA2/Satinarc4or15

AutocraftSA1SA2/Satinarc4or15

M.H. N.R. N.R. N.R. Stoody105or107/StoodySFlux

Lincoln M.S. LincolnweldLA-90/880Mor8500LincolnweldLAC-690/880M

/888+LincolnweldLAC-690/880M

/888 N.R.

L.S. L-60/L-61/761,860,960Flux L-60/L-61/761,860,960Flux L-60/L-61/761,860,960Flux L-60/L-61/761,860,960

M.H. N.R. N.R. LC25-S/880Flux Lincore30-S,Lincore42-S,Lincore50/880or802Flux

ESAB M.S. OKTubrod15.24S+OK10.62 OKTubrod13.43+OK10.62 OKTubrod15.27S+OK10.62 N.A.

L.S. OK12.22/OK10.71 OK12.22/OK10.71 OK12.22/OK10.71 N.A.

M.H. N.A. N.A. N.A. N.A.

SpecialisedWeldingProducts(SWP)

^WAG=WeldingAlloysGroup

M.S. S3Ni1MoWire/BF10Flux S3Ni1MoWire/BF10Flux S3Ni2.5CrMoWire/BF10Flux N.R.

L.S. SWPEM12KWire/WAG^

WAF325FluxSWPEM12KWire/WAG^

WAF325FluxSWPEM12KWire/WAG^

WAF325Flux N.R.

M.H. N.R. N.R. N.R.

WAG^HardfaceT-SWire/WAG^WAF325Flux

WAG^HardfaceP-SWire/WAG^WAF325Flux

WAG^HardfaceL-S/WAG^WAF325Flux

61


+Overmatchingstrength

Atthetimeofprintingallconsumableslistedwerecurrent/accuratebutconsultconsumablemanufacturerforuptodateinformation.

wELdIng ProCEdurES

Thespecificeffectsofweldingonweldjointpropertiesinanypracticalsituationwilldependonmanyfactorsincludingthechoiceofconsumables,totalweldheatinput,levelofrestraint,weldgeometryandproximityofadjacentwelds.

GuidanceonweldproceduresforspecificapplicationsmaybesoughtfromBisalloytechnicalstafforconsumablesuppliers.

ArC STrIkES

Arcstrikesoutsidetheweldedzonecanresultincracks,particularlyondynamicallyloadedstructures.Allstrikesshouldbemadewithinthejointpreparation.

TACk wELdIng

Tackweldsrequirespecialcareduetotheabnormalstressesandhighcoolingratesexperiencedbytheadjacentmaterial.Thesamepreheat,heatinputrequirementsshouldbeemployedandlowerstrengthweldingconsumablesconsidered.

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62

FILLET wELdIng

GoodfilletweldingtechniquesareimportantinweldingQ&Tsteelsbecauseoftenveryhighstressesareappliedinservice.Itisessentialthatweldshavegoodrootpenetration,besmooth,correctlycontouredandwellflaredintothelegsofthejoinedpieces.Lowerstrengthconsumablesaresuggestedwhendesignpermits.

WTIATech.Note15providesguidanceoncorrectproceduresforfilletwelding.

rEPAIr work

Itisgoodpracticetoweldrepairwithlowerstrengthconsumables(lowhydrogentype),sinceplatematerialswhichhavebeenhighlystressedinservicemaytendtowarpordistortslightlyduringweldingandimprovedductilitymayberequired.Insomesituations,suchasjointsunderrestraint,jointssubjectedtoimpact/fatiguestresses,etc,specialweldingconsumablesmaybenecessary.

wELdIng STrESSES

Itshouldbeemphasisedthattherecommendedvaluesofpreheatandheatinputarebasedonlowtomoderatelevelsofrestraint.Forconditionsofhighrestraintitisimportanttominimisethedegreetowhichfreecontractionishamperedanditmaybenecessarytousehigherpreheats.Properweldingsequenceandsmalljointconfigurationswouldbeconsideredimportantinhighrestraintsituationsanditisadvisabletoestablishweldingparameterswithsimulatedfullscaleweldtests.

Careshouldalsobeexercisedattheassemblystagetoavoidoffsetandangulardistortionattheplateedge,undercuttingandbadappearance.

STrESS rELIEF

StressreliefmaybeconductedonBISPLATE60,70,80and80PVgradesbutisadvisableonlyifabsolutelynecessary(eg.tocomplywithAS1210inthecaseofroadtankers).Stressreliefisrecommendedwithina540-570Ctemperaturerangeforonehourper25mmofthickness.ThermalcyclingisgenerallyperformedinaccordancewithAS1210CoderequirementsforQ&Tsteels.Thetoesofweldbeadsshouldbedressedbygrindingpriortoanystressrelieftreatmentinordertopreventstressreliefcracking.

63

WhenstressrelievingBISPLATE12mm(typically0.40CE(IIW))andmatchingstrengthacrosstheweldisarequirement,itisrecommendedtoweldwithminimumpermissiblepreheat/interpasstemperatures(Table2)andheatinput(Table3)conditionstominimisethedegreeofsofteningoranylossofstrengthwhichmayoccurintheHAZ.

ConsultBisalloySteelsforfurtherinformationifrequired.

PoST-wELd HEATIng

Post-weldheatingat200-250CmaybeconductedasaneffectivehydrogendissolutiontreatmentparticularlywhenconsumablesotherthanH5orH10areused.

HELPFuL HInTS

GeneralrulesforgoodqualityweldingofBISPLATE:Usealowhydrogenprocess,eg.GMAW(MIG),FCAW(gasshielded)Adheretothecorrectrulesforstorageandhandlingoflowhydrogenconsumablesperthemanufacturersrecommendations,orWTIATech.Note3

CleanjointareaofallcontaminantspriortoweldingRemove1-2mmfromflamecutorgougedsurfacesbygrindingSelecttherecommendedpreheat,interpassandheatinputparametersPositionfordownhandweldingwherepossibleAlwaysusestringerbeads,neverwideweavesUselowerstrengthconsumablesonrootrunsandfilletwelds(whenthedesignpermits)UsetemperbeadswhennecessaryArcstrikestobemadeinthejointpreparationParticularattentionshouldbegiventotackweldsrepreheat,heatinputandjointcleanlinessrequirementsGrindingtoesoffilletweldsisparticularlyimportantinfatigueapplications

rEFErEnCES/FurTHEr rEAdIng

AS1554Part4WeldingofQ&TSteelsAS1554Part5WeldingofSteelStructuresSubjecttoHighLevelsofFatigueLoadingWTIATechnicalNote15WTIATechnicalNote3WTIATechnicalNote1

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64

BEndIng, roLLIng, ForMIng, SHEArIng And PunCHIng BISPLATE

ForMIng

CoLd ForMIng

AlloftheBISPLATEquenchedandtemperedsteelgradescanbecoldformed,usingbrakepressbendingorplaterollingtechniques.

However,withanincreaseinbothhardnessandyieldstresscomparedtoplaincarbonsteelgrades,suitableconsiderationofsufficientmachinepower,platebendingdirectionandformerradiimustbemade.

Inaddition,springbackallowancesshouldbegreaterthanforplaincarbonsteelandwilldependonthetypeofforming.Plateedgesshouldbegroundsmooth,andforthickplatesandhighhardnessgrades,theplateedgesshouldberoundedpriortoforming.

Itisrecommendedforthehighhardnessgradesthatwherepossiblethebendaxisbeatrightanglestotheplaterollingdirection(transversebending).Forplate16mmandaboveinBISPLATE500grade,itissuggestedbendingbedoneinthetransversedirectiononly(refertofigure1a).

Figure1a:

Figure1b:

Figure2:

Schematic of transverse bend direction.

Plate Rolling Direction

Ben

d A

xis

Schematic of longitudinal bend direction.

Plate Rolling Direction

Bend Axis

Schematic diagram of brake press bending.

W = Width t = Thickness r = Radius

65

MInIMuM ForMEr rAdII (r) In MM For CoLd ForMIng

Table1followinggivestheminimumformerradiiforcoldformingoftheBISPLATEgrades(wherepossiblealargerformerradiishouldbeused).

Table1:

BISPLATEGRADE 60 70 80 320,400 450 500

BendDirection T L T L T L T L T L T L

PlateThickness(t)(mm)5681012162025324050

121212151824405064100140

121516202432506280120190

121212151824405080110150

121516202432506295130200

1215202530456575100125150

1215202530456575110140200

1520253035507080110170300

202535455575100125175250

253240486480100130160200

3040506080100130160200250

40506085100150250

7090110

T:TransverseBendingDirection(refertofigure1a)L:LongitudinalBendingDirection(refertofigure1b)

Notesre:Table11.Abovevaluesweredeterminedforplateatatemperatureof30C.Ifminimumformerradiivaluesaretobeused,plate

temperatureshouldbeatleast30C,maximum100C.Ifformingatatemperaturelessthan30C,anincreaseinformerradiiofminimum50%mustbemade

2.Whenpressingisbeingdoneinasinglepassoperation,anincreaseinformerradiiofminimum50%mustbemade3.Whenformingusingtheseminimumformerradii,flamecuthardenededge(heataffectedzoneof1-2mm)shouldberemoved4.Theuseofsmallerformerradiithaninthetableisnotrecommended5.Forbestcoldformingresults,ensureadequatelubricationbetweentheplate,dieandformer6.Dieopenings:refertoTable3

66

CAPACITy oF PrESS

AllBISPLATEgradeshaveyieldandtensilestrengthshigherthanforplaincarbonsteel.

Itisimportantthatthecapacityofthemachineissuitable,bendingpressmanufacturersprovideinformationonbendingloadsinrelationtoV-blockopening,platethicknessandsteelstrength.

Table2givesanindicationoftheapproximatebendingforcerequiredwhenformingBISPLATEgrades,comparedtoplaincarbonsteel(e.g.AS3678-Grade250).

Approximatebendingforce(P)requiredforBISPLATEgrades,comparedtoplaincarbonsteel,foragivenforminggeometry(referfigure2).

67

Table2:

STEELGRADE BENDINGFORCE(P)

AS3678Grade250 P

BISPLATE 60 2.0P

70 2.4P

80 2.8P

320 4.0P

400 5.0P

450 5.2P

500 6.4P

ApproximateDieOpenings(referfig2)

Table3:

BISPLATEGRADE W/tTRANSVERSEBENDINGW/tLONGITUDINAL

BENDING

607080320400450500

6.06.07.08.58.510.010.0

7.57.58.510.010.012.012.0

HoT ForMIng

TheoperationofhotformingisnotrecommendedfortheBISPLATEgrades,ashotformingisgenerallydoneatahightemperature(900-1000C)whichexceedsthetemperingtemperature.

Asaresult,themechanicalpropertiesofquenchedandtemperedsteelswillbereducedconsiderably.

However,ifhotformingisunavoidable,itisessentialthatthecomponentberequenchedandtemperedtorestoreoriginalmechanicalproperties.

SHEArIng And PunCHIng

ShearingandpunchingofthelowerhardnessBISPLATEgradescanbedonesuccessfully,providedamachineofsufficientpowerandstabilityisused.

BISPLATE60,70and80gradescannormallybecoldshearedupto25mmthickness.However,thenecessaryshearingforceisintheorderof2-3timesthatrequiredforplaincarbonsteelgrades.ThegradesofBISPLATE400,450and500shouldnotbeconsideredforshearing.

Theguillotinebladesshouldbeverysharpandsetwithaclearanceof0.250.40mm.Note,themaximumlimitingthicknessforcoldpunchingareapproximatelyhalfthecoldshearingvalues.

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He

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ing

& P

un

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68

MAxIMuM THICknESS For CoLd SHEArIng And PunCHIng

Table4:

BISPLATEGRADE COLDSHEARING COLDPUNCHING

607080320400450500

25mm25mm25mm10mm

NotRecommendedNotRecommendedNotRecommended

12mm12mm12mm6mm

NotRecommendedNotRecommendedNotRecommended

69

drILLIng, CounTErSInkIng And TAPPIng BISPLATE

gEnErAL InForMATIon

AllgradesofBISPLATEareabletobedrilled,countersunkandtappedalthough,aswithmostfabricationaspects,careshouldbetakenwiththesegradesofsteel.

Inallcases,suitablehighpoweredandrigiddrillingequipmentshouldbeused.

drILLIng oF HIgH STrEngTH STruCTurAL grAdES

WhendrillingthestructuralBISPLATEgrades60,70and80theuseofcobalttypehighspeedsteeldrillsisrecommended.Drillsequippedwithreplaceablecarbideinsertscanalsobeused.

drILLIng oF wEAr/ABrASIon rESISTAnT grAdES

BISPLATE320,400and450gradesmaybedrilledwitheithercobalttypehighspeedsteeldrillsordrillsequippedwithreplaceablecarbideinserts.

WithregardstothedrillingofBISPLATE500grade,werecommendonlytheuseofdrillsequippedwithreplaceablecarbideinserts.

rECoMMEndATIonS For IMProVEd rESuLTS

ThesupportingbarsundertheplateshouldbeplacedasclosetotheholeaspossibleIfpossible,useaplaincarbonsteelbackingplateundertheBISPLATE

ThedrillingheadshouldbeplacedascloseaspossibletothemainsupportShortlengthdrillsarepreferredThelastpartoftheholetobedrilledshouldbedonewithmanualfeedUsageofadequatecoolant(waterandoilemulsionmixture)

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APProxIMATE FEEdS And SPEEdS uSIng CoBALT TyPE HIgH SPEEd STEEL drILLS

Table1:

STEELGRADEPERIPHERAL

SPEED(m/min)

R.P.M.(UPPERFIGURES)ANDFEEDPERREVOLUTION(mm)FORGIVENDRILLSIZE HARDNESS(HB)

5mm 10mm 15mm 20mm 25mm 30mm

AS3678-Grade250 ~2314650.10

7350.15

4900.20

3700.25

2950.35

2450.4

~120

BISPLATE60 ~2012800.10

6400.10

4250.16

3200.23

2550.30

2100.35

~220

BISPLATE70 ~1912100.10

6100.10

4100.16

3000.23

2400.30

2000.35

~240

BISPLATE80 ~1811500.10

5750.10

3900.16

2900.23

2300.30

1900.35

~260

BISPLATE320 ~127600.07

3800.10

2500.16

1900.23

1500.30

1300.35

320(min)

BISPLATE400 ~95700.05

2850.10

1900.16

1500.23

1100.30

900.35

370(min)

BISPLATE450 ~74400.05

2200.09

1500.15

1100.20

900.25

750.30

425(min)

Note:Thistableapplieswhencobalttypehighspeeddrillsareusedwithacuttingfluid,ifnofluidisusedthespeedsshownabovemustbereduced

71

DrillTipConfigurationforCobaltTypeHighSpeedDrills

Fig2:

ApproximateFeedsandSpeedsUsingDrillsWithReplaceableCarbideInserts

rECoMMEndEd drILL TIP ConFIgurATIon For CoBALT TyPE HIgH SPEEd drILLS

Table2:

BISPLATEGRADE POINTANGLE LIP/CLEARANCEANGLE

607080

118deg.118deg.118deg.

10deg.10deg.10deg.

320400,450

125deg.150deg.

7.5deg.5deg.

Point AngleSchematic of Drill Tip

Lip/Clearance Angle

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APProxIMATE FEEdS And SPEEdS uSIng drILLS wITH rEPLACEABLE CArBIdE InSErTS

Table3:

BISPLATEGRADE INSERTGRADE SURFACESPEED(m/min) FEEDRATE(mm/rev) BRINELLHARDNESS

60 1020 125-210 0.06-0.18 ~220

70 1020 125-210 0.06-0.18 ~240

80 1020 125-210 0.06-0.18 ~260

320 1020 125-210 0.06-0.18 320-360

400 H13A 125-210 0.06-0.18 370-430

450 H13A 70-90 0.06-0.14 425-475

500 H13A 70-90 0.06-0.12 500(avg)

Note:AbovedrillingrecommendationsarebasedonusingaSandvikCoromantUdrillandisbasedonholesizesof12.7-60mmdiameter.Throughthetoolcoolantmustbeused.Itmaybenecessarytousedifferentinsertgradesandgeometriestosuittheapplication.

FurtherinformationcanbeobtainedfromyourlocalSandvikCoromantoffice.

73

CounTErSInkIng And CounTErBorIng

CountersinkingandcounterboringofholesispossibleinallBISPLATEgradeswithbestperformanceobtainedusingtoolswitharevolvingpilot.Thepilotincreasesthestabilityandallowstoolswithreplaceablecarbideinsertstobeused.

CobalttypehighspeedsteeldrillswithapilotcanbeusedfortheBISPLATEgrades60,70,80,320,400and450.Thecuttingdatawillvaryfrommachinetomachine.Acoolantshouldbeused.ReplaceablecarbideinserttoolsshouldbeusedonBISPLATE500grade.

CuTTIng SPEEdS And FEEdS wHEn uSIng HIgH SPEEd STEEL CoBALT TyPE TooLS

Table4:

BISPLATEGRADE

CUTTINGSPEED(m/min)

16 20 25 32 40 60

RPM FEED(mm/r) RPMFEED(mm/r) RPM

FEED(mm/r) RPM

FEED(mm/r) RPM

FEED(mm/r) RPM

FEED(mm/r)

60 10-12 250 0.05-0.2 200 0.05-0.2 160 0.07-0.3 110 0.07-0.3 90 0.07-0.3 70 0.07-0.3

70 9-11 210 0.05-0.2 170 0.05-0.2 130 0.07-0.3 90 0.07-0.3 60 0.07-0.3 60 0.07-0.3

80 7-9 170 0.05-0.2 130 0.05-0.2 100 0.07-0.3 70 0.07-0.3 60 0.07-0.3 40 0.07-0.3

320 6-8 150 0.05-0.2 120 0.05-0.2 90 0.07-0.3 60 0.07-0.3 50 0.07-0.3 40 0.07-0.3

400450

4-6 130 0.05-0.2 105 0.05-0.2 75 0.07-0.3 50 0.07-0.3 40 0.07-0.3 30 0.07-0.3

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CuTTIng SPEEdS And FEEdS wHEn uSIng rEPLACEABLE InSErT TooLS

Table5:

BISPLATEGRADE

CUTTINGSPEED(m/min)

20 25 32 40 60

RPM FEED(mm/r) RPMFEED(mm/r) RPM

FEED(mm/r) RPM

FEED(mm/r) RPM

FEED(mm/r)

60 90-110 1675 0.15-0.20 1320 0.15-0.20 935 0.10-0.15 760 0.10-0.17 560 0.10-0.15

70 80-100 1500 0.15-0.20 1195 0.15-0.20 840 0.10-0.15 680 0.10-0.17 500 0.10-0.15

80 70-90 1340 0.15-0.20 1060 0.15-0.20 750 0.10-0.15 605 0.10-0.17 445 0.10-0.15

320 40-60 840 0.15-0.20 660 0.15-0.20 470 0.10-0.15 380 0.10-0.17 280 0.10-0.15

400 28-35 550 0.15-0.20 420 0.15-0.20 300 0.10-0.15 250 0.10-0.17 175 0.10-0.15

450 25-30 450 0.15-0.20 360 0.15-0.20 250 0.10-0.15 200 0.10-0.15 150 0.10-0.15

500 17-20 300 0.15-0.20 240 0.15-0.20 170 0.10-0.15 136 0.10-0.17 100 0.10-0.15

TAPPIng

Withthecorrecttoolsandcuttingspeeds,tappingcanbeperformedinalltheBISPLATEgradesofsteel.ForthehighhardnessBISPLATE400,450and500grades,higheralloyedtapsmustbeused.

Difficultiesthatcommonlyarisewhenthreadcuttinghighertensilestrengthsteelsincludetapsticking,tornthreadsandtheshortlifeoftaps.ThePrototypebrandtoolshavebeenspecificallydevelopedfortappingintheBISPLATEgradesofsteel.

Withalltappingitisrecommendedthatthecuttingspeedisaccuratelycontrolled.

Forbestresults,cuttingoilorgreaseshouldbeused.Forthrough-holesofupto2timesdiameterinthreaddepth,inmetricsizes,thefollowingtappingtoolsarerecommended.

Note:Theintroductionofstressconcentrations(asaresultoftapping)isanimportantconsiderationinfatigueapplications

75

TAPPIng SPEEdS And TyPES rECoMMEndEd For BISPLATE grAdES

Table6:

BISPLATEGRADE TAPTYPE(prototype) TAPPINGSPEED(m/min) SIZERANGE LUBRICATION

60 Paradur20360 15 M3-M56 CuttingOil

70 Paradur20360 15 M3-M56 CuttingOil

80 PrototexInox202135 6-15* M1.6-M36 CuttingOil



450 PrototexNi202602 3 M1.6-M24 CuttingOil

500 ParadurH/C80311 1.6 M3-M12** CuttingOil

*6m/minusingsteamtemperedtapsand15m/minusingtincoatedtips

**Forlargersizethreads,threadmillingisrecommended

BisalloySteelswishtothanksSandvikCoromantandTi-Tekfortheinformationpertainingtodrilling,tappingandcountersinkingcontainedinthispublication.

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TurnIng And MILLIng BISPLATE

MILLIng And TurnIng rECoMMEndATIonS

MILLIng

MillingoperationscanbeperformedsatisfactorilyonallBISPLATEgrades;utilisationofcementedcarbidetoolingisrecommended.

Inmanysituations,themillingoperationentailsthedressingofaflamecutedge,andthensubsequentbulkmillingofmaterialtothedesiredsurfacefinishanddimensionaltolerance.

Caremustbetakentomakeafirstcutsufficientlydeeptoremovetheheataffectedzoneoftheflamecutedge.Cuttersmustbesufficientlyrobusttotakethisheavyloading.Insuchcircumstancesitisdesirablethat,duetothehighhardnessadjacenttotheflamecutsurfaces,cutterspeedsandfeedratesforinitialmillingshouldbereducedto40-50%ofthespeednormallyusedwhenmillingplaincarbonsteel.Theimportanceofadequatepreheatingpriortoflamecuttingandslowcoolingaftercuttingtominimiseedgehardeningisagainemphasised.Speedandfeedratesmaybeincreasedsomewhatforsubsequentbulkmillingto50-75%ofthesettingsusedforplaincarbonsteel.

MILLIng rECoMMEndATIonS

Table1:

BISPLATEGRADE CEMENTEDCARBIDETOOLINGGRADE SURFACESPEED FEED/TOOTH

607080320400450500

GC4030GC4030GC4030GC4030GC4030GC4030GC4030

295m/min275m/min257m/min131m/min110m/min100m/min87m/min

0.25mm0.25mm0.25mm0.25mm0.25mm0.25mm0.25mm

Note:Theserecommendationsaregivenasaguideonly,andarebasedonstableworkingconditions.Itissuggesteda45deg.approachangleoraroundinsertfacemillbeused.Incertainconditionsitmaybenecessarytousenegativegeometrymillingtools.Feedratesaredependentongeometryselected.Eg.PMmediummachining0.10.28fzmm/toothPHheavymachining0.10.42fzmm/tooth.

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AVoId VIBrATIonS

Indexableinsertsaresensitivetovibrations.Thesecanbeavoidedorreducedbyobservingthefollowing.

Whenturningormillinggascutedgesthecuttingdepthshouldbeatleast2mmtocopewiththehardnessandunevennessoftheedge.

Figure1: Figure2:

Showing the direction of milling. Showing the eccentricity milling cutter.oTHEr MILLIng rEQuIrEMEnTS

FirmclampingoftheworkpieceUsecutterswiththesmallestpossiblegapbetweentheteethMachinestabilitypermitting,unidirectionalmillingispreferable,seefigure1Ifalargecutterisusedforthemillingofsmallareas,placethemillingcuttereccentricallytogetasmanyteethaspossibleoperating,seefigure2

Avoid,ifpossible,theuseofauniversalcutterheadwhichgenerallycausesweakeningofthepowertransmissionandthetoolholder

tu

rn

ing

& M

illi

ng

Bis

Pla

te

Undirectional milling

Opposed milling

Normal width

Small width

78

TurnIng

AllBISPLATEgrades,includingthosewithhardnessinexcessof360HBcanbeturnedsatisfactorilywithcarbidetooling,providedspindlespeedsandfeedratesarereducedfromthosenormallyemployedwhencarryingoutsimilarmachiningoperationsonplaincarbonsteel.Reductionsof50-70%inspindlespeedandupto50%infeedratemaybenecessary,dependingonthehardnessofthecomponentbeingmachined.Highspeedtoolsarenotrecommended.

Asanexample,thefollowingsettingshavebeenfoundtogivesatisfactoryresultswhenturningcylindricalworkpiecesof25mmdiameterfromthevariousBISPLATEgrades.Withincreasesinstockdiameter,spindlespeedswillobviouslyneedtobedecreased.

TurnIng rECoMMEndATIonS

Table2:

BISPLATEGRADE CEMENTEDCARBIDETOOLINGGRADE SURFACESPEED

607080320400450500

GC4025GC4025GC4025GC4025GC4025GC4025GC4025

295m/min275m/min257m/min131m/min110m/min100m/min87m/min

ForoperationsunderfavourableconditionswherehigherproductivitycanbeobtainedGC4015couldbeused.ForoperationswithhightoughnessrequirementsandwhereincreasedsecurityisneededGC4035couldbeused.

Note:Theserecommendationsaregivenasaguideonlyandarebasedonstableworkingconditions.Thegeometryoftheinsertsusedwillbedependentontheoperation.Eg.PFforfinishing.PMformediummachining.PRforroughing.

79

Figure3:

Geometry of Turning insert: Finishing (F) Medium Machining (M) Roughing (R)

oTHEr TurnIng rEQuIrEMEnTS Figure4:

FirmclampingoftheworkpieceAvoidlongoverhangsforbothworkpieceandtoolholderUsecorrecttipradius:toolargeatipradius,combinedwithinsufficientclamping,causesvibrationsSmallsettinganglesalsocancausevibrations

Diagram showing that some coated inserts combine toughness and hardness.

Cutting depth

Feed

Wea

r R

esis

tanc

e

Toug

hnes

s

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& M

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80

ForMuLA For THE CALCuLATIon oF SPEEdS And FEEdS For gEnErAL MILLIng And TurnIng oPErATIonS.

Formulaforcalculationofcuttingspeed:v= Dnm/min 1000

Formulaforcalculationofturningspeed:n=v1000m/minD

Formulaforcalculationoftablefeed:u=nZSzm/min

v=cuttingspeedm/minD=DiameterinmmofmillingcutterorworkpieceZ=NumberofcuttersSz=Feedpercutter,mmn=Turningspeed,rpmu=Tablefeed,mm/min

BisalloySteelswishtothankSandvikCoromantforinformationpertainingtomillingandturningcontainedinthispublication.

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BISPLATE IdEnTIFICATIon MArkIng And CoLour CodIng

BisalloySteelshasaseriesofidentificationmarkingsandcolourcodestoclearlyidentifytheplatespecificationsanddifferentiatethegradesfromeachotherandothergradesofsteel.Itiscrucialthatwhenplatesareprofiledthatthisidentificationistransferredtoalloff-cutstopreventgradeandsizemixes.

grAdE IdEnTIFICATIon STEnCILS-therearetwogradeIDstencilsoneachplatelocatedatoppositeendssothatifplatesarehalvedtheneachendremainsidentified.Thesestencilsarecolourmatchedtothegradecolourcoding.

PLATE IdEnTIFICATIon STEnCILStherearetwoplateIDstencilsoneachplatelocatedatoppositeendssothatifplatesarehalvedtheneachendremainsidentified.

ForDomesticOrders ForExportOrders

Platesdeliveredviacentralstockwillnothaveacustomername.

Bis

Pla

te

id

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ica

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n M

ar

kin

g a

nd

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lou

r c

od

ing

CustomerNameDimensionsPlateWeightGradeAustralianStandard(ifapplic.)

CustomerNameCustomerO/No.DimensionsPlateWeightGradePlateNumber

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PLATE CornErStwodiagonalcornersoftheplatearecolouredwiththerelevantgradecolourcode.

Oneplatecornerishardstampedwiththeplatenumber.

PlatenumberColourcode

grAdE CoLour CodE

BISPLATE60 -WhiteBISPLATE70 -LimeGreenBISPLATE80 -Pink BISPLATE80PV -Pink/RedBISPLATE320 -LightBlueBISPLATE400 -OrangeBISPLATE450 -YellowBISPLATE500 -Black

R.D.

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TESTIng And CErTIFICATIon

MECHAnICAL TESTIng

BrInELL HArdnESS TESTBrinellhardnesstestisperformedinaccordancewiththerequirementsofAS1816.Allplatesareindividuallyhardnesstested.

TEnSILE TESTSStructuralsteelgradesonlyaretensiletestedinaccordancewiththerequirementsofAS1391andthesetensiletestsaredoneonabatchbasis,perrequirementofAS3597.

CHArPy V-noTCH IMPACT TESTSStructuralsteelgradesonlyareimpacttested.CharpyV-Notchtestsaredoneonabatchbasis,perrequirementofAS3597.

Standardtestdirectionislongitudinalandstandardtesttemperatureis-20degC.

TestsconductedinaccordancewithAS1544.2requirements.

te

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CErTIFICATIon

AseparateNATAcertifiedtestcertificatewillbeissuedforeachfullplatesupplied.TestsareconductedinourNATAcertifiedlaboratoryandwilldetailchemicalanalysis,hardnessandrelevantmechanicaltestinformationdependentonthegradeordered.

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HArdnESS TESTIng BISPLATE

wHAT IS HArdnESS?

Hardnessistheresistanceofmaterialtoplasticdeformationusuallybyindentationorpenetration.Italsodefinestheabilityofmaterialtoresistscratching,abrasionorcutting.

wHy TEST For IT?

Hardnesstestingisundertakento: 1.Specifyandcertifyarangeofwearresistanceproducts. 2.Doublecheckthetensilestrengthofstructuralgradematerials. 3.Assistinfailureanalysesandmaterialidentification.

Table1:

METHOD STANDARD BASIS MEASUREMENT ACCURACYAPPROX% MAXTEMP

Brinell(4) AS1816

10mmTungstenCarbideball(1)impressedunder3,000kgload

Surfaceareaforknownload

2 50C

Vickers(HV) AS1817136Diamondpyramidimpressedunderload

Surfaceareaforknownload

2 50C

Rockwell(HR)A,B,CAS1815

ISO6517-1

120ConicalDiamondSteelballusedforsoft

metals

Depthofimpressionunderknownload

(15-150kg)2 50C

Equotip(2) NIL ReboundMethod Heightofrebound Poor

Poldi(3) NIL10mmBallimpressedwithhammeredtestbar

ComparativeimpressionVeryPoor(20)

50C

Ha

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ne

ss

te

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ing

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86

wHErE To TEST?

Testingcanbecarriedoutinthelaboratory,workshoporonsite.

However,sitetestingwithportableequipmentcanoftenhavedifficultiesofaccess,surfacepreparationandvibration,whichmayreducetheaccuracyoftesting.

TESTIng ProCEdurES And EQuIPMEnT

Thetableabovesetsoutthemethodsofidentifyingcommonindentationhardness,andothertypesofhardnesstests.Itisabsolutelyvitaltounderstandthespecificuses,strengthsandanyweaknessesofandcorrectrequirementsandproceduresdemandedbyeachofthesemethodsinordertoensureconsistent,comparableresultsintesting.InTErPrETIng TABLE 1 SoME IMPorTAnT ConSIdErATIonS

1.Wherethemaximumhardnessoftheworkexceed450HB,butdoesntexceed650HB,thestandardsaysatungstencarbideballmustbeused.

2.Equotipisareboundmethodofhardnesstesting,whichdoesNOTmeasurehardness(indentationorplasticdeformation)butgivesaresultconvertiblewithinarestrictedrangeintoanindentationhardnessfigure.Thismethodisnotstandardisedandgivesonlyindicativeresults.Itisextremelydependentontheoperator,testmaterialandsurfacecondition.ItisNOTrecommendedonquenchedandtemperedsteel,orsurfacesthatarentbrightandsmoothlyground.

3.ThePolditestissometimesemployedinthefield.Eventhoughitisanimpressionmethod,itdisplaysverypooraccuracy.Itisnotrecommendedforquenchedandtemperedsteel.

4.TheBrinelltestisstronglyrecommendedforallBISPLATEgradesasitiswidelyacceptedastheindustrystandard.(Brinellgivesamoredefinitereading,byleavingamoredefiniteimpressionontheplate).ItisthestandardemployedatBisalloyandbyothermanufacturers,bothontheproductionlineandinthelaboratory.ThehardnessratingonacertificateissuedbyBisalloyismeasuredinBrinellhardness.ConvertedvaluesfromothermethodssuchasRockwellorVickers(moreoftenusedinlaboratorytestingsmallsamplesofsteel,orinsmall-partsengineering,andnotidealforuseintheproductionenvironment)cancausesmalldiscrepanciesfromtheBrinellratingonthecertificate.

87

ProPEr PrEPArATIon oF THE TEST SurFACE

SinceBISPLATEisaquenchedandtemperedsteel,somedecarburisationwilloccurontheplatesurfaceduringtheheattreatmentprocess.Thethicknessofthedecarburisedlayer(theverythinsurfacelayerwhichhaslostcarbonduringaustenitising)willvarydependingontheplatethickness.Thisdecarburisedlayerwillgetthickerastheplatethicknessincreases.

Toensuretestingaccuracy,surfacescaleandthedecarburisedlayermustalwaysberemovedbyeithergrindingormachiningfromtheareaswherehardnessmeasurementsaretaken.TheminimumgrindingormachiningdepthsarelistedintheTable2.

Table2:

PLATETHICKNESS MINGRINDINGORMACHININGDEPTHS(mm)

6 0.2

>6-10 0.3

>10-20 0.5

>20-50 0.7

>50-80 1.0

>80 1.5

Withoutremovingtheentiredecarburisedlayerbygrindingormachining,theresultsofthehardnesstestwillbeinvalid.

Itshouldalsobenotedthattheareatestedshouldbeamin.of75mmfromanythermallycutsurfacetoavoidanyheat-affectedzone.

Thetestedareamustrepresentthewholematerial,mustbeclean,freefromunwantedscale,andmustbeflat,sufficientlythickandsmooth.

Thetestpiecemustbewellsupportedandnotsubjecttomovementorvibration.

88

CALIBrATIon

Tofurtherensureaccuracyandconsistency,alltestingequipmentmustbecalibrated(usually3yearly)andcheckeddailyagainstcalibrationblocks.

PErSonnEL CoMPETEnCy

Foralltests,theoperatorrequirestraininginthecorrectmethodsandassessmentacceptabletotheemployer.PreferenceisgiventoNATAregisteredlaboratoriesforhigh-riskapplications.

rEPorTIng

Reportingshouldincludeplateidentification,location,method,result,date,surfacecondition,operatorsnameandsignature.RefertoAS1816.

Table3:

GRADE SPECIFIEDHARDNESS(HB) TYPICALHARDNESS(HB)

BIS80 255

BIS320 320-360 340

BIS400 370-430 400

BIS450 425-475 450

BIS500 477-534 500

89

CurrentlyalreadyuniqueamongothermanufacturersBisalloygoestotheextentofphysicallytestingeveryplateproducedthatis,eachonegoesthroughthefullprocessofgrinding,testandmeasure.

Thesizeoftheindentationismeasuredusingthelatestvideoimagingtechnology,whichisinterfacedwithadedicatedcomputertogenerateaBHnumbertowithinonepoint.

Thistestingprocedureisnowfullyautomatedincludingautomatedgrindingandindentation,guaranteeinganevengreaterandmoreconsistentlevelofaccuracyandrepeatability.

disclaimer Every care has been taken to ensure the accuracy of information contained in this manual which supersedes earlier publications, however Bisalloy Steels shall not be liable for any loss or damage howsoever caused or arising from the application of such information. Typical values are provided for reference information only and no guarantee is given that a specific plate will provide these properties. Specification correct at time of printing, however information is subject to change without notice.

registered trade Marks

Bisalloy Steels Bisalloy BIS BISPLATE are all registered trade marks of Bisalloy Steels Australia Pty Ltd. Print Date: October 2012

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For more information regarding BISPLATE refer to the technical information pdf documents provided on the Bisalloy Steels website at www.bisalloy.com.au

Bisalloy Steels Pty Ltd18 Resolution Drive, Unanderra PO Box 1246, Unanderra NSW, Australia, 2526

Ph: +61 2 4272 0444Fax: +61 2 4272 0456Email: [email protected]: www.bisalloy.com.au

Documents

Bisalloy Tech Guide 2012-2013(1)