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D R I V I N G I N N O V A T I O N
THE GROUP
ABOUT US
QUALITY ACCREDITATIONS
The Kalyani Group is one of the leading Industrial Houses in India, having diverse business interests in Engineering Steel, Forgings, Auto Components, Non Conventional Energy & Speciality Chemicals. The Group's Annual Turnover is over USD 2.4 billion and has joint ventures with some of the world leaders such as Arvin Meritor (USA), Carpenter Technology Corporation (USA), Hayes Lemmerz (USA), FAW Corporation (China) etc.
Bharat Forge Limited, the flagship company of the group is today among the largest and technologically most advanced manufacturer of Forged & Machined components for the automotive and non-automotive sector. Apart from Bharat Forge, the other major companies in the group are Kalyani Steels, Automotive Axles, Kenersys, BF Utilities, Kalyani Carpenter Special Steel, Kalyani Lemmerz, , Kalyani Thermal Systems, , Kalyani Global, Hikal Limited, Kalyani Infotech, Epicenter Technologies and Synise Technologies.
Kalyani Steels Ltd. was established in 1973 with its corporate office in Pune. Over the years, Kalyani Steels has been continuously upgrading its technology and infrastructure, resulting in manufacture of very high quality of final product. The facilities at KSL are at par with any sophisticated steel manufacturers in the world.
In 1997 the Kalyani Group set up a new plant at Ginigera near iron ore mines of Hospet-Bellary region of Karnataka state. This integrated steel complex has capacity of 650,000 tpa of carbon and alloy steels.
KSL has earned the status of preferred steel supplier for engineering, automotive, seamless tube and primary aluminium industry. Add to that a dynamic corporate vision towards global markets which is the most important factor that makes Kalyani Steels products compare favorably with the best steel makers in the world.
? ISO / TS 16949: Second edition
? ISO 9001: 2000
? ISO 14001: 2004
? OHSAS 18001: 2007
? Award for TPM excellence : First Category
1
D R I V I N G I N N O V A T I O N
QUALITY ASSURANCE
KALYANI STEELS ADVANTAGE
Kalyani Steels takes utmost pride in a well-earned record for supply of clean steels and reliable deliveries. Use of captive iron ore and coke enables to achieve low levels of tramp elements, resulting in clean steel, necessary for various critical applications in automotive and engineering industries. Computerized control at various stages in steel making gives an assurance of consistent product quality.Every customer order is first evaluated by a Technical Service Cell. This cell sets the production standard after considering the technical parameters. This detailed well-documented production quality standard is scrupulously followed at every stage of manufacturing. Further it is coupled with process control as well as level 2 Automated Production Facilities. Special requirements can also be tailor made.Quality testing system comprises modern equipment such as Metallographic microscope with image analyzer, X-ray fluorescence instrument, Electron emission spectrometer, Gas analyzers, Ultrasonic testing machine, Magnetic particle inspection and Mechanical & Chemical testing.
? Business partner to leading automobile manufacturers.? Fully integrated operations.? Clean steel manufacturing and reliable deliveries.
IRON ORE COKE LIMESTONE
MINI BLAST FURNACE
(250M³ X 2 Nos.) (350M3 X 1 No. )
ENERGY OPTIMISING FURNACE50 T CAPACITY
IRON & STEELSCRAP
(15–30%)
FERRO ALLOYS
REFINING
COMPUTERISED PROCESS CONTROL
FLUX ( LIME &
DOLOMITE )
VD 50 T X 2 Nos.
O2 BLOWING
FERRO ALLOYS
REFINING
TRIMMING OF CHEMISTRYUNDER VACUUM
CLOSED STREAM CASTING
COMPUTERISEDPROCESS CONTROL
VACUUM
DEGASSING
LF-1 50 T
LF-250 T
BLOOM CASTER10/18 m Radius
BILLET CASTER9/16 m Radius
ROLLING MILL
CLOSED STREAM CASTING
FLOW CHART
2
D R I V I N G I N N O V A T I O N
STEELS FOR WIRE RODS AND STRAIGHT LENGTH BARS FOR NON FORGING APPLICATIONS
PRODUCTS & SIZESWIRE RODS IN COIL FORM
ROUND BARS IN STRAIGHT LENGTH
HEXAGONAL BARS
WIRE ROD APPLICATIONS
KSL manufactures Wire rods / Straight lengths rounds and Hex Bars for Cold Heading application and Bright Bar application in Carbon, Alloy and Free cutting / Semi free cutting grades.
5.5 to 28 mm Diameter
25 to 60 mm Diameter
15.5 A/F mm to 40 A/F mm
1) CHQ Quality Wire rods for Manufacture of Fasteners
2) Free Cutting / Semi Free Cutting Steel Wire Rods / Bars for Cold Drawing / Machining Application
3) Free Cutting / Semi Free Cutting Steel Hex Bars / Wire Rods for Hex to Hex Drawing.
1
D R I V I N G I N N O V A T I O N
GRADES MANUFACTURED AND THEIR STANDARD CHEMICAL COMPOSITION
2
C Mn Si P S Cr Mo Ni V B Ti Al Pb
0.08 0.30 0.10 0.040 0.050 - - - - - - - -
0.13 0.60 Max Max Max - - - - - - - -
0.13 0.30 0.20 0.040 0.050 - - - - - - - -
0.18 0.60 Max Max Max - - - - - - - -
0.15 0.60 0.20 0.040 0.050 - - - - - - - -
0.20 0.90 Max Max Max - - - - - - - -
0.36 1.35 0.15 0.040 0.050 - - - - - - - -
0.44 1.65 0.30 Max Max - - - - - - - -
0.38 0.75 0.15 0.035 0.040 0.80 0.15 - - - - - -
0.43 1.00 0.30 Max Max 1.10 0.25 - - - - - -
0.18 0.70 0.20 0.040 0.040 0.40 0.15 0.40 - - - - -
0.23 0.90 0.35 Max Max 0.60 0.25 0.70 - - - - -
0.18 0.80 0.15 0.030 0.030 0.20 - - - 0.0005 - 0.020 -
0.23 1.20 0.35 Max Max Max - - - 0.0030 - 0.040 -
0.23 0.90 0.15 0.030 0.030 0.20 - - - 0.0005 - 0.020 -
0.28 1.20 0.35 Max Max Max - - - 0.0030 - 0.040 -
0.36 1.35 0.15 0.040 0.050 - - - - 0.0005 - - -
0.44 1.65 0.30 Max Max - - - - 0.0030 - - -
0.98 0.25 0.15 0.025 0.025 1.30 - - - - 0.0030 - -
1.10 0.45 0.30 Max Max 1.60 - - - - Max - -
0.07 1.40 0.80 0.025 0.035 - - - - - - - -
0.15 1.85 1.15 Max Max - - - - - - - -
0.08 0.80 0.10 0.07 0.20 - - - - - - - -
0.18 1.20 Max Max 0.30 - - - - - - - -
0.08 0.80 0.10 0.07 0.20 - - - - - - - 0.15
0.18 1.20 Max Max 0.30 - - - - - - - 0.35
0.35 0.60 0.05 0.060 0.060 - - - - - - - -
0.45 1.00 0.35 Max Max - - - - - - - -
0.40 0.70 0.05 0.060 0.060 - - - - - - - -
0.45 0.90 0.35 Max Max - - - - - - - -
0.35 1.00 0.25 0.06 0.12 - - - - - - - -
0.45 1.30 Max Max 0.20 - - - - - - - -
0.50 0.50 0.05 0.060 0.060 - - - - - - - -
0.60 0.80 0.35 Max Max - - - - - - - -
0.35 0.50 0.10 0.050 0.050 0.90 0.20 - - - - - -
0.45 0.80 0.35 Max Max 1.50 0.40 - - - - - -
0.90 0.30 0.10 0.050 0.050 1.00 - - - - - - -
1.20 0.75 0.35 Max Max 1.60 - - - - - - -
0.14 1.00 0.15 0.035 0.035 0.80 - - - - - - -
0.19 1.30 0.40 Max Max 1.10 - - - - - - -
0.17 1.10 0.15 0.035 0.035 1.00 - - - - - - -
0.22 1.40 0.40 Max Max 1.30 - - - - - - -
0.42 0.50 0.15 0.035 0.035 - - - - - - - -
0.50 0.80 0.35 Max Max - - - - - - - -
GRADES
SAE 1010
SAE 1015
SAE 1018
SAE 1541
SAE 4140
SAE 8620
10B21
15B25
15B41
SAE 52100
ER70S6
En 1A
En 1A(L)
En 8
En 8D
En 8M
En 9
En 19
En 31
16MnCr5
20MnCr5
CK-45
STANDARD
American Standard (CHQ)
American Standard(Bearing Steel)
American Standard(Welding Rods)
British Standard En Series(Free Cutting)
British Standard En Series
DIN Standard (CHQ)
DIN Standard (NON CHQ)
STEELS COMMONLY MANUFACTURED FOR FORGING APPLICATIONS
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D R I V I N G I N N O V A T I O N
AISI/SAE DIN B.S. JIS
1010 CK10 En 2A S10C
1015 CK15 En 32B S15C
1025 CK25 En 3B S25C
1035 CK35 En 8, En 8A S35C
1045 CK45 En 43B S45C/S48C
1055 CK55 En 9 S55C
1065 CK65 En 43D S58C
28Mn6/30Mn SMn420H/SMEn 15/A1541, 1548, 1043M 5/40Mn4 n443H
1137, 1141,1212 45M5BTUA2 En 15AM
SS4510
16MnCr5 SCR415,SUM420
20MnCr5
1320 15CrNi6 En 352
8822H
8620 En 353, En 354, SNCM420H21NiCrMoV5H8622 En 355
En 361, En 362, 4320 17CrNiMo6
En 36C
En 363
34Cr4,40Cr4B/5130 En 18A, En 18C SCR435C,41Cr4
5137H
39Cr5
5140 41Cr4 SCR440
4130 25CrMo4 En 19C SCM440H
4135 34CrMo4 SCM435,SCM420
4140 42CrMo4 En 19B
4340 -- En 24 SNCM431, SNCM439
SNCM447
SAE52100 100Cr6 En 31 SUJ1, SUJ2
SAE5160 -- En 45A SUP6, SUP7,SUP9, SUP11
94B17,15B25, 20MNCR5(B) SCRB435, 15B41 S48C(M)
ASB43
CATEGORY GENERAL APPLICATIONSPECIFICATION
Carbon +Manganese Steel
Semi Free Cutting & Free CuttingSteelsCarbon + Manganese + Titanium Steel
Chrome + Manganese Steel
Plain CarbonSteel
Chrome + Nickel Steel
Low CarbonChrome + Nickel Moly Steel
Chrome Steel
Chrome +Moly Steel
Medium CarbonChrome + Nickel +Moly Steel
Ball Bearing Steel
Spring Steel
Boron Steel
Micro AlloyedSteel
Gears , Hub front, Front axle beam, Spindle wheel, Spindle,
Spindle housing , R.A. Shaft,Camshaft
Steering knuckle, Crankshaft,Front axle beam, Axle arm
Fastners
R.A.Tubes
Stub axle, Axle arm,Transmission gears
Differential bevel gear, Crown Wheel/Pinion, Drill bits, Piston pins
Front axle beam , Crank shaft, Steering knuckle, Connecting rod
Crankshaft, Steering knuckle, MCA Knuckle, Stub axle, Rocker
lever forging, Spigot
Front axle beams, Crank shaft, Connecting rods, Case differential
Input shaft
Bearing races and Rolling elements
Leaf spring, Helical springs
Crown wheel & Pinion, Links,Bushes, Pins
V2904, V2903, 38MnVs6Ti, 38MnSiVs5, SHAEM105, C38+N2,46Mn5, 38MnS6, 15V24, C70S6
D R I V I N G I N N O V A T I O N
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PRODUCT SIZES
AS CAST125×125, 160×160, 200x200, 240×280 mmBillets / Blooms160, 200, 220 mm DiameterRounds
AS ROLLED 30, 32, 34, 36, 38, 40, 42, 45, 48, 50, 53, 55, 56, 58, 60, 63, 65, Rounds 68, 70, 75, 80, 83, 85, 90, 95, 97.5, 100, 105, 115, 117.5, 120,
125, 130, 135 mm
Round Cornered 50, 55, 60, 63, 65, 70, 75, 85. 90, 95, 100, 103, 110, 118, 125, Squares (RCS) 130, 136, 140, 147, 150, 160, 180 mm
160 X 70, 180 X 180, 180 X 80, 160 X 140, 150 X 100, Rectangles 150 X 90, 140 X 100 mm
Rolled Bar Length 4 to 6 meters
Straightness 3 mm/meter
Size Tolerance As per IS 3739 Grade 1
Grain Size 5 to 8 as per ASTM E 112
1.5 Thin / 1.0 Thick A, B, C, D max Inclusion rating (For non free cutting steels)
as per ASTM E 45
Macro etch C2R2S2 as per ASTM E 381
Note : Special requirements can also be accepted on mutual agreement.
DIMENSIONAL PARAMETERS
METALLURGICAL PARAMETERS
STEELS FOR SEAMLESS TUBE APPLICATIONS
1
D R I V I N G I N N O V A T I O N
KSL is a leading manufacturer of rounds for seamless tubes in India. It supplies steel to all seamless tube producers in the domestic market. KSL’s Ginigera plant is approved by Indian Boiler Regulations.
KSL is a well known steel maker for
? Supply of Boiler grade steel.
? IBR approved for critical seamless tube applications such as Boiler tubes.
? Creep resistant steel grades like SA 213 – T 11 & SA 213 – T 22 for use at elevated temperature.
KSL offers a range of carbon and alloy steel to major international specifications such as SAE, BS, DIN, and JIS & API.
En 19, API 5 CT, SAE 4125, SAE 4135, SAE 1541, API N80, API J55,
SAE 1010, SAE 1018,
A 106 Gr ‘B’, A 106 Gr ‘C’, A 179, A 192, A 210
BS 3059
SAE 52100, 100Cr6
SA213 T11, SA213 T22
As Cast 160, 200, 220 mm Diameter Round.
As Rolled 80, 90, 100, 105, 125, 130 mm Diameter Rounds & 182 mm RCS.
COMMONLY PRODUCED STEEEL GRADES
For OCTG sector (Drill Rods, Casing Pipes and Line Pipes)
For Boiler Applications
Bearing Steels
Creep Resistant Steels
SIZES
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