optim-raex-fenatran
TRANSCRIPT
Hannu Indrén9.10.2011 www.ruukki.com
Contents of technical presentations
High strength Optim-steels and wear resistan Raexsteels
Product properties and available dimensionsBenefits for the userBending and welding of Optim-steelsWelding of Raex-steels
Application examples from different customersegments
Lifting equipmentWaste collecting and handling, recyclingTipper bodies and other transportation equipment
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Hot-rolled plates, sheets and coils
100
300
500
700
900
1 100
1 300
Formable Steels
Yield Strength (N/mm2) Hardness (HBW)
Laser
Optim QLOptim MLOptim MC
Raex
High-Strength andUltra High-Strength Steels
Optim QC
400
500
300
Wear-resistantSteels
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Optim - Typical applications
Strip products
Optim 500 - 700 MC
Optim 700 MC Plus
Plate products
Optim 500 ML
Optim 700 QL
Strip products
Optim 900 1100 QC
Optim 960 QCW
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Optim Product range
Strip products
Optim 500 MC
Optim 550 MCW
Optim 650 MC
Optim 700 MC
Optim 700 MC Plus
Optim 900 QC
Optim 960 QC
Optim 960 QCW
Optim 1100 QC
Plate products
Optim 500 ML
Optim 700 QL
MC = thermomechanical rolled
ML = thermomechanical rollled
QC = direct quenched
QCW = direct quenched, weather
resistant
QL = quenched and tempered
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Characteristics of Optim steels
Optim steels are designed for customer applications utilizing high strength of the steel in order to increase pay-load and/or performance of the customersproduct.
High strength is achieved by thermomechanicalrolling or direct quenching, not by alloying.
Processing of Optim steels is easy thanks to the good formability (bendability) and weldability.
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Optim steels
Dimensions and mechanical properties
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Dimensions, Cut lengths (Strip products)
2.0 13.018002.0 12.0Optim 500 MC
2.0 13.016402.5 10.0Optim 650 MC
2.0 12.015503.0 10.0Optim 700 MC
2.0 12.016502.5 8.0Optim 900 QC
2.0 12.016502.5 8.0Optim 960 QC/QCW *)
2.0 12.015503.0 12.0Optim 700 MC Plus
Max. width[mm] **)
Thickness[mm]
Length[m]Steel grade
*) Weather resistant version**) Exact max. width depends on the thickness
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34 J / -40 oC8950 -900Optim 900 QC
34 J / -40 oC71000 -960Optim 960 QC
15
15
15
18
40 J / -60 oC750 930700Optim 700 MC Plus
40 J / -20 oC750 930700Optim 700 MC
40 J / -20 oC700 860650Optim 650 MC
40 J / -20 oC560 690500Optim 500 MC
Impact strength
A min. %
Tensile strength (N/mm2)
Yield strength (N/mm2)Steel grade
Mechanical properties, Strip Products
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Properties and dimensions,Optim heavy plates
16
14
27 J / -50 oC
30 J / -40 oC
570 - 720
770 940
500
690
Optim 500 ML
Optim 700 QL
Impact strength
Amin. %
Tensile strength (N/mm2)
Yield strength (N/mm2)Steel grade
2.0 15.0
2.0 12.0
1900 - 3300
2000 3000
8.0 60.0
6.0 40.0
Optim 500 ML
Optim 700 QL
Width [mm]
Thickness [mm]
Length [m]
Steel grade
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Benefits
Higher payload by lowerown weight
Lower fuel consumption
Lower carbon footprint
Higher reach
Lower weld seamvolumes, thanks to lower thicknesses
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Higher payload
Lower own weight of the wehicle offers an opportunityto increase payload
As a rule of thumb, thicknessof the structural material canbe reduced according to the formula at right
t2 = t1 x 1
2
t2 = 10.0 x355
700
Example:
Original material: 10 mm, S355
New material: Optim 700 MC
=> t2 = 7.1 mm
30 % reduction in thickness!
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Weight saving potential
0
10
20
30
40
50
60
0 500 1000 1500
Yield strength (MPa)
Wei
gh
t sa
vin
g (
%)
Optim 500 MC
S355
Optim 960 QC
Optim 1100 QC
Optim 700 MC
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Lower fuel consumption
When the weight of a vehicleis low the fuel consumption is reducedAs a rule of thumb 1 tonreduction in a 60 ton truck sown weight reduces fuelconsumption by 1 % whendriving emptyLower fuel consumptionresults in lower operatingcosts, increasedcompetitiveness and lowerCO2 emissions
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Higher reach
Skylifts are used for fireapplications and maintenance of wind mills
World s highest model todayreaches 112 m, materials areOptim 650 MC and Optim900 QC
It has been possible to increase the horizontal reachof a fire application by 10 - 20 % by changing to Optim 960 QCW steel
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Lower thickness, smaller weld seamvolume, lower fabrication cost
By changing to higherstrength material it is possibleto reduce material thickness
Reduction in thickness from10 mm to 8 mm reducesweigth by 20 %.
At the same time volume of weld seam is reduced by36 % =>
Lower consumption of fillermaterial and higherproductivity
t = 10 mm
t = 8 mm
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Bending of steel
Bending is fast, easy and cost effective way to form steel.
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Material factors influencing bendability
Material factorsStrengthSteel cleannessShape and location of impuritiesRolling directionDimensional accuracy
Other factorsWork piece surfacequalityWork piece edge preparation
CaAl(Ca -treatment)
Bending to small radius
Rolling dire
ction
Al2O3(no Ca -treatment)
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Work piece preparation for bending
Work piece preparation becomes more important factor when the strength level of the material is high:
Smooth cut faces are essential, scratches or grooves act as initiation points for cracks
Surfaces must be free of scratches or grinding marks across the bending line
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Minimum bending radius
Minimum recommended bending radius is a way to describe the bendability of material.
Ruukki offers tables where we recommend suitable tooling dimensions for particular plate thickness:
Pay attention to the condition of machines and tools
If possible, use bigger radius than the minimunguaranteed
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Minimum bending radiiStrip products
10.08.06.05.04.03.02.0 Steel grade
Thickness, mm
10,5
9,0
(3,0)
3,5
3.0
2.5
14.0
12.0
(4.0)
5.0
4.0
3.0
17.5
15.0
(5.0)
6.0
6.0
4.0
-28.022.0-Optim 960 QC/QCW
-24.018.0-Optim 900 QC
10.08.06.0-Optim 700 MC Plus
16.014.08.0-Optim 700 MC
14.012.08.0-Optim 650 MC
10.08.04.52.0Optim 500 MC
Thicknesses in parenthesis are available as trial deliveries
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Optim BendabilityHeavy plates
Minimum permissible internal bending radius, mm
60.054.048.042.036.030.024.0Optim 700 QL
Optim 500 ML 24.021.519.017.014.512.09.5
18-2016-1814-1612-1410-128-107- 8Steel grade
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Welding of Optim steels
Weldability of Optim steels is good thanks to the lowamount of alloying elements
All common weldingmethodes can be used
Choosing of weldingparametres has to be donecarefully in order to get the best possible mechanicalproperties over the weld
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Optim Strip Products WeldabilityCarbon equivalent, max
CEV, max / Optim CEV/EN 10149-2
Car
bo
n e
qu
ival
ent
Yield strength class N/mm2
460 500 550 600 650 700
CEV 0.41
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0900 960
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How to decide heat inputCooling time t8/5
Example of heat cycle during welding
t8/5 -cooling time shows how long it takes for temperature to change from 800°C to 500°C
Most used term in welding metallurgy
Helps welding engineer to decide correct welding parameters
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Cooling time t8/5 recommendationsfor Optim steels
Optim 700 MCt8/5 = 5 20 seconds
Optim 700 MC Plust8/5 = 5 20 seconds
Optim 700 QLt8/5 = 8 20 seconds
Optim 960 QCt8/5 = 4 15 seconds
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Welding consumables
High strength (matching) fillermaterials need to be used ifthere is a requirement for highstrength weld
If weld is not exposed to highstresses it is always beneficialto use softer (undermatching) filler materials
Recommendations for suitablefiller materials can be found on Ruukki s data sheets
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ExampleStrength cooling time
Optim 960 QC, welded joints with different t8/5
times, welding wire X96
700750800850900950
100010501100
0 5 10 15 20t8/5 -time
Mea
sure
d s
tren
gth
0
2
4
6
8
10
12
Rp 0.2% Rm Elongation A5Linear (Rp 0.2%) Linear (Rm)
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Welding of Optim-steelsSummary
When choosing the welding parameters pay attention to the designed stress level
Several welding wire distributors have suitable filler materials, some of them are listed on Ruukki s data sheetsWelding parameters, especially arc energy, affect the mechanical properties of the HAZFor high strength material: Pay attention to the cleanness of welding grooves !
Minor discontinues may cause lifetime decrease because of higher stress level
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To summarize Optim-steels
Wide range of high strength steelsYield strength range 500 1100 MPa
Wide dimensional rangeThin strip products and thick heavy platesare available, thicknesses from 2,5 mm upwards
Excellent workshop propertiesBendability and weldability
Availability guaranteedRuukki and PCP in co-operation
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RaexWear resistant steels
Decreased wear and increased lifetime
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Hot-rolled plates, sheets and coils
100
300
500
700
900
1,100
1,300
FormableSteels
Yield Strength (N/mm2) Hardness (HBW)
Laser
Optim QLOptim ML
Raex
High-Strength andUltra High-Strength Steels
Optim MC
Optim QC
400
500
300
Wear-resistantSteels
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Raex grades and typical applications
Raex 300
Delivered as strip productsConcrete mixers, light tippers
Raex 400Delivered as strip products, heavy plates and tubes
Tipper bodies, excavator buckets, agricultural machinery
Raex 450
Delivered as strip products and heavy plateproducts Heavy duty tipper bodies
BucketsRaex 500
Delivered as strip products and heavy plateproducts
Crushers, excavator bucket lip blades
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Hardness of wear resistant steels
Due to the nature of manufacturing process the hardness of wear resistant steels varies in a certain range
Hardness value presented in the product name, as for instance Raex 400, is an average value, not minimum
This is the case with all wear resistant steels from all manufacturers
360 HBW 440 HBW
Number of plates
Hardness range
Example 20 mm Raex 400
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Heavy plates420 5006.0 30.0 Raex 450
Cut lengths360 4402.5 8.0Raex 400
Heavy plates450 5406.0 40.0Raex 500
Heavy plates420 52030.0 40.0Raex 450
Heavy plates360 480 30.0 40.0Raex 400
Hardness values
Cut lengths450 5403.0 6.5Raex 500
Cut lengths420 5003.0 8.0Raex 450
Heavy plates360 4406.0 30.0Raex 400
Cut lengths270 3902.5 -8.0Raex 300
Product shapeHardness (HBW)Thickness mmSteel grade
Raex steels, hardness values
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Raex steels, dimensional range
Thickness ranges
6 40 3.0 6.5 Raex 500
6 403.0 8.0Raex 450
6 402.5 8.0Raex 400
-2.5 8.0Raex 300
Heavy plate(mm)
Cut lengths(mm)
Steel grade
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Raex steels, typical mechanical properties
Typical mechanical properties
-30°C816001250Raex 500
-40°C814501200 Raex 450
-40°C1012501000Raex 400
-40°C111000900Raex 300
Impact strengthCharpy V 20 J
ElongationAs %
Tensile strengthMPa
Yield strengthMPa
Steel grade
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Raex - relative lifetimeExample of abrasive wearing test results
1
1,5
2
2,5
3
3,5
4
4,5
5
150 200 250 300 350 400 450 500 550 600
Raex 500
Raex 450
Raex 400
S355S 700 MC
Hardness HBW
Rel
ativ
e lif
etim
e
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Welding of wear resistant Raex steels
Weldability is good.
All common welding processes may be used.
Special instructions for wear resistant steels must be followed.
The choice of working temperature, consumables and welding energy must be done carefully.
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Wear resistant steels are alloyed, which means
That the strength and hardness level of the base material is highHardenability of the material while thermal cutting or welding is increased compared to mild steels
Which affects
That the risk for cold cracking increases!
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Cold cracking (called also as delayedcracking, hydrogen cracking)
Cracks may appear some days after weldingMost critical issue when welding wear resistant steels especiallywhen plate thicknesses are highSusceptability for cold cracking must be taken in account whenplanning welding process of wear resistant steel
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Factors causing cold cracking
Caused by a combinationof following factors:
Hydrogen content of the weld metal and HAZ
Stress level of the welded structure
Microstructure of HAZ
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Hydrogen content and stressesRole of welding consumables
Hydrogen content of ferritic consumables must be low.
Undermatching filler metals are preferred if the welded joints are not exposed to heavy loading. Correspondingly, the use of matching filler metals is necessary, if a welded joint is exposed to hard wear or the filler metal is required to have high strength.
Alternatively, austenitic consumables may be used in joints where undermatchingconsumables are required. Austenitic consumables are not susceptible to cold-cracking. Thus, usually, the welding can be carried out without preheating.
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MicrostructureAffect of arc energy
Too rapid cooling increases the hardening of HAZ and makes the material more susceptible to cold cracking.
Too slow cooling decreases the hardness, strength and impact strength of the joint.
Optimal properties in welded structures are reached when cooling time t8/5 is in range of 10 s 20 s
For MAG welding of a 10 mm thick plate, the cooling time requirement corresponds to the arc energy range of 1.2 - 1.7 kJ/mm.
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Recommended welding parameters for Raex steels, Heat input
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Increasing the working temperature slows the cooling of welded joints, which decreases the generation of a hard and brittle microstructure in the heat affected zone (HAZ)
It is recommended to increase the working temperature of Raex 400, when the combined plate thickness exceeds about 40 mm. The respective thickness is about 30 mm for Raex 450 mm and 20 mm for Raex 500.
Raex 300 does not usually require an elevated working temperature in a normal workshop environment.
Working temperature
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Raex Practical tips for welding
Use non-alloyed, undermatchingfiller materials, when possible
If a good wear resistance of weld is needed, capping runs can be welded with alloyed filler materials
Elevated working temperature shall be used when hardness and/or plate thickness increases
Please, take a look on the tables on Ruukki s data sheet
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Raex Practical tips for welding
Welding should be done continuously
Excessive cooling of the welded plate should be avoided
Mineral wool can be used to avoid excessive cooling
Welding should be commenced in the middle of the plate
Dry welding consumables may only be used
For more detailed info, please take a look on the brochure
Welding and Thermal Cutting of Raex-steels at www.ruukki.com!
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To summarize Raex-steels
Wide range of high strength steelsHardness range 300 500 HBW
Wide dimensional rangeThin strip products and thickheavy plates, thicknesses from2,0 mm upwards
Excellent durability under heavy abrasive conditions
Availability guaranteedRuukki and PCP in co-operation