Bisalloy Bisplate Technical Manual

Bisalloy® Technical Manual

1 of 90 22 September 2006 Rev 2.

BISPLATE®

Technical Manual



Contents Chapters Page Numbers • Introduction 3 • How to Contact us 4 • Process Route 5 • Range of Grades 6 • Available Sizes 23 • Manufacturing Tolerances 24 • Cutting BISPLATE® 27 • Welding BISPLATE® 35 • Bending, Rolling, Shearing and Punching BISPLATE® 43 • Drilling, Countersinking & Tapping BISPLATE® 47 • Turning & Milling BISPLATE® 53 • Design Examples 57 • BISPLATE® Identification Marking and Colour Coding 69 • Testing and Certification 70 • Hardness Testing BISPLATE® 71 • BISPLATE® Wear Comparisons 74 • Fatigue resistance of BISPLATE® 79 • Performance of BISPLATE® at Elevated Temperatures 87 • Galvanising BISPLATE® 90



Introduction Bisalloy® Steels Pty Ltd, located at Unanderra close to BlueScope Steels integrated steel works at Port Kembla, is Australia’s only manufacturer of high strength, wear resistant and armour grade steel plate by the continuos roller quenching and tempering process. Quenching and tempering, defined as a combination of heating and cooling of a metal or alloy, changes the microstructure of the steel and improves the strength, hardness and toughness of the materials being treated. Utilising the most advanced heat treatment technology; furnace temperatures and quenching rates are scientifically controlled to obtain the optimum quality grades of steel with low alloy content. The resulting products of low alloy quenched and tempered steel offer designers the strength to weight advantages and wear resistant properties not available in conventional steels. High strength steel has a strength to weight ratio of more than three times that of mild steel. Principal applications lie in mining equipment, transport, telescopic cranes, materials handling equipment, high rise construction and forestry. High hardness grades offer improved wear life making it ideal for applications such as liners for chutes, buckets, dump trucks etc. BISPLATE® Armour grades are suitable for armoured personnel carriers and ballistic protection of military and civilian fixed plant and transport equipment. BISPLATE® grades can be readily cut, welded, formed and drilled using similar techniques to mild steel. Bisalloy® Steels operates an approved mechanical testing laboratory registered and monitored by the National Association of Testing Authorities (NATA). The company’s quality control and management system is assessed by Lloyds and accredited to ISO9001:2000. The capacity, quality and versatility of our heat treatment line enables us to compete in both domestic and international markets; including North and South America, Asia, New Zealand and Africa. Disclaimer



How To Contact Us Bisalloy Steels Pty Ltd 18 Resolution Drive Unanderra P.O.Box 1246 NSW 2526 Australia Tel Switch 61 (0)2 4272 0444 Fax 61 (0)2 4272 0456 Web Site www.Bisalloy.com.au Tasmania, Victoria, Western Australia and South Australia Greg Check tel 02 4272 0417 Mob. 0418 833030 [email protected] New South Wales, Queensland, Northern Territory & New Zealand Jim Devlin tel 02 4272 0419 Mob. 0418 427766 [email protected] Export Sales Willy Pang tel 02 4272 0418 Mob 0419 280765 [email protected] Sales & Marketing Manager Michael Sampson tel 02 4272 0412 Mob. 0418 603852 [email protected] Bisalloy Manager Nick Hardcastle tel 02 4272 0402 Mob. 0418 264370 [email protected] Technical Manager Russell Barnett tel 02 4272 0470 Mob. 0418 271948 [email protected]

http://www.bisalloy.com.au/

mailto:[email protected]








Schematic Diagram of BISPATE® Production Process



RANGE OF GRADES INTRODUCTION Bisalloy® Steel’s grades are world class, our structural grades complying with many of the international quenched and tempered steel plate standards. Each of the grades covered by this brochure has specific mechanical and chemical properties detailed. The process information detailed below is applicable to all BISPLATE® product manufactured by Bisalloy® Steels. BISALLOY®’S FEED PLATE The technology used in the manufacture of BISPLATE® is not only world class, but the demands of high strength and high hardness steels dictate the need for one of the most stringent process routes utilised in the manufacture of steel plate, anywhere in the world. Hot metal desulphurisation ensures low levels of sulphur and other impurities in steelmaking. Vacuum degassing is carried out to reduce the Hydrogen content of the steel whilst also decreasing the amount of undesirable Oxygen and Nitrogen in the steel. Control of impurities is additionally assisted through the use of hot metal injection and conditioning of the slag during the Basic Oxygen Steelmaking process. Close control of chemical composition and final microstructure is maintained through the use of ladle refining with Calcium injection, Argon bubbling through the heat during steelmaking and alloying additions made under vacuum. Following steelmaking, integrity of slab product is ensured by the use of electromagnetic stirring, continuous casting and controlled cooling of slabs prior to plate rolling. Finally, plate rolling is carried out in a computer controlled four high rolling mill in which each draft is modified during rolling for optimisation of final properties. The net result is steel with improved toughness, structural integrity and fatigue resistance, providing consistent product performance in service. BISALLOY®’S HEAT TREATMENT Plate is heated in our natural gas fired furnace prior to quenching in the Drever roller quench unit. Complete PLC control allows tight and consistent control of all furnace and quench operations including water flow rates and pressures, furnace temperatures and residency times. Pre and post heat treatment shot blasting removes scale and presents an attractive plate. This results in improvements in product properties, welding and cutting, as well as simplification during fabrication.



The final operation at Bisalloy® is plate leveling through the plate leveler in material up to 32mm thickness. This has resulted in significant improvements in flatness of plate to market, much tighter than the Australian Standard and other international standards. Our quality assurance system ensures that full traceability exists from initial steelmaking right through the process to the final plate. Each plate is individually hard stamped with a unique identification, and this links the overall traceability. All plates are tested for hardness, whilst all structural grades are tested in Bisalloy®’s NATA approved mechanical testing laboratory. Plates of all grades are certified. The entire process is carried out in compliance with ISO-9001 certified by LRQA (Lloyd’s Register Quality Assurance). BISALLOY®’S TECHNICAL DEVELOPMENT Each of the grades outlined in this brochure has been developed to optimise chemistry and mechanical properties in conjunction with Bisalloy®’s heat treatment process. Our world class steel grades ensure that properties such as ductility, weldability and toughness are maximised whilst complying with the required hardness and strength requirements. Ongoing R&D at Bisalloy® keeps our product range at the leading edge of available quenched and tempered steels. Already we are developing steels to meet the emerging requirements for still stronger structural and higher hardnesses grades, and these will be released to the market as demand dictates.



B I S P L A T E ® 6 0 BISPLATE® 60 is a low carbon, low alloy, high strength structural steel which exhibits excellent cold formability and low temperature fracture toughness. APPLICATIONS The combination of BISPLATE® 60 mechanical properties and ease of fabrication offers economical advantages in many structural applications. Some examples of applications for this grade include: • Storage tanks (Water/Oil/Gas) • High rise buildings (Columns/Transfer beams) • Lifting equipment (Mobile/Overhead cranes) FABRICATION BISPLATE® 60 can be welded successfully with minimal levels of preheat and has excellent low temperature fracture toughness. BISPLATE® 60 has been designed such that a low hardness level is produced in the heat affected zone (HAZ). As a result this steel has a low susceptibility to HAZ cracking. For further details on fabrication please refer to Bisalloy’s technical literature. MECHANICAL PROPERTIES

PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress 500 MPa (Min) 580 MPa

Tensile Strength 590 – 730 MPa 640 MPa

Elongation in 50mm G.L. 20% (Min) 30%

Charpy Impact (Longitudinal) -

20°C (10mm X 10mm) 80J (Min) 200J

Hardness 210HB

CHEMICAL COMPOSITION THICKNESS

(mm)

C P Mn Si S Cr Mo B CE(IIW) PCM

5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

≥16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30



BISPLATE® 70 BISPLATE® 70 is a low carbon, low alloy, high strength structural steel. This grade can be welded with minimal preheat and has excellent low temperature fracture toughness suitable for structural applications. APPLICATIONS The combination of BISPLATE® 70 mechanical properties and ease of fabrication offers economical advantages in many structural applications. Some examples of applications for this grade include: • Transport equipment (Trays/Low loaders/Outriggers) • Storage tanks (Water/Oil/Gas) • High rise buildings (Columns/Transfer beams) • Lifting equipment (Mobile/Overhead cranes) • Mining equipment (Dump truck trays/Structural applications) • Longwall mining supports FABRICATION BISPLATE® 70 exhibits excellent cold formability and low temperature fracture toughness. BISPLATE® 70 has been designed such that a low hardness level is produced in the heat affected zone (HAZ). As a result, this steel has a low susceptibility to HAZ cracking. For further details on fabrication please refer to Bisalloy's technical literature. MECHANICAL PROPERTIES






20°C (10mm X 10mm)

75J (Min) 180J

Hardness 230HB

CHEMICAL COMPOSITION

THICKNESS (mm)


5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

≥16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30



BISPLATE® 80 BISPLATE® 80 is a high strength, low alloy steel plate with a yield strength three times that of carbon steel and featuring low carbon, excellent notch toughness, good weldability and formability. APPLICATIONS Utilising the high strength properties of BISPLATE® 80 allows reduction in section thickness, without loss of structural integrity. The following lists some applications where the strength advantage has been realised: • Transport equipment (Low loaders) • High rise buildings (Columns) • Mining equipment (Dump truck trays/Longwall roof supports) • Lifting equipment (Mobile Cranes/Container handling equipment) • Bridges • Storage tanks • Induced draft fans • Excavator buckets FABRICATION BISPLATE® 80 is a high strength steel manufactured with a controlled carbon equivalent for optimum weldability. BISPLATE® 80 can be successfully welded to itself and a range of other steels, provided low hydrogen consumables are used and attention is paid to preheat, interpass temperature, heat input and the degree of joint restraint. Stress Relieving can be achieved at 540°C - 570°C. Heating above this temperature should be avoided to minimise any adverse effects on mechanical properties. Cold forming can be successfully conducted, provided due account is taken of the increased strength of the steel. For further details on fabrication please refer to Bisalloy's technical literature. MECHANICAL PROPERTIES






20°C (10mm X 10mm)

40J (Min) 160J

Hardness 255HB


THICKNESS (mm)


5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

≥16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30



BISPLATE® 8OPV BISPLATE® 80PV is a high strength steel alternative for designers of unfired pressure vessels which meets the requirements of AS1210 and achieves a light weight structure. APPLICATIONS BISPLATE® 80PV has been approved by statutory authorities and complies with the requirements of AS1210 for pressure applications and is supplied ultrasonically tested to AS1710-Level 1. The high strength offers substantial weight reductions in the following areas: • Transportable road tankers • Storage tanks (Spherical and cylindrical) • Railroad tankers (LPG/Liquid ammonia) • Refinery and Petro chemical equipment (Tube plates/Channel covers) FABRICATION BISPLATE® 80PV is a high strength, low alloy pressure vessel steel with a controlled carbon equivalent for optimum weldability. BISPLATE® 80PV can be successfully welded to itself and a range of other steels, provided low hydrogen consumables are used and attention is paid to preheat, interpass temperature, heat input and the degree of joint restraint. Stress relieving can be achieved at 540°C - 570°C. Heating above this temperature should be avoided to minimise any adverse effects on mechanical properties. Cold forming can be conducted successfully, provided due account is taken of the increased strength of the steel. MECHANICAL PROPERTIES


0.2% Proof Stress 690 MPa* (Min) 750 MPa



Lateral Expansion 0.38mm (Min) 0.70mm

Charpy Impact - 55J

Hardness - 255HB

*Dependant on plate thickness.


THICKNESS (mm)


6-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25*

≥16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30

*Low heat input butt welding required to ensure transverse weld tensile properties are achieved. Alternate chemistry may be specified when necessary.



BISPLATE® 320 BISPLATE® 320 is a through hardened, abrasion resistant steel plate, offering long life expectancy in high impact abrasion applications. APPLICATIONS BISPLATE® 320 offers the optimum combination of hardness, impact and formability for wear applications which require extensive forming/drilling or fabrication, in impact abrasive applications such as: • Deflector plates • Chutes • Storage bins • Dump Truck liners • Earthmoving buckets FABRICATION BISPLATE® 320 is a high hardness, abrasion resistant steel with a controlled carbon equivalent for optimum weldability. With appropriate attention to heat input, preheat and consumable selection, BISPLATE 320 can be readily welded to itself and other steels, using conventional processes. Cold forming of BISPLATE® 320 plates is possible in all thicknesses, provided the high strength of this steel is taken into account. Adequate allowance must be made for increased springback relative to mild steel. Heating above 400°C should be avoided, otherwise the mechanical properties may be affected. MECHANICAL PROPERTIES


0.2% Proof Stress - 970 MPa

Tensile Strength - 1070 MPa

Elongation in 50mm G.L. 18%

Charpy Impact (Longitudinal)

+20°C (10mm X 10mm)

- 60J

Hardness 320 – 360HB 340HB


THICKNESS (mm)


5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

≥16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30



BISPLATE® 400 BISPLATE® 400 is a through hardened, abrasion resistant steel plate, offering long life expectancy in high impact abrasion applications. APPLICATIONS BISPLATE® 400 offers excellent wear and abrasion resistance and impact toughness in applications which include: • Dump truck wear liners • Cyclones • Screw conveyors • Deflector plates • Chutes • Ground engaging tools • Storage bins • Cutting edges • Earthmoving buckets FABRICATION BISPLATE® 400 is a high hardness, abrasion resistant steel offering very good impact toughness properties. BISPLATE® 400 provides an optimum combination of abrasion resistance, toughness and weldability Due to its low alloy content, BISPLATE® 400 can be readily welded using conventional welding processes and low hydrogen consumables. Cold forming of BISPLATE® 400 is achievable on all thicknesses although an allowance for the higher strength should be taken into account. Bending machine capabilities should also be taken into consideration prior to any forming operation. Heating above 350°C should be avoided, otherwise mechanical properties may be affected. MECHANICAL PROPERTIES




Elongation in 50mm G.L. - 14%


+20°C (10mm X 10mm)

- 55J





THICKNESS (mm)


5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

≥16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30


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BISPLATE® 400XT BISPLATE® 400XT is a through hardened, abrasion resistant steel plate, offering long life expectancy in high impact abrasion applications. APPLICATIONS BISPLATE® 400XT offers excellent wear and abrasion resistance and impact toughness in applications which include: • Dump truck bodies • Armoured Face Conveyors • Mining Bucket Construction • Cutting Edges • Tipper Body Construction FABRICATION BISPLATE® 400XT is a through hardened, abrasion resistant steel plate, offering long life expectancy in very high impact abrasion applications. BISPLATE® 400XT offers excellent wear and abrasion resistance, and is supplied with guaranteed impact toughness. Due to its low alloy content, BISPLATE® 400XT can be readily welded using conventional welding processes and low hydrogen consumables. Cold forming of BISPLATE® 400XT is achievable on all thicknesses although an allowance for the higher strength should be taken into account. Bending machine capabilities should also be taken into consideration prior to any forming operation. Heating above 350°C should be avoided, otherwise mechanical properties may be affected. MECHANICAL PROPERTIES






40°C (10mm X 10mm)

- 45J


GUARANTEED CHARPY-V IMPACT TOUGHNESS THICKNESS (mm) TEST PIECE MIN ENERGY,

LONGITUDINAL -40°C 6-8 10 X 5 17J

10 X 7.5 10 X 7.5 21J 12-50 10 X 10 25J

CHEMICAL COMPOSITION *TYPICAL

THICKNESS (mm)

C P Mn Si S Ni Cr Mo B CE(IIW) PCM

6-20 Maximum 0.165 0.025 1.25 0.25 0.005 0.25 0.25 0.25 0.002 0.39* 0.23*

>20-50 Maximum 0.21 0.025 0.40 0.60 0.005 0.35 1.20 0.30 0.002 0.44* 0.28*


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BISPLATE® 425 BISPLATE® 425 is a through hardened, abrasion resistant steel plate, offering long life expectancy in sliding and gouging abrasion applications, with impact loading. APPLICATIONS BISPLATE® 425 offers exceptionally long life in high abrasion applications with impact loading. Applications include: • Dump truck wear liners • Chutes • Wear liners • Ground engaging tools • Cutting edges FABRICATION BISPLATE® 425 is a medium carbon, high hardness, abrasion resistant steel. With appropriate attention to heat input, preheat and consumable selections, BISPLATE® can be successfully welded to itself and a range of other steels by conventional techniques. Because of its high hardness, cold forming of BISPLATE® 425 requires higher bending and forming forces, and greater allowances must be made for springback. Heating above 300°C should be avoided, otherwise mechanical properties may be affected. MECHANICAL PROPERTIES






+20°C (10mm X 10mm)

- 40J


THICKNESS (mm)


6-100 Typical 0.29 0.015 0.30 0.30 0.003 1.00 0.25 0.0010 0.61 0.40


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BISPLATE® 500 BISPLATE® 500 is a through hardened, abrasion resistant steel plate, offering long life expectancy in sliding and gouging abrasion applications. APPLICATIONS BISPLATE® 500 is the hardest steel produced by Bisalloy Steels and offers exceptionally long life in sliding abrasion applications such as: • Dump truck wear liners • Chutes • Wear liners • Earthmoving buckets • Cutting edges • Ground engaging tools FABRICATION BISPLATE® 500 is a medium carbon, high hardness, abrasion resistant steel. With appropriate attention to heat input, preheat and consumable selections, BISPLATE® 500 can be successfully welded to itself and a range of other steels by conventional techniques. Because of its high hardness, cold forming of BISPLATE® 500 is difficult, requiring higher bending and forming forces, and greater allowances must be made for springback. If heating is necessary, this should not exceed 200°C, otherwise mechanical properties may be affected. MECHANICAL PROPERTIES






+20°C (10mm X 10mm)

- 35J


THICKNESS

(mm)


6-100 Typical 0.29 0.015 0.30 0.30 0.003 1.00 0.25 0.0010 0.61 0.40


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BISPLATE® HIGH HARDNESS ARMOUR PLATE INTRODUCTION BISPLATE® High Hardness Armour (BISPLATE® HHA) is a quenched and tempered steel armour plate suitable for use in both military and civil applications where light weight and resistance to ballistic projectiles is required. METHOD OF MANUFACTURE BISPLATE® HHA is a hot rolled steel product that is subsequently heat treated to promote its high strength and toughness, high hardness and ballistics properties. BRINELL HARDNESS THICKNESS SPECIFICATION TYPICAL 6 – 25mm 477 – 534HB 500HB *Other thicknesses may be available on request TENSILE PROPERTIES

PROPERTY TYPICAL 0.2% Proof Stress 1400MPa Tensile Strength 1640 MPa

Elongation in 50mm G.L. 14% CHARPY IMPACT VALUES THICKNESS TEST PIECE TEST TEMP MIN ENERGY

(TRANSVERSE) MIN ENERGY

(LONGITUDINAL) 5mm 10 x Thk -20°C By Agreement By Agreement

6 -<9.5mm 10 x 5 -20°C 8J 10J 9.5 - <12mm 10 x 7.5 -20°C 12J 15J ≥12mm 10 x 10 -20°C 16J 20J

MECHANICAL TEST FREQUENCIES

TEST FREQUENCY Hardness Per Plate Charpy (L) Per Batch Charpy (T) Per Batch

Tensile Testing By Agreement Thickness Testing Per Plate Ballistic Testing By Agreement

CHEMISTRY The chemical specification conforms with the requirements of MIL-A-46100, although it is tighter than the requirements of that specification so as to optimise the materials performance. Product chemical analyses are taken on a per heat basis. Chemical analysis is as follows:


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THICKNESS (mm)

C P Mn Si S Ni Cr Mo B CE(IIW) PCM

6-25 Max 0.32 0.025 0.40 0.35 0.005 0.35 1.20 0.30 0.002 0.61 0.40

*Note Nickel and Vanadium are intentionally added. Ballistic Properties AS 2343 PART 2 – 1997 BULLET RESISTANT PANELS FOR INTERIOR: OPAQUE PANELS

CLASS CALIBRE AMMUNITION MEASURED VELOCITY @

DISTANCE FROM MUZZLE

RANGE MINIMUM

REQUIRED HHA

THICKNESS

G2 44 MAGNUM 15.6g LEAD SEMI-

WAD CUTTER BULLET

488 + 10m/s @ 1.5m 3m 6mm

SO 12 GUAGE (FULL CHOKE)

12 GUAGE 70mm HIGH VELOCITY MAGNUM 32g SG

SHOT

403 + 10m/s @ 1.5m 3m 6mm

S1 12 GUAGE (FULL CHOKE)

12 GUAGE 70mm 24.8g SINGLE SLUG 477 + 10m/s @1.5m 3m 6mm

R1 5.56mm M193 5.56mm 3.6g FULL METAL CASE

BULLET 980 + 15m/s @ 5m 10m 10mm

R2 7.62mm

NATO STANDARD 7.62mm 9.3g FULL

METAL CASE BULLET

853 + 10m/s @ 5m 10m 6mm

CLASS G – HAND GUN CLASS S – SHOTGUN CLASS R – RIFLES RESIDUAL MAGNETISM Residual Magnetism will be the maximum 20 gauss.


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GRADE EQUIVALENTS

GRADE COUNTRY OF ORIGIN STEEL STANDARD COMMENTS

60 Australia AS3597-1993 Grade 500 Min. yield 500 MPa 60 ISO ISO 4950/3 Grade E500 Min. yield 500 MPa 60 Japan JIS G3106 SM58 Min. yield 430 MPa 60 UK BS4360 Grade 55F Min. yield 430 MPa 60 USA ASTM A572 Grade 60 Min. yield 415 MPa 60 USA ASTM A572 Grade 65 Min. yield 450 MPa 60 USA ASTM A537 CI.2 Min. yield 485 MPa 60 USA ASTM A852 Min. yield 485 MPa 60 Europe EN10137-2 S500Q Min. yield 500 MPa 70 Australia AS3597-1993 Grade 600 Min. yield 600 MPa 70 ISO ISO 4950/3 Grade E620 Min. yield 620 MPa 70 USA ASTM A533 Type A.CI.3 Min. yield 570 MPa 70 Europe EN10137-2 S620Q Min. yield 620 MPa 80 Australia AS3597-1993 Grade 700 Min. yield 690 MPa 80 ISO ISO 4950/3 Grade E690 Min. yield 690 MPa 80 USA ASTM A514 Min. yield 690 MPa 80 Europe EN10137-2 S690Q Min. yield 690 MPa 80 Japan JIS G3128 Min. yield 685 MPa

80PV Australia AS3597-1993 Grade 700PV Min. yield 690 MPa 80PV USA ASTM A517 Min. yield 690 MPa


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SUMMARY TABLES STRUCTURAL STEEL GRADES

MECHANICAL PROPERTIES TENSILE CHARPY V-NOTCH IMPACT

STEEL GRADE

PLATE THICKNESS

(mm)

CARBON EQUIVALENT

(IIW)

BRINELL HARDNESS (HB3000/10) PLATE

THICKNESS

(mm)

0.2% PROOF STRESS (MPa)

TENSILE STRENGTH

(MPa)

ELONGATIONIN 50mm G.L

PLATE THICKNESS

(mm)

ENERGY (J)

TEST TEMP.

(°C)

TEST DIRECTION

Bisplate 60 (AS 3597 Grade 500)

5-<16

≥16-80

>80-100

0.40

0.50

0.58

210 5-100 500 590-730 20

5

6-9.5

9.5-12

13-100

By Agmnt

45

60

80

-20

-20

-20

-20

L

L

L

L


5-<16

≥16-80

>80-100

0.40

0.50

0.58

230

5-100 600 690-830 20

5

6-9.5

9.5-12

13-100

By Agmnt

40

60

75

-20

-20

-20

-20

L

L

L

L


5-<16

≥16-80

>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

6-9.5

9.5-12

13-100

By Agmnt

20

30

40

-20

-20

-20

-20

L

L

L

L

Bisplate 80PV (AS 3597 Grade 700PV)

6-<16

≥16-80

>80-100

0.40

0.50

0.50

255

6-65

70-100

690

620

790-930

720-900

18

16

6 – 100 Lateral Expansion 0.38mm

min

By Agmnt

max 0°C

T


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HIGH HARDNESS STEEL GRADES

MECHANICAL PROPERTIES TENSILE CHARPY V-NOTCH IMPACT

STEEL GRADE

PLATE THICKNESS

(mm)

CARBON EQUIVALENT

(IIW

BRINELL HARDNESS (HB3000/10)

0.2% PROOF STRESS

(MPa)

TENSILE STRENGTH

(MPa) ELONGATION IN 50mm G.L

ENERGY (J)

TEST TEMP.

(°C) TEST

DIRECTION

BISPLATE 320

5-<16

≥16-80 >80-100

0.40

0.50 0.58

320-360

970

1070

18

60

+20

L

BISPLATE 400

5-<16

≥16-80 >80-100

0.40

0.50 0.58

370-430

1070

1320

14

55

+20

L

BISPLATE 400XT

6-20 >20-50

0.39 0.44 370-430 1070 1320 16 45 -40 L

BISPLATE 425 6-100 0.61 400-460 1260 1480 11 40 +20 L

BISPLATE 500 6-100 0.61 477-534 1400 1640 10 35 +20 L

LEGEND L Longitudinal T Transverse Guaranteed Values Typical Values (provided for reference information only) ||W Carbon Equivalent Formula: C.E. = C + Mn + Cr+Mo+V + Ni+Cu 6 5 15 Please Note: 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. Information is subject to change without notice.


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BISPLATE® SIZE RANGE SIZE RANGE STANDARD SIZE SCHEDULE Table 1:

Plate mass (tonnes) calculation = 7.85 x W x T x L (m) NON STANDARD SIZES

• Available subject to sales enquiry. • Minimum order quantities may apply.

EDGE CONDITION

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

• All other plate is supplied with trimmed edge.

PLATE MASS IN TONNES

GRADE BISPLATE® 60, 70,80 ,320, 400 BISPLATE® 450 BISPLATE® 500

WIDTH (mm) 1525 1525 1900 2485 2485 3100 2485 3100 1525 1900 2485 2485

LENGTH (m) 8 6 6 6 8 8 8 8 6 6 5 8

Thickness (mm)

5 0.479 6 0.575 0.936 0.431 0.585 8 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 3.894 3.12125 3.901 4.867 3.90132 4.994 4.99440 6.242 6.24250 7.803 7.80360 7.023 5.852 70 6.264 6.264 75 6.712 5.387 80 7.159 5.746 90 6.464 6.464

100 7.183 7.183


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MANUFACTURING TOLERANCES THICKNESS TOLERANCE Table 2:

Notes: 1. Measurement can be conducted anywhere on plate. 2. All dimensions are in millimetres. WIDTH TOLERANCE TRIMMED EDGE PLATE Table 3: Note: All dimensions are in millimetres UNTRIMMED EDGE PLATE Table 4: Note: All dimensions are in millimetres.

Thickness (+ / - mm) WIDTH

≤6 >6 ≤8

>8 ≤10

>10 ≤13

>13 ≤18

>18 ≤22

>22 ≤30

>30 ≤42

>42 ≤63 >63

<1600 0.53 0.60 0.60 0.68 0.83 0.90 1.05 1.28 1.73 2.55

≥1600 <2100 0.60 0.68 0.68 0.75 0.90 0.98 1.13 1.35 1.80 2.63

≥2100 <2700 0.75 0.75 0.83 0.90 0.98 1.05 1.28 1.50 1.95 -

≥2700 - 0.98 1.05 1.13 1.20 1.35 1.43 - - -

THICKNESS <16 ≥16 <50 ≥50

Width Plus Minus Plus Minus Plus Minus

<1520 16 0 20 0 25 0

≥1520 20 0 25 0 30 0

ALL THICKNESS PLUS MINUS

Width

≤1800 40 0

>1800 50 0


25 of 90 18 August 2006 Rev 2.

LENGTH TOLERANCE Table 5: Note: All dimensions are in millimetres. CAMBER EDGE CAMBER TOLERANCE Table 6: Note: All dimensions are in millimetres

Edge Camber shall be limited so that it shall be possible to inscribe the dimensions of the ordered plate within the delivered size.

THICKNESS <25 ≥25

Length Plus Minus Plus MINUS

<6000 25 0 30 0

≥6000 <12000 30 0 45 0

≥1200 50 0 65 0

SPECIFIED WIDTH TRIMMED EDGE UNTRIMMED

EDGE

ALL 4 6


26 of 90 18 August 2006 Rev 2.

FLATNESS Measurement of flatness tolerance should be made when the product,

resting under its own mass, is placed on a flat horizontal surface. A straight edge shall be placed on the plate and the maximum vertical distance from the plate shall be measured (H).

Table 7:

Notes: 1. The tolerances apply when measured at least 20mm from the longitudinal edges and 100mm from the transverse edges.

2. Where the distance between the points of contact is between 500mm and 1000mmm,

the permissible deviation is obtained as follows.

DISTANCE BETWEEN POINTS OF CONTACT x H 1000

Where H = allowable deviation for 1000mm Note: This table is an extract of the AS1365 - 1986 (table 3.4). However Bisalloy® Steels Pty Ltd internal manufacturing tolerances are considerably more restrictive.

3. All dimensions are in millimetres.

SPECIFIED WIDTH OF PLATE (mm) SPECIFIED THICKNESS

PLATE (mm)

DISTANCE BETWEEN POINTS OF CONTACT

(mm) <1500 ≥1500

<1800 ≥1800 <2400

≥2400 <3000 ≥3000

≤8 1000

2000

8

15

8

15

8

15

10

25

15

30

>8 ≤12 1000

2000

6

10

6

10

8

15

10

20

15

25

>12 ≤25 1000

2000

6

8

6

10

6

12

10

16

10

16

>25 1000

2000

6

8

6

8

6

10

6

10

6

10


27 of 90 18 August 2006 Rev 2.

FLAME CUTTING, PLASMA CUTTING, LASER CUTTING, WATERJET CUTTING AND SAWING RECOMMENDATIONS

All grades of BISPLATE® quenched and tempered steel can be cut by either thermal cutting, laser cutting, waterjet cutting or power saw operations. The cutting operations can be carried out either in the workshop or, in the case of flame cutting, in field conditions. Both the high strength structural grades and the wear and abrasion resistant grades can be cut using the same type of equipment employed in cutting plain carbon steels.

CUTTING OPERATIONS Dependant on the grade and thickness being cut, the following operations can be used on BISPLATE® grades. Flame Cutting (Oxy-LPG and Oxy-acetylene) Plasma Cutting Laser Cutting Waterjet Cutting Power Sawing FLAME CUTTING Both Oxy-LPG and Oxy-acetylene processes are acceptable for sectioning all thicknesses of BISPLATE®. With these processes, the following

techniques are recommended:

Gas pressure to be the same as for cutting the equivalent thickness in plain carbon steel.

Reduce travel speeds by 30% when compared to the equivalent thickness plain carbon steels when using a standard cutting nozzle.

Nozzle size to be the same as for equivalent thickness plain carbon steel.

Correct selection of nozzle size for the plate thickness being cut is important to ensure efficient cutting and to minimise the width of the heat affected zone (HAZ).

As with all plate steels, the smoothness of the cut is affected by surface scale. If this is present, it is advisable to remove it prior to cutting. (BISPLATE® is normally supplied in the shotblasted condition) Under normal Oxy cutting conditions, the total heat affected zone adjacent to the flame cut edge will extend into the plate approximately 2-3mm, as shown left in figure 2a for BISPLATE® 80. It should be noted that the heat affected zone produces a ‘hard’ layer adjacent to the flame cut edge, with a ‘soft’ layer inside this. The original plate hardness


28 of 90 18 August 2006 Rev 2.

returns after the 2-3mm distance from the cut edge. For BISPLATE® 500 the HAZ may extend as much as 4-5mm into the plate as shown in figure 2b.

Preheating BISPLATE® steel prior to flame cutting will minimise the hardness of the flame cut edge and also reduce the risk of delayed cracking from this cut edge. This is particularly important in cold environments where plate temperature is less than 20°C and for the high hardenability grades of BISPLATE® 425 and 500.

Table 1 below, gives guidance on the preheat requirements. It is recommended that the zone to be preheated should extend at least 75mm either side of the line of cut, with the temperature being measured on the opposite surface and at a distance of 75mm, as shown in figure 3.

Recommended Minimum Preheat Temperatures for Flame Cutting of BISPLATE® Grades

Table 1:

BISPLATE® GRADE PLATE THICKNESS (mm)

MINIMUM PRE-HEAT TEMPERATURE

60, 70 8 – 32 20°C

80, 80PV 5 – 31

32 – 100

20°C

50°C

320, 400, 450 5 – 31

32 - 100

20°C

50°C

500 6 – 20

21 – 100

50°C

100°C

If the flame cut surface is to be the face of a welded joint, the heat affected zone from the flame cutting need not be removed. However, all slag and loose scale should be removed by light grinding, and prior to welding, the cut surface should be dry and free from organic matter such as oil, grease, etc (as directed by good workshop practice). Recommended preheat zone and location of Preheat measurement

When stripping plates, the use of multiple cutting heads will help to minimise distortion of the cut pieces. Correct nozzle size, gas pressure and travel speed will also minimise distortion during cutting. Softening on edges can also occur when flame cutting small strips, eg. 50mm wide x 50mm thick plate. Quench cutting of BISPLATE® grades to minimise distortion is not recommended, while cooling in still air is preferred. The technique of stacking plates during profile cutting should also be avoided.


29 of 90 18 August 2006 Rev 2.

SUMMARY OF FLAME CUTTING RECOMMENDATIONS For Oxy processes use gas pressures and nozzle sizes as for an equivalent thickness of plain carbon steel. For oxy processes use cutting speeds two thirds of that recommended for an equivalent thickness of plain carbon steel. Flame cutting produces a heat affected zone on all grades. The risk of delayed cracking is reduced by using preheat especially for thick plate and for BISPLATE® 500 grade. Use multiple cutting heads when stripping plates. Still air cooling after cutting. Do not stack cut. Do not quench cut plates. Use thermal crayons or surface thermometers to measure preheat temperatures. REFERENCES/FURTHER READING WTIA Technical Note 5 “Flame Cutting of Steels.”

PLASMA CUTTING

Plasma cutting is an acceptable method of sectioning all grades of BISPLATE®. The process offers particular advantages of productivity over flame cutting in thicknesses up to 20mm using currently available equipment. For instance, the cutting speed of 6mm BISPLATE® 400 may be up to 9 times that recommended for conventional flame cutting techniques.

The cut quality may be inferior, however, due to rounding of the top edges and difficulty in obtaining a square cut face of both edges. Guidance on the optimum settings for nozzle size, gas pressure, gas composition and cutting speeds will be provided by the equipment manufacturer. BISPLATE® with low alloy contents should be treated similarly to conventional structural steels. The heat affected zone from a plasma cut is narrower than that produced from flame cutting but peak hardnesses are generally higher. General recommendations for the removal of this hardened zone are outlined below. Hardness Profile Characteristics for Plasma Cutting


30 of 90 18 August 2006 Rev 2.

Table 2: PLATE THICKNESS (mm)

RECOMMENDED DEPTH OF REMOVAL (mm)

PEAK HARDNESS (HB)

BISPLATE®

60, 70, 80

320

400

BISPLATE®

450

BISPLATE®

500

5 – 8

>8 – 12

>12 - 20

0.4 – 0.5

0.6 – 0.8

1.0 – 1.2

430

450

450

480

480

480

540

540

540

The plasma cut HAZ typically extends 0.5 – 1.0mm into the plate under normal conditions. As is the case for flame cutting, complete removal by grinding is recommended if cold forming of the cut plate is contemplated. All other comments for flame cutting regarding preheating, removal of the HAZ, stripping and stack cutting of plates would apply to plasma cutting. LASER CUTTING

Laser cutting is a productive method for sectioning all grades of BISPLATE® up to 12mm thickness, particularly where high levels of accuracy and minimal distortion is required. Currently, with thicknesses above 12mm, productivity levels drop when compared with other processes. The laser cutting process is unlike other thermal cutting in so far as the material is essentially vapourised from the kerf rather than melting and removal by kinetic energy.

The laser concentrates its energy into a focused beam resulting in low levels of excess heat. This results in very small HAZ areas (0.05 – 0.15mm) and small kerfs (0.3mm). Comparison of Flame, Plasma and Laser Cutting on 6mm BISPLATE® 400 Table 3:

PROCESS KERF WIDTH (mm) HAZ WIDTH (mm) Flame cutting 0.9 1.5 Plasma cutting 3.2 0.5 Laser cutting 0.3 0.2 Cutting speeds are typically 5000mm/min and the edge is generally square, burr free and minimal dross. Peak hardness levels are lower than those obtained from alternate cutting methods previously described. Removal of the HAZ is generally not considered necessary for most applications, however, for forming operations it is advised that Bisalloy® Steels are contacted for guidance.


31 of 90 18 August 2006 Rev 2.

POWER SAWING All BISPLATE® grades can be cut with power saws, provided lower blade speeds and blade pressures up to 50% higher than those used for cutting plain carbon steel are used. Best results have been achieved using power saw blades normally recommended for cutting stainless steel (generally, blades having 4-6 teeth per 25mm). Sawing directly onto a flame cut surface should be avoided where possible.

Correct practice of sawing BISPLATE® grades Incorrect practice of sawing BISPLATE® grades WATERJET CUTTING

Waterjet cutting can be performed on all grades of BISPLATE®, although its widespread use is limited due to the current machines available in Australia and their low cutting speeds.

A key advantage of water jet cutting is that it leaves the surface free of HAZ. Cutting without heat protects against metallurgical changes in the plate, ensuring original plate mechanical properties are maintained.

Recent tests performed by the CSIRO Division of Manufacturing Technology on waterjet cutting 8mm BISPLATE® 500 at 40mm/min resulting in near perfect cut edges. Speeds to 75mm/min are possible but with reduced smoothness of the cut edge.

The micrographs show the parent material adjacent to the cut edge for waterjet cutting in comparison to laser cutting. The waterjet cut shows no change in material structure at the edge of the cut. The laser cut edge shows a distinct change in structure to a depth of 0.2mm.

Both laser cutting and waterjet cutting are industrial processes which should be considered by structural designers and fabricators as alternate means to avoiding problems associated with fit up, cut edge squareness, shape precision, dross and gross HAZ’s which can occur with conventional thermal cutting processes.

Bisalloy® steels wish to thank the Australian Welding journal, CSIRO-DMT, Ian Henderson,CRC for Materials Welding and joining and Rory Thompson, CSIRO Industry Liasion Manager for information pertaining to laser and waterjet cuting contained in this publication . Please Note: 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 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. Information is subject to change without notice.


32 of 90 18 August 2006 Rev 2.

WELDING OF BISPLATE® QUENCHED AND TEMPERED STEELS

GENERAL INFORMATION All grades of BISPLATE® can be readily welded using any of the conventional low hydrogen welding processes. Their low carbon content and carefully balanced, but relatively small additions of alloying elements (Mn, Cr, Mo, Ni, B) ensures good weldability, in addition to the advantages of high strength, impact toughness and high hardness. HYDROGEN CONTROL To ensure adequate welding of BISPLATE®, it is necessary to be more mindful of the levels of hydrogen, preheat temperatures and arc energy inputs in order to minimise the hardening and maintain the properties of the weld Heat Affected Zone (HAZ). Particular attention must be paid to the control of hydrogen content to minimise the risk of weld and HAZ cracking. Weld hydrogen content is minimised by careful attention to the cleanliness and dryness of the joint preparations and the use of hydrogen controlled welding consumables. Recommendations on the correct storage and handling of consumables may be obtained from welding consumable manufacturers, for instance the use of “Hot Boxes” for storage and reconditioning are required when using manual metal arc welding electrodes. Refer WTIA Tech Note 3 for further guidance. HEAT AFFECTED ZONE PROPERTY CONTROL The HAZ, a region directly adjacent to the weld, experiences a thermal cycle ranging from unaffected parent plate to near melting at the fusion boundary. The properties of this zone are determined by the steel composition as well as the cooling rate. STEEL COMPOSITION BISPLATE® grades and chemical compositions may be divided into categories based on Carbon Equivalent and Pcm, as follows: Table 1:

BISPLATE® GRADE

PLATE THICKNESS (mm)

CARBON EQUIVALENT (IIW) TYPICAL

Pcm% (JWES) TYPICAL

CET

60, 70, 80 320, 400

5-12 0.40 0.25 0.29

60, 70, 80 320, 400

13 - 80 0.50 0.29 0.35

60, 70, 80 320, 400

81 - 100 0.58 0.30 0.34

450 6-20 0.45 0.29 0.29 500 5 - 100 0.62 0.39 0.42


33 of 90 18 August 2006 Rev 2.

Notes: 1. C.E. (IIW) = C + Mn + Cr+Mo+V + Cu+Ni

6 5 15 2. Pcm% (JWES) = C + Si + Mn+Cu+Cr + Ni + Mo + V + 5B

30 20 60 15 10

3. CET = C + Mn +Mo + Cr + Cu + Ni 10 20 40 These categories give an indication of the degree of care required in the proper selection of welding preheat/heat inputs. COOLING RATE Limitations on both preheat and heat input are necessary to ensure that the HAZ cools at an appropriate rate and that the correct hardness and microstructure are achieved. Too slow a cooling rate can result in a soft HAZ and thus a loss of tensile and fracture toughness properties. Too rapid a cooling rate produces a hard HAZ which may cause loss of ductility. Cooling is controlled by a balance between preheat and heat input for a particular plate thickness and joint configuration. PREHEAT/HEAT INPUT The preheat/heat input recommendations outlined in tables 2 and 3 will ensure that the cooling rate of the HAZ is satisfactory.

Recommended Preheat/Interpass Temperatures (°C) for BISPLATE® Table 2:

MAXIMUM THICKNESS IN JOINT (mm) BISPLATE® GRADE <13 >13<25 >25<50 >50

Minimum Preheat Temp°C

High Strength Structural

Grades

60 (AS 3597 Grade 500)

70 (AS 3597 Grade 600)

80 (AS 3597 Grade 700)

Nil*

Nil*

Nil*

50

50

50

75

75

75

140

140

140

Abrasion Resistant Grades

320

400

450

500

50

50

Nil***

100

75

75

150

125

125

150

150

150

**

Maximum Interpass

Temperature°C

All Grades

150

175

200

220

*Chill must be removed from plates prior to welding. **Refer to Bisalloy® Steels for availability, preheat/interpass requirements. ***Nil preheat up to a max thickness in the joint of 20mm. Note that under rigid weld joint restraint conditions preheating temperature should be increased by 25°C.


34 of 90 18 August 2006 Rev 2.

Above details on recommended minimum preheat and maximum interpass temperatures are based on low restraint butt weld joint configurations. Increase in preheats is necessary for more complex joint configurations. Guidance is provided in WTIA Tech. Note 15 i.e. calculation of Joint Combined Thickness and determination of minimum preheat and interpass temperature conditions. Permissible Heat Input (kJ /mm) for BISPLATE® Table 3:

MAXIMUM PLATE THICKNESS IN JOINT (mm) WELDING PROCESS 3 – 12*** >12 – 25 >25 – 32 >32 - 100

MMAW 1.25 – 2.5 1.25 – 3.5 1.25 – 4.5 1.5 – 5.0

GMAW 1.0 – 2.5 1.0 – 3.5 1.25 – 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

Heat input (kJ/mm) = Volts x Amps x0.06 Travel Speed (mm/minute) ***For these thicknesses in structural grades, the maximum arc energy input may need to be limited to 1.5kJ/mm maximum in specific applications. Refer to Bisalloy® Steels for further guidance if required.


35 of 90 18 August 2006 Rev 2.

WELDING CONSUMABLES Welding Consumable Selection Guide for BISPLATE® (AS Classifications) Table 4a:

BISPLATE® 60

BISPLATE® 70

BISPLATE® 80

BISPLATE® 320, 400, 450, 500

MMAW Consumables1

Warning: Only use

Hydrogen Controlled

consumables

Strength Level

Hardness

Matching

Lower

Lower

Matching

E55XX/E62XX+

E48XX

E48XX

N.R.

E69XX*

E55XX

E48XX

N.R.

E76XX

E55XX/E62XX

E48XX

N.R.

N.R.

E55XX

E48XX

1430-AX, 1855-AX**

GMAW Consumables 2

Strength Level

Hardness

Matching

Lower

Lower

Matching

W55XX/W62XX+

W50XX

W50XX

N.R.

W69XX*

W55XX

W50XX

N.R.

W76XX

W62XX/W69XX

W55XX.X

N.R.

N.R.

W55XX

W50XX

1855-BX**

FCAW Consumables3

Strength Level

Hardness

Matching

Lower

Lower

Matching

W55XX.X/

W62XX.X+

W50XX.X

W50XX.X

N.R.

W69XX.X*

W62XX.X

W55XX.X

N.R.

W76XX.X

W62XX.X

W55XX.X

N.R.

N.R.

W55XX.X

W50XX.X

1430-BX, 1855-BX, 1860–BX**

SAW Consumables4

Strength Level

Hardness

Matching

Lower

Lower

Matching

W55XX/W62XX+

W50XX

W40XX

N.R.

W69XX*

W50XX

W40XX

N.R.

W76XX

W50XX

W40XX

N.R

N.R.

W50XX

W40XX

1855-BX**

Table 4a courtesy of WTIA (Tech Note 15) Notes:

1 MMAW - AS/NZS 1553.1 - 1995 and AS1553.2 - 1987 consumable classification.

2 GMAW - AS271 7.1 - 1984 consumable classification.

3 FCAW - AS2203 - 1990 consumable classification. 4 SAW - AS1858. 1 - 1996 and AS1858.2 - 1989 consumable classification. X = A Variable - any value allowed by the relevant standard may be acceptable provided that the consumable is hydrogen controlled (ie

low hydrogen).

+ E62XX and W62XX type consumables overmatch the strength requirements but may be used. *These Consumables may be difficult to obtain. In some cases E62XX or W62XX type consumables may be substituted, otherwise use

E76XX or W76XX types. **AS2576 and WTIA TN 4 Classifications. N.R. Not Recommended.


36 of 90 18 August 2006 Rev 2.

Welding Consumable Selection Guide for BISPLATE® (AWS Classifications) Table 4b:

Table 4B courtesy of WTIA (Tech Note 15) Notes:

1 MMAW – AWS A5. 1-91 and AWS A5.5-81 consumable classification.

2 GMAW – AWS A5. 18-93 and AWS A5.28-79 consumable classification.

3 FCAW – AWS A5.20-79 and AWS A5.29-80 consumable classification.

4 SAW - AWS A5.17-89 and AWS A5.23-90 consumable classification. X = A Variable - any value allowed by the relevant standard may be acceptable provided that the consumable is hydrogen controlled (ie

low hydrogen).

+ E90XX, ER90S, E9XTX and F9XX type consumables overmatch the strength requirements but may be used. *These Consumables may be difficult to obtain. In some cases E90XX, ER90S, E9XTX or F9XX type consumables may be substituted,

otherwise use E110XX, ER110S, E11XTX or F11XX types. **AS2576-1982 WTIA TN 4 Classifications. N.R. Not Recommended.

BISPLATE® 60

BISPLATE® 70

BISPLATE® 80 BISPLATE® 320, 400, 450, 500

MMAW Consumables1

Warning: Only use

Hydrogen Controlled

consumables

Strength Level

Hardness

Matching

Lower

Lower

Matching

E80XX/E90XX+

E70XX

E70XX

N.R.

E100XX*

E80XX

E70XX

N.R.

E110XX

E80XX/E90XX

E70XX

N.R.

N.R.

E80XX

E70XX

1430-AX, 1855-AX**

GMAW Consumables 2

Strength Level

Hardness

Matching

Lower

Lower

Matching

ER80S-X/ER90S-X+

ER70S-X

ER70S-X

N.R.

ER100S-X*

ER80S-X

ER70S-X

N.R.

ER110S-X

ER90S-X/ER100S-X

ER80S-X

N.R.

N.R.

W55XX

W50XX

1855-BX**

FCAW Consumables3

Strength Level

Hardness

Matching

Lower

Lower

Matching

E8XTX-X/E9XTX-X+

E7XTX-X

E7XTX-X

N.R.

E10XTX-X8

E9XTX-X

E8XTX-X

N.R.

E11XTX-X

E9XTX-X

E8XTX-X

N.R.

N.R.

E8XTX-X

E7XTX-X

1430-BX, 1855-BX, 1860–BX**

SAW Consumables4

Strength Level

Hardness

Matching

Lower

Lower

Matching

F8XX/F9XX+

F7XX

F6XX

N.R.

F10XX*

F7XX

F6XX

N.R.

F11XX

F7XX

F6XX

N.R.

N.R.

F7XX

F6XX

1855-BX**


37 of 90 18 August 2006 Rev 2.

MANUFACTURERS’ WELDING CONSUMABLES Welding Consumables suitable for matching strength, lower strength and matching hardness are readily available from a range of consumable manufacturers as per following tables 5 to 8. Welding Consumables for Manual Metal Arc Welding (MMAW) Table 5:

M.S. – Matching Strength L.S. – Lower Strength M.H. – Matching hardness N.R. – Not Recommended N.A. Not available N.B. – Consumables in brackets will match mechanical property requirements in the majority of instances as per manufacturer’s recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should be carried out to establish actual Weld metal properties. *Consumable recommendations overmatch mechanical property requirements.

BRANDS BISPLATE® 60 BISPLATE® 70 BISPLATE® 80 BISPLATE® 320400, 450, 500

CIGWELD M.S. L.S. M.H.

Alloycraft 90 Ferrocraft 61 Multicraft 7016 N.R.

Alloycraft 110*, (Alloycraft90) Ferrocraft 61 Multicraft 7016 N.R.

Alloycraft 110 Ferrocraft 61 Multicraft 7016 N.R.

N.R. Ferrocraft 61 Multicraft 7016 Cobalarc 350, 650

Lincoln Electric M.S. L.S. M.H.

Jetweld LH90-MR Jetweld LH70, LH75-MR N.R.

(Jetweld LH90-MR) Jetweld LH70, LH75-MR N.R.

Jetweld LH110M-MR Jetweld LH70, LH75-MR N.R.

NR Jetweld LH70, LH75-MR Wearshield ABR

LiquidArc M.S. L.S M.H.

N.A. Easyarc 16GP, Easyarc 18MR N.R.



N.R. Easyarc 16GP, Easyarc 18MR Liquidarc HF 600

W.I.A M.S. L.S. M.H.

Austalloy 6218-M (Austarc 18TT) Austarc 18TT, 16TC, Weldwell PH77, PH56S N.R.

Austarc 761 8-M, (621 8-M), Weldwell PH118 Austarc 18TT, 16TC, Weldwell PH77, PH56S N.R.

Austalloy 7818-M, Weldwell PH118 Austarc 18TT, 16TC, Weldwell PH77, PH56S N.R.

N.R. Austarc 18TT, 16TC, Weldwell PH77, PH56S AbrasoCord 350, 700, Weldwell PH400, PH600

Eutectic Castolin

M.S. L.S. M.H.

N.A. Eutectrode 66*66 N.R.



N.R. Eutectrode 66*66 N.R.

SWP/Metrode Products

M.S. L.S. M.H.

E9018-D1 MP51 N.R.

E1001 8-D2 MP51 N.R.

E11018-M MP51 N.R.

N.R. MP51 Methard 350, Methard 650

ESAB M.S. L.S. M.H.

OK 48.08 OK 48.04 N.R.

OK 74.78 OK 48.04, OK 48.08 N.R.

OK 75.75 OK 48.04, OK 48.08 N.R.

N.R. OK 48.04, OK 48.08 OK 83.28, OK 83.50


38 of 90 18 August 2006 Rev 2.

Welding Consumables for Gas Metal Arc Welding (GMAW) Table 6: M.S. – Matching Strength L.S. – Lower Strength M.H. – Matching hardness N.R. – Not Recommended

N.A. Not available N.B. – Consumables in brackets will match mechanical property requirements in the majority of instances as per manufacturer’s recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should be carried out to establish actual Weld metal properties. *Consumable recommendations overmatch mechanical property requirements.

BRANDS BISPLATE® 60 BISPLATE® 70 BISPLATE® 80 BISPLATE® 320400, 450, 500

CIGWELD M.S.

L.S.

M.H.

Autocraft Mn Mo/

Argoshield 51 or 52

Autocraft LW1/

Argoshield 51 or 52,

Autocraft LW1-6/

Argoshield 51 or CO2

N.R.

Autocraft Ni Cr Mo*/

Argoshield 60 or 52,

(Autocraft Mn Mo/

Argoshield 51 or 52)

Autocraft LW1/

Argoshield 51 or 52

Autocraft LW1-6/


N.R.

Autocraft Ni Cr Mo/

Argoshield 60 or 52

Autocraft LW1

Argoshield 51 or 52

Autocraft LW1-6/


N.R.

N.R.

Autocraft LW1/

Argoshield 51 or 52

Autocraft LW1-6/


Cobalarc 350-FC,

Cobalarc 650-FC

Lincoln Electric M.S.

L.S.

LA-90/C02 or Ar+CO2

L54, L54 Ultra/

CO2 or Mixed Gas,

L56 Ultra/CO2

LA-100/AR+2%O2

L54, L54 Ultra/

CO2 or Mixed Gas,

L56 Ultra/C02

N.A.

L54, L54 Ultra/

CO2 or Mixed Gas,

L56 Ultra/CO2

N.R.

L54, L54 Ultra/

CO2 or Mixed Gas,

L56 Ultra/CO2

LiquidArc M.S.

L.S

M.H.

LA6047*/CO2 or Mixed Gas

Steelmig Super 4/

CO2 or Mixed Gas

Steelmig Super 6/CO2

LA6047*/CO2 or Mixed Gas

Steelmig Super 4/

CO2 or Mixed Gas


LA6047*/CO2 or Gas

Steelmig Super 4/

CO2 or Mixed Gas


N.R.

Steelmig Super 4/

CO2 or Mixed Gas


W.I.A M.S.

L.S.

M.H.

Austmig ESD2/CO2

or Mixed Gas

Austmig ES6/

CO2 or Mixed Gas

PZ6000/

CO2 or Mixed Gas

N.A.

PZ6047/CO2

Or mixed Gas

Austmig ES6/

CO2 or Mixed Gas

PZ6000/

CO2 or Mixed Gas

N.A.

PZ6047/CO2

Or mixed Gas

Austmig ES6/

CO2 or Mixed Gas

PZ6000/

CO2 or Mixed Gas

N.A.

N.R.

Austmig ES6/

CO2 or Mixed Gas

PZ6000/

CO2 or Mixed Gas

TD600/CO2

or Mixed Gas

Eutectic

Castolin

M.S.

L.S.

AN45252/

CO2 or Mixed Gas

DO*65/CO2

Or Mixed Gas

AN45252/

CO2 or Mixed Gas

DO*65/CO2

Or Mixed Gas

AN45252/

CO2 or Mixed Gas

DO*65/CO2

Or Mixed Gas

N.R.

DO*65/CO2

Or Mixed Gas


39 of 90 18 August 2006 Rev 2.

Welding Consumables for Flux Cored Arc Welding (FCAW) Table 7:

BRANDS BISPLATE® 60 BISPLATE® 70 BISPLATE® 80 BISPLATE® 320, 400, 450, 500


Verti-Cor 91-K2/ Argoshield 52 SupreCor 5 or Verti-Cor 80 Ni 1/ Argoshield 52 N.R.

Tensi-Cor 110TXP*/ CO2 (Verti-cor 91-K2/ Argoshield 52) SupreCor 5 or Verti-Cor 80 Ni 1/ Argoshield 52 N.R.

Tensi-Cor 110TXP*/ CO2 SupreCor 5 or Verti-Cor 80 Ni 1/ Argoshield 52 N.R.

N.R. SupreCor 5 or Verti-Cor 80 Ni 1/ Argoshield 52 Cobalarc 350 FC, Cobalarc 650 FC

Lincoln Electric M.S. L.S. M.H

O/Shield 91K2-H/Ar +25% CO2 O/Shield 70, 71, 71M/ CO2 or Ar+25% CO2 O/Shield 71C-H, 75H/ Ar+25% CO2 I’Shield NS3M, NR232 NR203M N.R.

O/Shield MC100/Ar+5% CO2 or 2% CO2 O/Shield 70, 71, 71M/ CO2 or Ar+25% CO2 O/Shield 71C-H, 75H/ Ar+25% CO2 I’Shield NS3M, NR232 NR203M N.R.

O/Shield MC 120-55Ar +2% O2 O/Shield 70, 71, 71M/ CO2 or Ar+25% CO2 O/Shield 71C-H, 75H/ Ar+25% CO2 I’Shield NS3M, NR232 NR203M N.R.

N.R. O/Shield 70, 71, 71M/ CO2 or Ar+25% CO2 O/Shield 71C-H, 75H/ Ar+25% CO2 I’Shield NS3M, NR232 NR203M Lincore 55

LiquidArc M.S. L.S. M.H

N.A. Easy-Core 70T-1/ CO2 or mixed gas, Easy Core 71M/CO2 Or mixed gas Easy-Core 71C-H, 75-H/ Ar+25% CO2 N.R.



N.R. Easy-Core 70T-1/ CO2 or mixed gas, Easy Core 71M/CO2 Or mixed gas Easy-Core 71C-H, 75-H/ Ar+25% CO2 N.A.

W.I.A M.S. L.S. M.H

Fluxofil 41/CO2 or Mixed gas Fluxofil 20, 31, 36/ CO2 or Mixed gas N.R.



N.R Fluxofil 20,31,36/ CO2 or Mixed gas Fluxodur 1430, 1855/ CO2 or Mixed gas

Eutectic Castolin

M.S. L.S. M.H.

N.A. Teromatec OA2020 N.R.




SWP/Welding Alloys Ltd

M.S. L.S. M.H

X91X-T5-K2/ CO2 or Ar+20% CO2 X71-T1/CO2 or Ar+20% CO2 X71-T5/CO2 or Ar+20% CO2 N.R.

X110-T5-K4*/ CO2 or Ar+20% CO2 X71-T1/CO2 or Ar+20% CO2 X71-T5/CO2 or Ar+20% CO2 N.R.

X110-T5-K4/ CO2 or Ar+20% CO2 X71-T1/CO2 or Ar+20% CO2 X71-T5/CO2 or Ar+20% CO2 N.R.

N.R. X71-T1/CO2 Or Ar+20% CO2 X71-T5/CO2 Or Ar+20% CO2 Hardface T-O/S/G, L-O/S/G

ESAB/Alloy Rods M.S. L.S. M.H.

Dualshield II-70/Ar + 25% CO2 Dualshield II-71/CO2 Dualshield T-5/mixed gas Dualshield 7000/mixed gas N.R.

Dualshield II-100/CO2 Dualshield T-5/mixed gas Dualshield 7000/mixed gas N.R.

Dualshield II-110/CO2 Dualshield T-5/mixed gas N.R.

N.R. Dualshield T-5/mixed gas N.R.

M.S. – Matching Strength L.S. – Lower Strength M.H. – Matching Hardness N.R. – Not Recommended N.A. Not available N.B. – Consumables in brackets will match mechanical property requirements in the majority of instances as per manufacturer’s recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should be carried out to establish actual Weld metal properties. *Consumable recommendations overmatch mechanical property requirements.


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Welding Consumables for Submerged Arc Welding (SAW) Table 8:

BRANDS BISPLATE® 60 BISPLATE® 70 BISPLATE® 80 BISPLATE® 320, 400, 450, 500


N.A. Autocraft SA1, SA2/ Satinarc 4 N.R.



N.A. Autocraft SA1, SA2/ Satinarc 4 Cobalarc 107-SA/ Satinarc 4

Lincoln Electric M.S. L.S. M.H.

LA 100/880M* L60,L61/761,780 or 860 N.R.

LA 100/Mil 800H L60, 61/761,780 or 860 N.R.

LACM2/880M or 880 L60, 61/761,780 or 860 N.R.

N.R. L60, 61/761,780 or 860 Lincore 55/802

WIA M.S. L.S. M.H.

N.A Austmatic SD3/OP121TT N.R.

Fluxocord 42/OP121TT* Austmatic SD3/OP121TT* N.R.

Fluxocord 42/OP121TT Austmatic SD3/OP121TT* N.R.

N.R. Austmatic SD3/OP121TT N.A.

M.S. – Matching Strength L.S. – Lower Strength M.H. – Matching Hardness N.R. – Not Recommended N.A. Not available N.B. – Consumables in brackets will match mechanical property requirements in the majority of instances as per manufacturer’s recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should be carried out to establish actual Weld metal properties. *Consumable recommendations overmatch mechanical property requirements. WELDING PROCEDURES The specific effects of welding on weld joint properties in any practical situation will depend on many factors including the choice of consumables, total weld heat input, level of restraint, weld geometry and proximity of adjacent welds. Guidance on weld procedures for specific applications may be sought from Bisalloy®® Technical staff or consumable suppliers. ARC STRIKES Arc strikes outside the welded zone can result in cracks, particularly on dynamically loaded structures. All strikes should be made within the joint preparation. TACK WELDING Tack welds require special care due to the abnormal stresses and high cooling rates experienced by the adjacent material. The same preheat, heat input requirements should be employed and lower strength welding consumables considered.


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FILLET WELDING Good fillet welding techniques are important in welding Q and T steels because often very high stresses are applied in service. It is essential that welds have good root penetration, be smooth, correctly contoured and well flared into the legs of the joined pieces. Lower strength consumables are suggested when design permits. WTIA Tech. Note 15 provides guidance on correct procedures for fillet welding. REPAIR WORK It is good practice to weld repair with lower strength consumables (low hydrogen type), since plate materials which have been highly stressed in service may tend to warp or distort slightly during welding and improved ductility may be required. In some situations, such as joints under restraint, joints subjected to impact/fatigue stresses, etc, special welding consumables may be necessary. WELDING STRESSES It should be emphasised that the recommended values of preheat and heat input are based on low to moderate levels of restraint. For conditions of high restraint it is important to minimise the degree to which free contraction is hampered and it may be necessary to use higher preheats. Proper welding sequence and small joint configurations would be considered important in high restraint situations and it is advisable to establish welding parameters with simulated full scale weld tests. Care should also be exercised at the assembly stage to avoid offset and angular distortion at the plate edge, undercutting and bad appearance. STRESS RELIEF Stress relief may be conducted on BISPLATE® 60, 70, 80 and 80PV grades but is advisable only if absolutely necessary (eg. to comply with AS1210 in the case of road tankers). Stress relief is recommended within a 540 - 5700C temperature range for one hour per 25mm of thickness. Thermal cycling is generally performed in accordance with AS 1210-1989 Code requirements for Q and T steels. The toes of weld beads should be dressed by grinding prior to any stress relief treatment in order to prevent stress relief cracking. When stress relieving BISPLATE® ≤12mm (typically 0.40 CEIIW) and matching strength across the weld is a requirement, it is recommended to weld with minimum permissible preheat/ interpass temperatures (Table 2) and heat input (Table 3) conditions to minimise the degree of softening or any loss of strength which may occur in the HAZ. Consult Bisalloy® Steels for further information if required. POST-WELD HEATING Post-weld heating at 200-250° may be conducted as an effective hydrogen dissolution treatment particularly when consumables other than H5 or H10 are used.


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HELPFUL HINTS General rules for good quality welding of BISPLATE®: • Use a low hydrogen process, eg GMAW (MIG), FCAW (gas shielded). • Adhere to the correct rules for storage and handling of low hydrogen consumables

per the manufacturers’ recommendations, or WTIA Tech. Note 3. • Clean joint area of all contaminants prior to welding. • Remove 1 - 2mm from flame cut or gouged surfaces by grinding. • Select the recommended preheat, interpass and heat input parameters. • Position for downhand welding where possible. Always use stringer beads, never

wide weaves. • Use lower strength consumables on root runs and fillet welds (when the design

permits). • Use temper beads when necessary. • Arc strikes to be made in the joint preparation. • Particular attention should be given to tack welds re preheat, heat input and joint

cleanliness requirements. • Grinding toes of fillet welds is particularly important in fatigue applications.

REFERENCES/FURTHER READING • AS1554 Part 4 - 1989 Welding of Q & T Steels. • AS1554 Part 5 - 1995 Welding of Steel Structures Subject to High Levels of Fatigue

Loading. • WTIA Technical Note 15, 1996. • WTIA Technical Note 3, 1994.


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BENDING AND ROLLING. FORMING, SHEARING AND PUNCHING RECOMMENDATIONS

FORMING COLD FORMING All of the BISPLATE® quenched and tempered steel grades can be cold formed, using brake press bending or plate rolling techniques. However, with an increase in both hardness and yield stress compared to plain carbon steel grades, suitable consideration of sufficient machine power, plate bending direction and former radii must be made. In addition, springback allowances should be greater than for plain carbon steel and will depend on the type of forming. Plate edges should be ground smooth, and for thick plates and high hardness grades, the plate edges should be rounded prior to forming. It is recommended for the high hardness grades that where possible the bend axis be at right angles to the plate rolling direction (transverse bending). For plate 16mm and above in BISPLATE® 500 grade, it is suggested bending be done in the transverse direction only (refer to figure 1a).


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MINIMUM FORMER RADII (R) IN MM FOR COLD FORMING Table 1 following gives the minimum former radii for cold forming of the BISPLATE® grades (where possible a larger former radii should be used). Table 1: BISPLATE® GRADE

60 70 80 320,400 450 500

Bend Direction T L T L T L T L T L T L Plate Thickness (t) (mm) 5 6 8 10 12 16 20 25 32 40 50

12 12 12 15 18 24 40 50 64 100 140

12 15 16 20 24 32 50 62 80 120 190

12 12 12 15 18 24 40 50 80 110 150

12 15 16 20 24 32 50 62 95 130 200

12 15 20 25 30 45 65 75 100 125 150

12 15 20 25 30 45 65 75 110 140 200

15 20 25 30 35 50 70 80 110 170 300

20 25 35 45 55 75 100 125 175 250 -

32 40 48 64 80

40 50 60 80 100

- 25 40 50 60 85 100 150 250 - -

- 50 70 90 110 - - - - - -

T: Transverse Bending Direction (refer to fig 1a). L: Longitudinal Bending Direction (refer to fig 1b).

Notes re Table 1 1. Above values were determined for plate at a temperature of 30۫C. If minimum

former radii values are to be used, plate temperature should be at least 30°C, maximum 100°C. If forming at a temperature less than 30°C, an increase in former radii of minimum 50% must be made.

2. When pressing is being done in a single pass operation, an increase in former radii of minimum 50% must be made. 3. When forming using these minimum former radii, flame cut

hardened edge (heat affected zone of 1-2mm) should be removed. 4. The use of smaller former radii than in the table is not

recommended.

5. For best cold forming results, ensure adequate lubrication between the plate, die and former.


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CAPACITY OF PRESS All BISPLATE® grades have yield and tensile strengths higher than for plain carbon steel. It is important that the capacity of the machine is suitable, bending press manufacturers provide information on bending loads in relation to V-block opening, plate thickness and steel strength. Table 2 gives an indication of the approximate bending force required when forming BISPLATE® grades, compared to plain carbon steel (e.g. AS3678-Grade 250). Approximate Bending Force (P) Required for BISPLATE® Grades, Compared to Plain Carbon Steel, for a Given Forming Geometry (refer fig 2) Table 2:

STEEL GRADE BENDING FORCE (P)

AS3678 – Grade 250 BISPLATE® 60 70 80 320

400 450 500

P 2.0P 2.4P 2.8P 4.0P 5.0P 5.0P 6.4P

Approximate Die Openings (refer fig 2) Table 3:

BISPLATE® GRADE

W/t TRANSVERSE BENDING

W/t LONGITUDINAL BENDING

60 70 80 320 400 450 500

6.0 6.0 7.0 8.5 8.5 8.5 10.0

7.5 7.5 8.5 10.0 10.0 10.0 12.0


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HOT FORMING The operation of hot forming is not recommended for the BISPLATE® grades, as hot forming is generally done at a high temperature (900-1000°C) which exceeds the tempering temperature. As a result, the mechanical properties of quenched and tempered steels will be reduced considerably. However, if hot forming is unavoidable, it is essential that the component be requenched and tempered to restore original mechanical properties. SHEARING AND PUNCHING Shearing and punching of the lower hardness BISPLATE® grades can be done successfully, provided a machine of sufficient power and stability is used. BISPLATE® 60, 70 and 80 grades can normally be cold sheared up to 25mm thickness. However, the necessary shearing force is in the order of 2-3 times that required for plain carbon steel grades. The grades of BISPLATE® 400, 450 and 500 should not be considered for shearing. The guillotine blades should be very sharp and set with a clearance of 0.25 to 0.40mm. note, the maximum limiting thickness for cold punching are approximately half the cold shearing values. Maximum Thickness for Cold Shearing and Punching Table 4: BISPLATE® GRADE COLD SHEARING COLD PUNCHING 60 70 80 320 400 450 500

25mm 25mm 25mm 10mm Not recommended Not recommended Not recommended

12mm 12mm 12mm 6mm Not recommended Not recommended Not recommended


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DRILLING, COUNTERSINKING & TAPPING BISPLATE® DRILLING, COUNTERSINKING AND TAPPING RECOMMENDATIONS GENERAL INFORMATION All grades of BISPLATE® are able to be drilled, countersunk and tapped although, as with most fabrication aspects, care should be taken with these grades of steel. In all cases, suitable high powered and rigid drilling equipment should be used. DRILLING OF HIGH STRENGTH STRUCTURAL GRADES When drilling the BISPLATE® grades 60, 70 and 80 the use of cobalt type high speed steel drills is recommended. Drills equipped with replaceable carbide inserts can also be used. DRILLING OF WEAR/ABRASION RESISTANT GRADES BISPLATE® 320, 400 and 450 grades may be drilled with either cobalt type high speed steel drills or drills equipped with replaceable carbide inserts. With regards to the drilling of BISPLATE® 500 grade, we recommend only the use of drills equipped with replaceable carbide inserts. RECOMMENDATIONS FOR IMPROVED RESULTS • The supporting bars under the plate should be placed as close to the hole as possible. • If possible, use a plain carbon steel backing plate under the BISPLATE®. • The drilling head should be placed as close as possible to the main support. • Short length drills are preferred. • The last part of the hole to be drilled should be done with manual feed. • Usage of adequate coolant (water and oil emulsion mixture).

Delta C Drills. The grades of Bisplate 60, 70, 80, 320, 400 and 450 can be drilled using these types of drills. (Drills courtesy of Sandvik Coromant)


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Approximate Feeds and Speeds Using Cobalt Type High Speed Steel Drills Table 1:

R.P.M (UPPER FIGURES) AND FEED PER REVOLUTION (mm) FOR GIVEN DRILL SIZE

STEEL GRADE

PERIPHERAL SPEED (m/min) 3mm 6mm 12mm 20mm 25mm

HARDNESS BRINELL

AS3678-Grade 250 23 2300 0.050

1150 0.100

575 0.200

385 0.300

285 0.400

~120

BISPLATE® 60 16 1450 0.040

720 0.060

380 0.130

250 0.190

200 0.254

~220

BISPLATE® 70 15 1400 0.040

700 0.060

360 0.130

240 0.190

180 0.254

~240

BISPLATE® 80 14 1370 0.040

685 0.060

340 0.130

230 0.190

170 0.254

~260

BISPLATE® 320 9 920 0.025

460 0.050

230 0.100

150 0.150

115 0.200

320 (min)

BISPLATE® 400 7 460 0.025

230 0.050

115 0.100

110 0.150

90 0.200

360 (min)

BISPLATE® 450 7 440 220 115 110 90 425 (min)

Note: This table applies when cobalt type high speed drills are used with a cutting fluid, if no fluid is used the speeds shown above must be reduced.

Drill Tip Configuration Using Cobalt Type High Speed Steel Drills

Table 2: BISPLATE® GRADE POINT ANGLE LIP/CLEARANCE ANGLE 60 70 80

118 deg. 118 deg. 118 deg.

10 deg. 10 deg. 10 deg.

320 400, 450

125 deg. 150 deg.

7.5 deg. 5 deg.


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Approximate Feeds and Speeds Using Drills With Replaceable Carbide Inserts Table 3: BISPLATE® GRADE

INSERT GRADE SURFACE SPEED (m/min)

FEED RATE (mm/rev)

HARDNESS BRINELL

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: Above drilling recommendations are based on u sing a Sandvik Coromant U drill and is based on hole sizes of 12.7 - 60mm diameter. Through the tool coolant must be used. It may be necessary to use different insert grades and geometrics to suit the application. Further information can be obtained from your local Sandvik Coromant office.

COUNTERSINKING AND COUNTERBORING Countersinking and counterboring of holes is possible in all BISPLATE® grades with best performance obtained using tools with a revolving pilot. The pilot increases the stability and allows tools with replaceable carbide inserts to be used. Cobalt type high speed steel drills with a pilot can be used for the BISPLATE® grades 60, 70, 80, 320, 400 and 450. The cutting data will vary from machine to machine. A coolant should be used. Replaceable carbide insert tools should be used on BISPLATE® 500 grade. Cutting Speeds and Feeds When Using High Speed Steel Cobalt Type Tools


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Table 4: Ø 16 Ø 20 Ø 25 Ø 32 Ø 40 Ø 60 BISPLATE®

GRADE CUTTING SPEED (m/min)

Rpm FEED (mm/r)

Rpm FEED (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

400 450

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

Fig 4: Fig 5:


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Cutting Speeds and Feeds When using Replaceable Insert Tools Table 5:

Ø 20 Ø 25 Ø 32 Ø 40 Ø 60 BISPLATE® GRADE

CUTTING SPEED (m/min)

Rpm FEED (mm/r)

Rpm FEED (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

205 0.10-0.17

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 With the correct tools and cutting speeds, tapping can be performed in all the BISPLATE® grades of steel. For the high hardness BISPLATE® 400, 450 and 500 grades, higher alloyed taps must be used. Difficulties that commonly arise when thread cutting higher tensile strength steels include tap sticking, torn threads and the short life of taps. The Prototyp brand tools have been specifically developed for tapping in the BISPLATE® grades of steel. With all tapping it is recommended that the cutting speed is accurately controlled. For best results, cutting oil or grease should be used. For through-holes of up to 2 times diameter in thread depth, in metric sizes, the following tapping tools are recommended. † Note: The introduction of stress concentrations (as a result of tapping) is an important consideration in fatigue applications.


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Tapping Speeds and Types Recommended for BISPLATE® Grades Table 6:

BISPLATE® GRADE

TAP TYPE (prototype)

TAPPING SPEED (m/min)

SIZE RANGE LUBRICATION

60 Paradur 20360 15 M3 – M56 Cutting Oil 70 Paradur 20360 15 M3 – M56 Cutting Oil 80 Prototex Inox

202135 6 – 15* M1.6 – M36 Cutting Oil

320 Prototex Inox 202135

6 – 15* M1.6 – M36 Cutting Oil

400 Prototex Inox 202135

6 – 15* M1.6 – M36 Cutting Oil

450 Prototex Ni 202602 3 M1.6 – M24 Cutting Oil 500 Paradur H/C 80311 1.6 M3 – M12** Cutting Oil

* 6m/min using steam tempered taps and 15m/min using tin coated tips.

** For larger size threads, thread milling is recommended.

Straight fluted gun-nose tap for through-hole. Spiral sluted tap foe blind holes. (Taps coutesy of Ti-Tek)

Bisalloy®® Steels wish to thanks Sandvik Coromant and Ti-Tek for the information pertaining to drilling, tapping and countersinking contained in this publication.


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TURNING MILLING MILLING AND TURNING RECOMMENDATIONS MILLING Milling operations can be performed satisfactorily on all BISPLATE® grades; utilisation of cemented carbide tooling is recommended. In many situations, the milling operation entails the dressing of a flame cut edge, and then subsequent bulk milling of material to the desired surface finish and dimensional tolerance. Care must be taken to make a first cut sufficiently deep to remove the heat affected zone of the flame cut edge. Cutters must be sufficiently robust to take this heavy loading. In such circumstances it is desirable that, due to the high hardness adjacent to the flame cut surfaces, cutter speeds and feed rates for initial milling should be reduced to 40-59% of the speed normally used when milling plain carbon steel. The importance of adequate preheating prior to flame cutting and slow cooling after cutting to minimise edge hardening is again emphasised. Speed and feed rates may be increased somewhat for subsequent bulk milling to 50-75% of the settings used for plain carbon steel. Milling Recommendations Table 1: BISPLATE® GRADE

CEMENTED CARBIDE TOOLING GRADE

SURFACE SPEED FEED/TOOTH

60 70 80 320 400 450 500

GC4030 GC4030 GC4030 GC4030 GC4030 GC4030 GC4030

295m/min 275m/min 257m/min 131m/mon 110m/min 100m/min 87m/min

0.25mm 0.25mm 0.25mm 0.25mm 0.25mm 0.25mm 0.25mm

Note: These recommendations are given as a guide only, and are based on stable working conditions. It is suggested a 45 deg. Approach angle or a round insert facesmill be used. In certain conditions it may be necessary to use negative geometry milling tools. Feed rates are dependant on geometry selected. Eg. PM medium machining (0.1 – 0.28) fz mm/tooth PH heavy machining (0.1 – 0.42) fz mm/tooth. AVOID VIBRATIONS Indexable inserts are sensitive to vibrations. These can be avoided or reduced by observing the following. When turning or milling gas cut edges the cutting depth should be at least 2mm to cope with the hardness and unevenness of the edge.


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OTHER MILLING REQUIREMENTS • Firm clamping of the workpiece. • Use cutters with the smallest possible gap between the teeth. • Machine stability permitting, unidirectional milling is preferable, see figure 1. • If a large cutter is used for the milling of small areas, place the milling cutter eccentrically to get as many teeth as possible operating, see figure 2. • Avoid, if possible, the use of a universal cutterhead which generally causes

weakening of the power transmission and the tool holder. TURNING All BISPLATE® grades, including those with hardness in excess of 360 Brinell can be satisfactorily with carbide tooling, provided spindle speeds and feed rates are reduced from those normally employed when carrying out similar machining operations on plain carbon steel. Reductions of 50-70% in spindle speed and up to 50% in feed rate may be necessary, depending on the hardness of the component being machined, High speed tools are not recommended. As an example, the following settings have been found to give satisfactory results when turning cylindrical workpieces of 25mm diameter from the various BISPLATE® grades. With increases in stock diameter, spindle speeds will obviously need to be decreased.


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Turning Recommendations Table 2: BISPLATE® GRADE

CARBIDE TOOLING GRADE

SURFACE SPEED

60 70 80 320 400 425 500

GC4025 GC4025 GC4025 GC4025 GC4025 GC4025 GC4025

295m/min 275m/min 257m/min 131m/min 110m/min 100m/min 87m/min

For operations under favourable conditions where higher productivity can be obtained GC 4015 could be used. For operations with high toughness requirements and where increased security is needed GC 4035 could be used. Note: These recommendations are given as a guide only. And are based on stable working conditions. The geometry of the inserts used will be dependant on the operation. Eg. PF for finishing. PM for medium machining PR for roughing.

OTHER TURNING REQUIREMENTS

• Firm clamping of the workpiece • Avoid long overhangs for both workpiece and tool holder. • Use correct tip radius: too large a tip radius, combined with insufficient clamping,

causes vibrations. • Small setting angles also can cause vibrations.


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Fig 4

FORMULA FOR THE CALCULATION OF SPEEDS AND FEEDS FOR GENERAL MILLING AND TURNING OPERATIONS.

Formula for calculation of cutting speed: v = π • D • n m/min

1000

Formula for calculation of turning speed: n = v • 1000 m/min

π • D

Formula for calculation of table feed: u = n • z • sz m/min v = cutting speed m/min D = Diameter in mm of milling cutter or workpiece Z = Number of cutters Sz = Feed per cutter, mm n = Turning speed, rpm u = Table feed, mm/min Bisalloy® Steels wish to thank Sandvik Coromant for information pertaining to milling and turning contained in this publication.


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DESIGN EXAMPLES The following five structural design examples demonstrate the significant savings which can be achieved in the areas of weight and cost by using Grade 690 MPa Bisplate 80 steel instead of the more commonly used lower grade structural steels. These examples primarily compare Bisplate 80 to Grade 300 Plus Steel which is currently the most commonly used structural steel in Australia. Comparison with other steels are noted where appropriate. The design examples are as follows: • Heavily Loaded Column • Heavily Loaded Beam - I section • Heavily Loaded Beam - Box section • Heavily Loaded Truss • 70 MI Water tank Where appropriate, these examples have been simplified as much as possible in order to facilitate ease of comparison between the different steels. Each example contains a brief explanation of the structural element and the loading applied. Also provided are some typical examples of applications in which the structural element may be utilised. DESIGN CODES RELATING TO THE USE OF HIGH STRENGTH QUENCHED AND TEMPERED PLATE MEMBERS IN STRUCTURAL ENGINEERING APPLICATIONS. There is currently no Australian Standard covering the design of structural elements utilising high strength quenched and tempered steels. The SAA Steel Structures Code, AS 4100-1990, may be used for the design of structures in steel grades up to 450 MPa, beyond which the general provisions of the code are not applicable. AS4100 does not exclude the use of structural steels in excess of 450 MPa yield stress. However, in order to adequately design and demonstrate the validity of a design in such steels, it is necessary to engage an appropriate international standard which has been specifically developed to cater for the use of high strength steels. One such code, and the most commonly used in Australia for design in high strength steels is the American Institute of Steel Construction’s (AISC) Specification For Structural Steel Buildings - Allowable Stress Design and Plastic Design, June 1, 1989. This code has been proven to provide relatively simple and efficient methods of structural design for all types of structural elements, and has been used in the development of each of the design examples contained within this publication. A limit state version of the AISC specification is also available, and should be equally effective in the design of High Strength Steel structures. It should also be noted that Bisplate 80 steel, at 690 MPa yield stress, is right on the upper limit of 100 ksi yield stress steel covered by the AISC specification. Above this yield stress the AISC specification is not applicable.


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EXAMPLE 1 HEAVILY LOADED COLUMN

Consider a braced column, 10m high, loaded axially with an 11,000 KN factored live load (Fig. 1).

Some examples of practical applications where such a column may be required are as follows:

• In multi-storey construction • Heavy industrial structures • Storage silos/Hopper supports

Structural column design was carried out for Grade 300 MPa steel using AS4100-1990. C Corresponding design was carried out for

Grade 690 MPa Bisplate 80 Steel using the AISC specification.

The results of each design are summarised in Table 1. Representative calculations are provided on following pages. STEEL GRADE MPa SECTION WEIGHT Kg/m

300 500WC383 383

690 tf = 20 d1 = 400tw = 16 bf = 500 207


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COLUM DESIGN USING GRADE 300 STEEL COLUMN DESIGN USING GRADE 690 MPA YIELD Design in accordance with AS4100 – 1900. Fig 3

AS4100 500WC383 Reference

Section Capacity 6.2.1 NS = KfAnfy

An=Ag=Ae

Kf = 1.0 Ns = 13664 KN ØNs = 12,298 KN > N* OK

Member Capacity

6.3.3 Nc = αc Ns≤ N

Αc = ξ {[1-√[1-(90/ξλ)2]} = 0.8945 Nc = 12,222 KN ØNc = 11,000 KN ≤ N* OK Nominal Mass of Column = 383 kg/m

STRENGTH BISPLATE 80 Design in accordance with American Institute of Steel Construction Specification for Structural Steel Buildings - 1989.

AISC Spec. Design Load = 11,000 = 7,333 KN Reference 1.5 fa = 7,333 = 277.78 MPa Ag Fa = 40.29 ksi B5 Check Local Buckling Table B5.1 Flanges : 95 = 95 = 9.5 < b = 12.1 Fy 100 t √ Kc √ 1.0 Slender Element Table B5.1 Web: 253 = 253 = 25.3 > b = 25.0 √ Fy √ 100 t Non-Compact Element Slender elements involved

Design by Appendix B App. B Stress Reduction Factor for Flange, B5a Qs = 1.293 – 0.00309 b Fy = 0.907 t √Kc

Stress Reduction Factor for Web, Qa = 1.0 Member stress reduction factor, Q = QsQa = 0.907

Ag = 48,800 mm2 Ix = 1,890 x 106mm4

Iy = 751 x 106mm4 rx = 197mm ry = 124mm fy = 280 MPa

Ag = 26,400 mm2 = An = Ae Iy = 416.8 x 106mm4 Ry = Iy √A = 125.7mm fy = 690 MPa = 100 Ksi


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COLUMN DESIGN USING GRADE 690 MPA YIELD STRENGTH BISPLATE 80 (CONTINUED) AISC Spec. Reference B5c Allowable Stress, Fa C1

c = 79.44 > kl r kl 2 r Q 1 - Fy

2Cc,2

Fa = Eq A-B5-11 kl kl 3

5 3 r r

3 + 8Cc’ 8Cc’3

Fa = 43.13 ksi > fa OK Nominal mass of Column = 208 kg/m


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Practical applications where such a beam mayrequired are: • In multi-storey construction • Heavy industrial structures • Roof support in underground mining

EXAMPLE 2 HEAVILY LOADED BEAM (I – SECTION) Consider a beam with full lateral restraint spanning 10m, loaded continuously with a live load of 470 KN/m (factored) as shown in Fig.5.

Structural beam design was carried out for Grade 300 MPa steel using AS4100-1990. Corresponding design was carried out for Grade 690 MPa Bisplate 80 steel using the AISC specification. The results of each design are summarised in Table 2. Representative calculations are provided on the following pages.

Note that a significant reduction in the depth of the beam was achieved through the use of Bisplate 80, in addition to the weight waving, while still satisfying the permissible deflection requirements. This is of great importance in underground mining and multi-storey construction applications, where head room is at a premium.

STEEL GRADE MPa SECTION WEIGHT Kg/m

300 1200WB392 392

690 tf = 25 d1 = 850 tw = 12 bf = 450 256


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BEAM DESIGN USING BEAM DESIGN USING GRADE 690 MPA GRADE 300 STEEL YIELD STRENGTH BISPLATE 80 Design in accordance with AS4100 – 1990.


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EXAMPLE 3 HEAVILY LOADED BEAM (BOX SECTION) Consider a beam with full lateral restraint spanning 10m, loaded continuously with a live load of 470 KN/m (factored) as shown in Fig 9.

Practical applications are : • Heavy industrial structures • Roof support in mining • A box section is effective in long spans where additional lateral restraint is required within

the beam section to compensate for a lack of external restraints. • A common application of a box section fabricated from high strength Q & T steel

in which the load configuration varies significantly from that described above, is in the lifting booms of mobile cranes.

Structural beam design was carried out for both Grade 250 MPa steel and Grade 690 MPa Bisplate 80 steel using the AISC specification. The results of each design are summarised in Table 3. Representative calculations are provided on the following pages. Table 3:

STEEL GRADE MPa SECTION WEIGHT Kg/m

250 tf = 40 d1 = 1120 tw = 10 bf = 500 490

690 tf = 25 d1 = 850 tw = 8 bf = 450 284


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BOX SECTION BEAM DESIGN USING BOX SECTION BEAM DESIGN USING GRADE 250 MPA ASTM A36 GRADE 690 MPA BISPLATE 80 In accordance with AISC Spec. In accordance with AISC Spec.


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EXAMPLE 4 HEAVILY LOADED TRUSS Consider a heavily loaded truss spanning 40m. Some examples of practical applications where such a truss may be required include :

• Underground construction supporting a trafficable roof (e.g. a hydro-electric power station).

• Multi-storey construction supporting several floors.

In this example the following loading parameters have been considered. Truss spacing 10m Live Load 3 KPa Dead Load 1 KPa Occasional Load 20 KN mid span The resulting load configuration is illustrated in Fig.13.


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Structural member design was carried out for Grade 300 and 350 MPa steels using AS4100 – 1990. Corresponding design was carried out for Grade 690 Bisplate 80 steel using the American Institute of Steel Construction Specification for Structural Steel Buildings. Results are summarised in Tables 4 and 5. TRUSS DESIGN SUMMARY Grade 300 & 350 MPa – AS4100 – 1990 Table 4:

MEMBER SECTION kg/m TOTAL LENGTH m

TOTAL WEIGHT TONNES

Top Cord 310 UC 137 137 40 5.480 Bottom Cord 310 UC 96.8 96.8 40 3.872

Webs 250 UC89.5

* (250 x 250 x 6 SHS)

89.5

(45)

87.3

(87.3)

7.814

(3.929) Total Weight = 17.166

(13.281)

*Figures in brackets correspond to the use of Grade 350 square Hollow Sections as web members. All other members are Grade 300.

Grade 690 Bisplate 80 – AISC Spec. Table 5:

MEMBER SECTION kg/m TOTAL LENGTH m

TOTAL WEIGHT TONNES

Top Cord tf = 10 d1 = 212 tw = 8 bf = 256

55 40 2.200

Bottom Cord tf = 10 d1 = 212 tw = 10 bf = 260

58 40 2.320

Webs tf = 8 d1 = 225 tw = 6 bf = 256

43 87.3

3.754

Total Weight = 8.274


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EXAMPLE 5 REVISED DESIGN FOR A LARGE WATER STORAGE TANK A water storage tank was originally designed in AS3678-1990 Grade 250 and 350 steel plate to the following parameters: Height = 14.25m Diameter = 83.8m Capacity = 70 MI The stress calculations for the original design are as shown in Table 6. Table 6:: DEPTH (m) PRESSURE

(KPa) HOOP

TENSION (KN/m)

PLATE YIELD STRENGTH

(MPa)

PLATE THICKNESS

(mm)

STRESS (MPa)

2.85 28.5 1194 250 10 119 5.70 57.0 2388 250 20 119 8.55 85.5 3582 250 25 143

11.40 114.0 4777 350 28 171 14.25 142.5 5971 350 36 166

A revised design incorporating 690 MPa yield strength Q & T steel plates in the lower two sections produced the following set of values, shown in Table 7. Table 7: DEPTH (m) PRESSURE

(KPa) HOOP

TENSION (KN/m)

PLATE YIELD STRENGTH

(MPa)

PLATE THICKNESS

(mm)

STRESS (MPa)

2.85 28.5 1194 250 10 119 5.70 57.0 2388 250 20 119 8.55 85.5 3582 250 20 179

11.40 114.0 4777 690 20 239 14.25 142.5 5971 690 20 298

As shown in Fig. 15, this revised design resulting in a saving of 25% in the mass of steelwork in the walls of the tank.


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Please Note: Every care has been taken to ensure the accuracy of the design examples, however, the information is provided as a guide only. A structural engineer should be consulted with respect to use for specific projects. Bisalloy does not warrant the suitability of the design examples for a particular purpose. The purchaser relies on its own skill and judgement as to the suitability of Bisalloy 80 (Bisplate 80) for its purpose. Bisalloy Steels shall not be liable for any loss or damage howsoever caused arising from the application of such information.


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BISPLATE® Identification Marking and Colour Coding Bisalloy® Steels has a series of identification markings and colour codes to clearly identify the plate specifications and differentiate the grades from each other and other grades of steel. It is crucial that when plates are profiled that this identification is transferred to all off-cuts to prevent grade and size mixes. Grade identification stencils - there are two grade id stencils on each plate located at opposite ends so that if plates are halved then each end remains identified. These stencils are colour matched to the grade colour coding. Plate identification stencils – there are two plate id stencils on each plate located at opposite ends so that if plates are halved then each end remains identified. For domestic orders Plates delivered via central stock will not have a customer name For Export Orders Plate Corners – two diagonal corners of the plate are coloured with the relevant grade colour code. The other two plate corners are hard stamped with the plate number, which is then over sprayed with the plate number. Grade Colour Code BISPLATE® 60 - White BISPLATE® 320 - Blue BISPLATE® 70 - Lime Green BISPLATE® 400 - Orange BISPLATE® 80 - Pink BISPLATE® 450 - Yellow BISPLATE® 80PV - Pink/Red BISPLATE® 500 - Black

Customer Name Dimensions Plate Weight Grade Australian Standard (if applic.)

Customer Name Customer O/No. Plate Dimensions Plate Weight Grade Plate Number

R.D.

Colour Code Plate number


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Testing and Certification Mechanical testing Brinell Hardness Test – Brinell hardness test is performed in accordance with the requirements of AS 1816 – 1990. All plates are individually hardness tested. Tensile Tests – Structural steel grades only are tensile tested in accordance with the requirements of AS1391 – 1991 and these tensile tests are done on a batch basis, one test per heat per 20 tonne (max.) per thickness production run. Charpy V-Notch Impact Tests – Structural steel grades only are impact tested. Charpy V-Notch tests are done on a batch basis, one test per heat per 20 tonne production run. Standard test direction is longitudinal and standard test temperature is –20 deg C. Tests conducted in accordance with AS 1544.2 – 1989 requirements Certification A separate NATA certified test certificate will be issued for each full plate supplied. Tests are conducted in our NATA certified laboratory and will detail chemical analysis, hardness and relevant mechanical test information dependent on the grade ordered.

Bisalloy Customer


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HARDNESS TESTING BISPLATE® WHAT IS HARDNESS? Hardness is the resistance of material to plastic deformation – usually by indentation or penetration. It also defines the ability of material to resist scratching, abrasion or cutting. WHY TEST FOR IT? Hardness testing is undertaken to:

1. Specify and certify a range of wear resistance products. 2. Double check the tensile strength of structural grade materials. 3. Assist in failure analyses and material identification. Table 1:

Method Standard Basis Measurement Accuracy Approx %

Max Temp

Brinell (4) AS1816 10mm Tungsten Carbide ball (1) impressed under 3,000kg load

Surface area for known load

± 2 50°C

Vickers (HV)

AS1817 136° Diamond pyramid impressed under load

Surface area for known load

± 2 50°C

Rockwell (HR) A, B, C

AS1815 ISO6517-1

120° Conical Diamond Steel ball used for soft metals

Depth of impression under known load (15 – 150kg)

± 2 50°C

Equotip (2) NIL “Rebound” Method Height of rebound Poor - Poldi (3) NIL 10mm Ball

impressed with hammered test bar

Comparative impression Very Poor (± 20)

-

WHERE TO TEST? Testing can be carried out in the laboratory, workshop or on site. However, site testing with portable equipment can often have difficulties of access, surface preparation and vibration, which may reduce the accuracy of testing. TESTING PROCEDURES AND EQUIPMENT The table above sets out the methods of identifying common indentation hardness, and other types of hardness tests. It is absolutely vital to understand the specific uses, strengths and any weaknesses of – and correct requirements and procedures demanded by – each of these methods in order to ensure consistent, comparable results in testing.


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Interpreting Table 1 – Some Important Considerations 1. Where the maximum hardness of the work exceed 450 HB, but doesn’t exceed

650 HB, the standard says a tungsten carbide ball must be used. 2. Equotip is a “rebound” method of hardness testing, which does NOT measure

hardness (indentation or plastic deformation) but gives a result convertible within a restricted range into an indentation hardness figure. This method is not standardized and gives only indicative results. It is extremely dependent on the operator, test material and surface condition. It is NOT recommended on quenched and tempered steel, or surfaces that aren’t bright and smoothly ground.

3. The Poldi test is sometimes employed in the field. Even though it is an impression method, it displays very poor accuracy. It is not recommended for quenched and tempered steel.

4. The Brinell test is strongly recommended for all BISPLATE® grades as it is widely accepted as the industry standard. (Brinell gives a more definite reading, by leaving a more definite impression on the plate). It is the standard employed at Bisalloy® and by other manufacturers, both on the production line and in the laboratory. The hardness rating on a certificate issued by Bisalloy® is measured in Brinell hardness. Converted values from other methods such as Rockwell or Vickers (more often used in laboratory testing small samples of steel, or in small-parts engineering, and not ideal for use in the production environment) can cause small discrepancies from the Brinell rating on the certificate.

Proper Preparation of the test surface Since BISPLATE® is a quenched and tempered steel, some decarburisation will occur on the plate surface during the heat treatment process. The thickness of the decarburised layer (the very thin surface layer which has lost carbon during austenitising) will vary depending on the plate thickness. This decarburized layer will get thicker as the plate thickness increases. To ensure testing accuracy, surface scale and the decarburized layer must always be removed by either grinding or machining from the areas where hardness measurements are taken. The minimum grinding or machining depths are listed in the Table 2. Table 2:

Plate Thickness Min Grinding or Machining Depths

(mm) ≤ 6 0.2

>6 – 10 0.3 >10 – 20 0.5 > 20 – 50 0.7 > 50 – 80 1.0

> 80 1.5 Without removing the entire decarburized layer by grinding or machining, the results of the hardness test will be invalid.


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It should also be noted that the area tested should be a min. of 75mm from any thermally cut surface to avoid any hear-affected zone. The tested area must represent the whole material, must be clean, free from unwanted scale, and must be flat, sufficiently thick and smooth. The test piece must be well supported and not subject to movement or vibration. CALIBRATION To further ensure accuracy and consistency, all testing equipment must be calibrated (usually 3 yearly) and checked daily against calibration blocks. PERSONNEL COMPETENCY For all tests, the operator requires training in the correct methods and assessment acceptable to the employer. Preference is given to NATA registered laboratories for high-risk applications. REPORTING Reporting should include plate identification, location, method, result, date, surface condition, operator’s name and signature. Refer to AS1816-2002. Table 3 Grade Specified

Hardness (HB) Typical Hardness (HB)

BIS80 255 BIS320 320 – 360 340 BIS400 360 – 430 400 BIS425 400 – 460 440 BIS450 425 - 475 450 BIS500 477 - 534 500 Currently – already unique among other manufactures – Bisalloy® goes to the extent of physically testing every plate produced – that is, each one goes through the full process of grinding, test and measure. The size of the indentation is measured using the latest video imaging technology, which is interfaced with a dedicated computer to generate a BHN number to within one point. This testing procedure is now fully automated including automated grinding and indentation, guaranteeing an even greater and more consistent level of accuracy and repeatability.


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BISPLATE® WEAR COMPARISONS THEORY OF ABRASIVE WEAR Abrasive wear is wear by displacement of material caused by hard particles or protuberances. Abrasive wear occurs when particles slide or roll under pressure across a surface of the material and may be classified generally as a) gouging abrasion, b) high stress grinding abrasion and c) low stress scratching abrasion or erosion. A similar action is involved in all three types of abrasive wear; i.e. a hard particle is dragged across a softer surface and material removal takes place by the formation of chips, leaving a scratch in the surface as shown in Fig. 1.

Fig 1 Material removal takes place by formation of chips Abrasive wear is determined by: • Properties of wear material. • Properties of abrasive material. • Nature and severity of the interaction between abrasive and wear materials. They are related to the hardness of the material, hardness of the particles and the pressure between the particle and the material surface. According to the simplified abrasion wear theory, volume loss (Q) is proportional to the applied load (N) and inversely proportional to the hardness (H) of the abraded surface for a certain abrasive material applied Q = N/H It can be seen that, in a specific working environment, the wear loss of a material is dependent on hardness of the material. In general, as the hardness of the material increases, the wear rate decreases. To assess the wear properties of BISPLATE®, three grades of BISPLATE® (BIS80, 360/400 and 500) have been tested against mild steel, overseas Q&T steels and clad plates under sliding abrasive wear environment complying ASTM standard G65-86. DRY SAND RUBBER WHEEL WEAR TEST (DSRW) ASTM G65-86 DSRW is a standardised low stress sliding abrasion wear test designed to simulate the wear experienced in applications such as chutes or bin and dump truck liners for post crushed ore.


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Fig. 2 Schematic diagram of test apparatus (Dry Sand / Rubber Wheel abrasion wear) Parameters set up for wear testing (ASTM Standard G65-86) Specimen Abrasive Rubber Wheel Dimension (mm)

Surface Condition

Sand Grade

Sand Flow (g/min)

Diameter & Width

Rubber Hardness

Revolution (r.p.m)

Time

Load

25x10x76 Ground 60 360-380 228 & 12.7mm

A-60 200 30min 130N

RESULTS 1. Relationship between Wear Resistance and Hardness of the Materials

In general, as the hardness of a wear resistant material increases, the wear resistance ratio increases (Abrasion Resistance Ratio = mass loss of mild steel / mass loss of tested steel). That is, steel with a hardness of 250 Brinell, i.e. BIS80, has relatively higher wear resistance than mild steel, which has a hardness of 120 Brinell. BIS500 has a hardness twice high as that of BIS80. Therefore it is expected that BIS500 has a resistance one time higher than BIS80 (see Fig. 3a and b).

Weights

Mounted Rubber Ring

Rotation

Steel Disk

Specimen

Sand flow

Specimen Holder

Sand Nozzle


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Mild Steel BIS® 80 BIS® 400 BIS®500

Fig. 3 Wear resistance comparison between BISPLATE® and mild steel 2. Wear Rate Comparison between BISPLATE® and Other Q&T Products BIS® 80 Structural Type BIS® 80 wear was slightly better than one Japanese brand and slightly worse than another. All grades were however very similar in wear resistance. BIS® 80 wear resistance was 60% better than mild steel.

Fig.4 Comparison of wear resistance between BIS80 and Japanese products

BIS® 400 Wear Grade BIS® 400 performed best from all the 400 grades tested. European grades, which were water quenched with leaner chemistry, were slightly worse than BIS® 400. Oil quenched 400 type was about 5% worse than BIS® 400 in the wear resistance rate.

Fig. 5 Comparison of wear resistance between BIS® 400 and other products


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BIS® 500 Wear Type BISPLATE® 500 performed very well compared to most Japanese 500 grade plates, 10% better than European water quenched and 30% better than European oil quenched plate.

Fig. 6 Wear resistance comparison between BIS® 500 and other products

PADDLE IMPACT ABRASION TEST The Paddle Wear Testing was conducted at the Advanced Manufacturing Technologies Centre (AMTC), a Division of Central TAFE, Subiaco WA. The testing offers a medium stress impact & sliding abrasion wear normally experienced by such components as chute liners, grizzly bars, and other impact plate liners in mining industries. The testing is performed by placing two specimens (test material and reference material) to be compared against each other at either end of the Paddle Arm located in a Drum. Both the arm and the drum rotate in the same direction with their speeds being 270 rpm and 45 rpm respectively as shown in Figure 1. Blue metal ore sized between 5.5 and 14.0 mm was used as the abrasion medium. Each test lasts 15 minutes. Three materials were chosen as reference specimens, BIS80, BIS400 and BIS500. The testing materials are listed in Table 1 below, including three Japanese products, four European plates and tow clad (overlaid) products. Fig. 1 Schematic set-up of Paddle Wear Tester

Drum (rotating at 45 rpm)

Test specimen (held by the arm rotating at 270rpm)

Gravel (5.5 –14 mm in size)

Reference sample


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Table 1 Test and reference materials

Test Material Mild steel Jap400-1 Jap400-2 Euro400 EurO4* Reference BIS80 BIS400 BIS400 BIS400 BIS400

Test Material Jap500 Euro500 EurO8* DClad D60 Reference BIS500 BIS500 BIS500 BIS500 BIS500

* European oil quenched 400 and 500 grade products RESULTS Two samples from each material were tested against two same reference samples. The relative wear rate (RWR) of the test material was recorded as: RWR = (MLt x ρt) / (MLr x ρr), Where: MLt and MLr – mass loss (g) of test specimen and reference specimen respectively, and ρt, ρr are specific densities (g/cm3) of test and reference materials respectively. Table 5 Lists average relative wear rates for the Paddle tested specimens.

Test Material (HB) Reference Material (HB) Relative Wear Rate Mild Steel (121) BIS80 (255) 1.518 Jap400-1 (425) BIS400 (424) 1.115 Euro400 (401) BIS400 (424) 1.015 EurO4 (391) BIS400 (424) 1.064 Jap400-2 (398) BIS400 (424) 1.044

Euro500 (495) BIS500 (503) 0.984 Jap500 (514) BIS500 (503) 1.036 EurO8 (465) BIS500 (503) 1.223 D60 (664) BIS500 (503) 1.462 Dclad (573) BIS500 (503) 1.164

It can be seen that BIS80 performed 50% better than mild steel under impact abrasion condition. 400 and 500 grade Q&T plates did not show major differences between manufacturers although BISPLATE®s did perform slightly better than most overseas products. Clad plates performed poorly under impact abrasion wear conditions compared to Q&T steel, especially high hardness D60 which experienced almost 50% more wear compared to Q&T plate. Higher mass loss from clad materials compared to quenched plates are caused by chipping off due to impact. Clad layer contains high volume of CrC and this layer is hard but can be very brittle. Under impact, brittle material tends to be fractured and chipped off easily compared to quenched plate.


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FATIGUE WHAT IS FATIGUE A metal component subjected to repeated or cyclic stresses may eventually fail even when the maximum applied stress is less than the yield stress of the parent steel. This phenomenon is known as fatigue. It is known that in machines and other kinds of structures that are subjected to fatigue loads, that 80-90% of all fractures that occur are fatigue fractures. However, it is relatively easy to appreciate why this occurs, since structures are usually designed against plastic deformation (i.e. yielding) and not against fatigue! FATIGUE FAILURES CHARACTERISTICS OF FATIGUE FAILURES The surface of a fatigue fracture is distinctive and from a knowledge of various characteristics of the fracture surface considerable information can be obtained about the cause(s) of crack nucleation and the nature of the fatigue loading. The material adjacent to a fatigue fracture displays no evidence of plastic deformation. The fracture surface is relatively smooth and generally contains concoidal markings which appear to radiate from a particular point on the outer surface, see figure 6.5.

Fatigue cracks generally nucleate at the surface, and because crack growth requires a tensile stress, the direction of the fatigue crack is always perpendicular to maximum tensile stress.

Figure 6.5 Fatigue fracture surface of a failed gear showing the concoidal “beach markings” radiating from the oil hole, marked (A). Also shown are the “beach markings” associated with fatigue crack growth (B), and the area where ductile overload occurred (C).


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Because the load is applied in a pulsating manner, the crack grows in small steps. Pulsating loads are invariably not uniform (as say a sine wave would be), so that crack growth rate variations occur and these reflected in the form of ridges on the fracture surface as can be seen in figure 6.5. These are given the name “beach markings”, and are the single most distinctive feature of fatigue crack failure. As the crack grows, the section supporting the load is progressively reduced. As such the stress of each cycle is progressively increased and the crack growth rate become faster, and the beach markings become larger and more distinct. Ultimately, the cross sectional area supporting the load is reduced to such an extent that it is too small to support the applied load, and final failure occurs by ductile overload; the area marked C in figure 6.5. WHY IS KNOWLEDGE OF FATIGUE IMPORTANT WHEN DESIGNING WITH HIGH STRENGTH STEELS? There are two main reasons:

• Firstly, fatigue cracks propogate at approximately the same rate in all steels, and since the life of welded joints is dependent upon crack propogation, welded sections of high strength steels exhibit the same strength at around 2 x 106 load cycles as welded plain carbon steels.

• Secondly, a principal reason for using high strength steels is to reduce plate thickness (i.e. weight reduction). When this is done, the stresses in the steel – both static and fatigue stresses – will naturally increase for a given load case. As a result, design against fatigue is more important when high strength steel is used in welded structures, since fatigue strength does not increase at the same rate as static strength. In addition, high strength steels are often used is applications that are naturally subjected to high fatigue loads, e.g. mining and transport equipment.

FATIGUE STRENGTH OF STEELS

FATIGUE DATA

Fatigue data generated under laboratory conditions is generally in the form of “the number of cycles to cause failure at a particular stress amplitude”.

This may be in the form of simple bending, so that a point on the surface of the specimen may be in tension when bending occurs in one direction, followed by compression when bending occurs in the opposite direction. Alternatively, the specimen may be subjected to a pulsating axial load causing alternate tension and compression. This simple situation can be presented as a sine wave as shown in figure 6.6.


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Figure 6.6 Diagram showing the sinusoidal type of pulsating load generally applied in laboratory type work (carried out to determine fatigue data).

The fatigue diagrams produced from “cycles to failure” tests can be presented as either stress amplitude (Sa) or stress range (Sr) and for most steels takes a form similar to that shown in figure 6.7, the cycles to failure generally being represented on a logarithmic scale.

Fig. 6.7 Diagram showing the form in which data is presented, relating number of cycles to failure for a particular stress.

It can be seen in figure 6.7 that after about 2 x 106 cycles the curve tends to flatten out, indicating an almost infinite fatigue life at stress loadings below a critical value. The critical value is generally referred to as the fatigue limit and for most steels is referred to at 2 x 106.


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Figure 6.6 and 6.7 represent a situation where the tensile stress and compressive stress are equal in magnitude so that SMAX = -SMIN. There are however, other cyclic stress situations. For example, after the application of a tensile load the specimen may simply return to zero stress before re-application of the tensile load. Alternatively, an applied static tensile load may be present and an alternating cyclic load may be superimposed. To differentiate between such loading conditions a convenient means to define the loading conditions is achieved by the use of the stress ratio, R which is defined as: R = SMIN SMAX For the simple bending situation of equal tension and compression stress (shown diagrammatically in fig. 6.6) where SMAX = -SMIN, R= -1. If only a tensile pulsating load is applied and SMIN = 0, then R = 0. When a pre-existing tensile static load is present and pulsating loads are applied R becomes positive; the limiting case of R = 1 when the static load equals the tensile strength of the steel. Obviously there can exist a variety of loading conditions between R=-1 and R = 1. These are represented in the form of a Goodman Diagram as shown in figure 6.8. It can be seen that Smin is represented on the abscissa (negative and positive) and Smax is represented on the ordinate. In such diagrams, the line ABCDE represents the stress ratio, R, at failure from -1 to +1 for a specified number of cycles to failure, i.e. 2 x 106.


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Fig. 6.8 Goodman Diagram depicting the various stress configurations required to determine the points on the diagram.


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From laboratory controlled fatigue tests the Goodman Diagrams for two steels having tensile strengths of 400MPa (AS3678-Grade 250), and 800MPa (BISPLATE® 80 grade) are shown in figure 6.9. Here it can be seen that over the entire fatigue stress range there is a distinct advantage in using the higher strength BISPLATE® 80 grade steel.

However, most structures involve welded connections, so that when examining a simple butt weld joint (with the weld bead left in place) a different Goodman Diagram emerges.

It can be seen in figure 6.10 that for butt welds when R = -1 (equal tension and compression) the fatigue strength of BISPLATE® 80 is reduced by more than half its base material value (fig 6.9) and to substantially the same values of AS3678-Grade 250. This indicates that there is very little advantage in using high strength steels under such loading condition. On the other hand, for conditions where R is positive, i.e. high static loads with a superimposed pulsating load, there is a distinct advantage in the use of high strength steels.


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WHERE CAN HIGH STRENGTH STEELS BE USED TO ADVANTAGE? There are a number of key areas in which high strength steels can be used to advantage, in structures subjected to fatigue loading, as follows: PARENT PLATE MATERIAL UNAFFECTED BY WELD Welding can influence the fatigue behaviour of steels due to:

(a) the existence of geometrical stress concentrations in the vicinity of welds due to weld deposit profiles.

(b) The presence of welding deposits such as porosity, lack of fusion, slag inclusions, etc, which facilitate the initiation of fatigue cracks, and

(c) The generation of residual stresses in the welded component. Obviously, in structures in which welds are absent are absent or where welds can be suitably located in areas of low stress, high strength steels can be used to advantage (as fatigue strength is higher than for plain carbon steels). HIGH STRESS LEVELS In many structures, the load consists of a high static load with a “superimposed” smaller fatigue load. In this instance, it is relatively easy to exceed the permissible static stress or the yield of plain carbon steels. As we have seen previously, we can permit the same stress range at high stress levels as at low low stress levels. In these cases, R is in the range R = 0 to R = +1. LOW LOAD CYCLE NUMBERS The region for the permissible stress range is limited by the S-N curve and by the yield stress (or permissible static stress) of the steel. In other words, high strength steels are advantageous when the number of load cycles is less than 105, there is a full load spectrum (constant amplitude) and R = 0. SUITABLE LOAD SPECTRA In many situations, there are multiple fatigue loading conditions (different amplitudes) and hence it is incorrect to design with constant amplitude data if the load is of variable amplitude. WHEN IT IS POSSIBLE AND DESIRABLE TO INCREASE THE FATIGUE STRENGTH OF THE WELDS. There are a number of techniques available to improve the fatigue strength of welded joints, including: redesign of the joint itself, removal of butt weld reinforcement,


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reduction of the stress concentrating effects by grinding or TIG dressing the toes of fillet welds, and reduction of the residual stress pattern around welds by thermal stress relieving treatments or shot peening. With each of these techniques, substantial improvement in the fatigue strength of the as-welded joint is possible, although the resultant fatigue strength will always be less than that of the parent plate material. References/further reading

• Fatigue of Welded Structures, T.R. Gurney, Cambridge University Press UK 1979 • Australian Standard AS1554 Part 5- 1989. SAA Structural steel welding code “welding of steel

structures subject to high levels of fatigue loading.” • American Institute of Steel Construction, Specification for the design, fabrication and erection of

structural steel for buildings, 1978.


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PERFORMANCE AT ELEVATED TEMPERATURE BISPLATE® processed grades perform favorably against other types of structural steels at elevated temperature. This can be seen below in Table 1, where the performance of BISPLATE® 80 is superior when compared with other well-known structural grades at an elevated temperature of 600°C.

GRADE 0.2% Proof Stress @ 600◦C BISPLATE® 80 300 MPa AS3678-250 127 MPa AS3678-350 140 MPa

Table 1: 0.2% Proof Stress at elevated temperature of 600۫C. However, the use of BISPLATE® at elevated temperatures should be approached with caution. Prolonged exposure to excessive heat will lead to loss of mechanical properties including strength and hardness. This is primarily due to a microstructural change of the plate due to over-tempering. Any proposal for the use of BISPLATE® at temperatures above 150°C should be referred to the manufacturer. The following graphs show the results of high temperature tests performed on BISPLATE® 80 and BISPLATE® 400. Please note that these graphs depict instantaneous tensile measurements only and are not indictative of results when BISPLATE® is exposed to excessive heat for a prolonged period of time.


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BISPLATE 80 (12mm)

0100200300400500600700800900

0 100 200 300 400 500 600

Temperature (deg.C)

Stre

ss (M

Pa)

0.2% Proof Stress Tensile Strength

BISPLATE 400 (12mm)

0200400600800

1000120014001600

0 100 200 300 400 500 600

Temperature (deg.C)

Stre

ss (M

Pa)

0.2% Proof Stress Tensile Strength

The results of this project indicate the Bisalloy® processed grades perform comparably or favourably with other types of structural steel in terms of the temperature at which the strength of the material is half that of its room temperature strength. This temperature was identified as being between 500°C and 600°C for processed grades. This temperature for greenfeed grades was seen to be beyond 600۫C. There was no significant difference in 0.2% Proof Stress at 600◦C between the processed and greenfeed samples, all values being in the vicinity of 300°MPa. This compares with 127MPa and 140MPa for AS3678-250 grade and AS3678-350 grade respectively at 600°C The results confirm the suitability of Bisalloy® products for use in structural and elevated temperature applications.


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Table 1. Results summary for all samples

Sample number/grade. Temp. (deg. C) Reduction in area 0.2%P.S. (MPa) U.T.S. (MPa) Elongation (%) Yield/tensile PX441/ BIS53, 20mm 20

200 300 400 500 600

45% 64% 58% 71% 83% 89%

504 475 530 486 434 327

706 637 697 650 520 393

16% 15% 5% 19% 23% 19%

0.71 0.75 0.76 0.75 0.83 0.83

PX461/ BIS52, 12mm 20 100 200 300 400 500 600

62% 67% 57% 58% 85% 79% 90%

496 483 476 679 515 401 297

659 620 618 705 596 481 349

20% 16% 16% 21% 25% 20% 22%

0.75% 0.78% 0.77% 0.96% 0.86% 0.83% 0.85%

71815/ BIS400, 12mm 20 100 200 300 400 500 600

56% 44% 48% 70% 84% 82% 89%

971 976 1017 922 789 580 297

1338 1318 1374 1234 962 679 431

4% 9% 4% 12% 4% 15% 20%

0.73 0.74 0.74 0.75 0.82 0.85 0.69

71831/ BIS400, 20mm 20 100 200 300 400 500 600

52% 5% 42% 68% 77% 79% 91%

1020 1024 989 955 757 582 293

1416 1328 1462 1340 986 674 438

11% 10% 11% 14% 14% 14% 26%

0.72 0.77 0.68 0.71 0.77 0.86 0.67

RF464A1, BIS1, 100mm 20 100 200 300 400 500 600

65% 71% 62% 64% 71% 79% 87%

560 572 561 550 501 464 336

752 663 709 737 717 593 421

17% 16% 12% 15% 16% 16% 7%

0.74 0.86 0.79 0.75 0.70 0.78 0.80

77873, BIS80, 100mm 20 100 200 300 400 500 600

72% 70% 70% 68% 78% 86% 84%

713 638 527 512 490 460 327

773 704 617 673 559 522 407

16% 15% 16% 7% 19% 17% 17%

0.92 0.91 0.85 0.76 0.82 0.88 0.80

71974/BIS80, 12mm 20 100 200 300 400 500 600

62% 61% 55% 80% 79% 90%

815 795 759 720 664 538 272

862 843 829 837 748 600 382

13% 13% 11% 11% 17% 15% 28%

0.95 0.94 0.91 0.86 0.89 0.90 0.71

72005/BIS80, 20mm 20 100 200 300 400 500 600

63% 58% 58% 61% 75% 82% 91%

816 800 746 741 635 553 290

876 859 833 846 736 633 413

17% 13% 11% 15% 15% 15% 24%

0.93 0.93 0.90 0.88 0.86 0.87 0.70


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GALVANISING BISPLATE® structural grades can be readily galvanised. BISPLATE® wear grades are not suitable for galvanising. BISPLATE® achieves sound and continuous galvanised coatings because they contain 0.20% Silicon, which is an optimal level for galvanising. Galvanising does not affect the mechanical properties of BISPLATE® structural grades. However, there are some precautions & recommendations that should be taken into account when galvanising BISPLATE®.

• DO NOT ACID DESCALE to prepare the surface. Acid descaling can lead to hydrogen being absorbed into the steel, increasing the likelihood of hydrogen embrittlement.

• To prepare the surface it is recommended to use grit/shot blasting. This

method not only ensures there is no hydrogen contamination it assists the galvanizing process by increasing the surface reactiveness to molten zinc.

• Care should be taken when galvanizing BISPLATE® structures that contain

severe internal stresses, such as those caused by large weldments, as liquid metal embrittlement may occur. In these cases, it may be appropriate to prototype test or attain the use of painted or sprayed coatings in place of galvanizing.

Bisalloy Bisplate Technical Manual

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