Scs Briefing - Vol. 1 Issue 1

briefing

MATERIAL ADVANTAGES

What are the material advantages of SCS over Hot-Rolled Black and Pickled and Oil? LASER CUTTING Oil, dirt and scale on the sheet surface diffraction, and rust can cause auto shut-off due to excessive surface variation.

PREP AND PAINTING HRB needs extensive cleanup before painting, plus phosphating pretreatment to obtain acceptable adherence and corrosion resistance. P&O steel needs expensive, multi-stage pretreatment before painting. Anything less degrades its corrsosion resistance.

The Scs surface if so smooth, clean and flat that laser and plasma cutting speed can be increased as much as 50%, while ‘springback’ is reduced or eliminated.

A lean 2-stage rinse is all that’s needed to prep SCS for most applications. Smooth SCS yields a superior finish for high gloss paints and better corrosion resistance.

The ‘SCS Lasering Guidelines’ help you optimise laser setup for increased speed with SCS. Visit www.servosteel.co.uk to download the guidelines.

• Speed increases of 20 to 50% • Laser through two sheets at a time with stretcher-leveled SCS sheets. • Superb quality in cut, pierce and mark.

WELDING Oil is tough on welders; it attracts excess dirt to wipe off, degrades weld integrity, increases the level of hazardous fumes. Cleaner steel makes better welds, so with HRB you either clean (even grind!) the area to weld , or let weld integrity suffer. Clean, SCS welds better, giving a more uniform, stronger bead. Scs has no oil smoke so metallic particulates disperse much less - important for safeguarding your welders’ respiratory health.

‘SCS Welding Guidelines’ give you settings and suggested consumables to optimise SCS welding. Visit www.servosteel.co.uk to download the guidelines.

• Scs welds tested 20% stronger than P&O welds in shear strength tests. • 30% savings in fuller wire over P&O

BENDING AND FORMING SCS in rollforming and pressbrake work performs beautifully. With no oil, there’s no ‘slip’ in tooling and its excellent shape yeilds consistent final product shapes. For bends of 30% or more, some breaking loose of surface scale on the inside radius is expected. Loose scale is easily wiped or rinsed away and paint adherence is not diminished. Scale on outer radii shouldn’t break loose and there’s no microcracking.

Welcome Welcome to our new Servosteel SCS Briefing, the first in a new series of publications to mark Servosteel’s new £3.4m investment in SCS capability.This edition tells you more about our new machine and where it is to be located. Most importantly of all it sets out the ever expanding list of benefits that you as a potential user of SCS can derive from the material.

struction is now underway and the project is scheduled to be completed by Christmas. Improvements to the site access will follow in due course with the site entrance being located some 100m further down Pensnett Road.

Following order placement last September we are expecting delivery

For more information on SCS please contact us via telephone 01384 471371 and ask for Jim Spencer of Phil Guest. Alternatively you can email us at [email protected]

Premises After a rather protracted planning approval process we are very pleased to announce that our existing building at Dudley is being extended by some 46,000 square feet. Allowing for nonproduction areas, this will expand our covered storage space by approx. 50%. With demolition of old buildings and site clearance now completed, con-

OTHER PROCESSES Stamping SCS lets lubricant contact the steel, rather than scale or a film of oil so it works better. HRB scale can foul dies enough to reduce part quality, but SCS keeps dies cleaner. P&O stamped parts have areas that rust, but SCS prevents such rusting.

The new SCS coil-to-coil; line

PICKLE LINE

NEW EXTENSION AREA

Punching/turret work is cleaner with SCS and, due to SCS’ flatness, more consistent. SCS shows no difference from P&O, including tool life.

DECOILER 1

DECOILER 2

Grinding SCS eliminates the need to grind away rust, since it inhibits rusting. SCS keeps grinding tools from getting ‘gummed up’ with P&O’s oils. See our ‘Guidelines for Grinding SCS’.

of our new SCS Line during mid/late October and we expect to have the line commissioned and in production by December.

SCS Coil-To-Coil Line

SLITTER 2

Visit www.servosteel.co.uk to download the guidelines.

See ‘SCS Paint Prep Guidelines’ for SCS rinse regimen. Note that SCS surface ‘shadows’— even from removed rust­—do not show throught the paint. Visit www.servosteel.co.uk to download the guidelines.

SCS PLANS ROLL FORWARD

SLITTER 1

TUBE PRODUCTION Tubes made from HRB require cleanup prior to coating or painting and rust is always a concern. it’s often the most frequent reason for rejecting HRB tubes. Tubes made from P&O require extensive cleanup prior to welding, fabricating, or coating/painting. SCS tubes, structural or mechanical, can be ready to weld right off the mill, ready to paint right off the mill. The SCS shape, with no edge wave, and SCS cleanliness yields a better, more uniform seam weld. . in trials to date SCS welds faster then P&O, so tube ‘SCS Welding Guidelines’ give you settings and suggested mills may run faster. consumables to optimise SCS welding.

• SCS process removes surface rust, yielding a highly paintable surface. • Big savings fron ‘leaner’ paint prep with no phosphating stages.

Vol. 1 Issue 1

SCS LINE

LOADING BAY The Servosteel factory floor, showing our new extension and the location of the SCS line.

THE SCS COIL LINE The SCS coil line brings an impressive level of efficiency and automation to the production of SCS coils. One operator can perform all functions - from coil loading and threadup, setup of the cartridge roller leveller, the centering control system and SCS Brushing Machine, to recoiling, banding and removing processed coils. A color touchscreen operator console puts all process monitoring, system status and control functions at the o p e r a t o r ’s f i n g e rtips.

• elimination of hazardous hydrochloric acid, since SCS uses ordinary water in a closed-loop recirculating cooling/flushing system. Besides producing a superb SCS surface, the SCS Coil Line also produces extremely flat material. How? Excellent performance of the line’s roller levellers combined with extreme tension in the coil generated by the pulling

For many applications SCS will become a replacement for a traditional P&O process, the SCS process (depicted at right) involves:

There is a built-in facility in the line for oiling SCS material for customers who may need it. A similar provision has been make to degrease oiled galvanised coil. At a later date a second brushing machine will be inserted to increase line capacity to 32000tpm or indeed a second independent line.

ONE STOP SHOP Another great advantage for those wanting to buy SCS to reduce their manufacturing costs is that at Servosteel their coil can be slit or decoiled on the same site, saving further on transport and double handling charges.

Recovery Opportunities In addition the future installation of a degreasing unit will enable coated coil which has been oiled at source (e.g. made for automotivce applications) to go through the SCS process and used where oiled material is not appropriate. Another great application for SCS is with coild which has been subject to water damage either on land or at sea. Imagine the savings this will have for the user whether the material is hot rolled, cold reduced or galvanised.

A hot roll black coil wiped with a clean cloth prior to processing on the SCS Coil Line. Dirt, grit and surface rust often found on these coils leaves clear traces on the cloth.

A third plus on recovery is the way the line will take really bad shape material and using the poewrful levellers and huge tension to produce amazingly flat coil. Look on our website at www.servosteel.co.uk to see the video of this being done.

Safeguards built into equipment and control logic ensures personnel, equipment and product are always protected. SCS Coil Lines are built by Red Bud Industries, a recognized leader in service center processing systems for over 45 years. Known for building accurate, durable equipment and for top-notch service and training,

edge wave of over 1700 I units (a 50mm wave in 600mm of coil) emerge remarkably flat from the SCS Coil Line.

force of the recoiler. This serves to eliminate practically all traces of coil breaks and to get poor shape material very flat. How flat? Coils with

Same coil wiped with fresh clean cloth after processing on SCS Coil Line. The surface is now smooth, clean and rust inhibitive.

• 20% of the floorspace of a P&O line, SERVOSTEEL SCS LINE Dimensions

14m x 45m

Capacity

18000tpm

Materials

Hot Rolled/Cold Reduced

Thickness

0.9-8mm

Width

600-1905mm

Max coil

32tonne

Max O.D.

2130mm

I.D. entry

483-965mm

I.D. exit

508-610mm

Line speed

45mpm

WATER FILTRATION SYSTEM (not shown) This patented closed-loop system filters and recirculates the ordinary, untreated water used to flush away scale removed in the SCS process. The compact, two-stage unit collects metallic scale, which is disposed of with scrap steel, and purifies water for re-use.