8:45 AM-9:00 AM
Welcome & Opening Remarks
SESSION – High Carbon Processing
9:00 AM-12:00 PM
9:00 AM-9:30 AM
“Characterization of Tensile and Shear Loading on Indented PC-Strand Cable Bolts,” by Anand Bhagwat and Stephen C. Tadolini, Minova USA, Inc.; and Steven Derycke, NV Bekaert SA
PC strands are becoming widely acceptable as a roof support system in underground mining applications for their superior strength and flexibility. Laboratory testing was completed to evaluate the tensile and shear strength of individual wires and completely wound PC-strand cables. Both smooth wires and the recent anchorage enhancement innovation of indentation were evaluated and compared. The results demonstrate that the difference between smooth and indented wires is statistically insignificant, and that indentation does not adversely affect strand properties and performance.
9:30 AM-10:00 AM
“Development of High-Quality Wire Rod Through Steel Mill Continuous Improvement,” by Craig Hlady and Jeff Kramer, Cascade Steel Rolling Mills
This paper outlines the internal and external challenges of a customer’s requirement for additional strength and reduced breakage rates in PC (Prestressed Concrete) Strand. In order to remain successful manufacturing this product, Cascade Steel employed a multi-faceted approach involving changes and improvements to melting, rolling, and handling of the product. In addition, eddy current signal data was analyzed using a more sophisticated approach to improve surface defect detection. Finally, basic metallurgical principles were employed to design a more robust chemistry.
10:00 AM-10:30 AM
11:00 AM-11:30 AM
“High-Carbon Grades for Wire Rod Lines,” by Claudio Fabbro and Maicol Cimolino, Danieli & C. Officine Meccaniche SpA
The increasing demand for high-carbon wire rod is challenging producers to enhance technologies by combining high plant productivity and efficiency with process flexibility. The possibility of changing the process route according to the final application of the wire rod and to simplify production planning represent one key to success. This paper focuses on the most important metallurgical targets and on the in-line heat treatment technologies.
11:30 AM-12:00 PM
“Microstructural Characterization of High-Carbon Wire Steels,” by Emmanuel De Moor, Colorado School of Mines, and Stephanie Kaster, US Air Force Academy
The effects of vanadium and niobium microalloying on the microstructural evolution of high-carbon wire steels were studied by dilatometry to develop continuous cooling transformation (CCT) curves, solubility modeling, and electrochemical dissolution. A detailed microstructural characterization of the microalloyed steels was conducted using field emission scanning electron microscopy and atomprobe tomography. Enrichment of vanadium in cementite was observed whereas silicon was rejected from cementite.
12:00 PM-1:00 PM
Lunch & Keynote Speaker
"Made in the USA—The Next Industrial Revolution," Frank A. McGrew IV, McNally Capital
This lunchtime session provides an economic review and outlook for the broader economy and various metals markets. It addresses how having the right connections with automation, machines, government, and people can truly make a difference. It also offers predictions for the industrial future of man and machines as well as the rise of robots, along with suggestions for how to benefit from digital disruptors that are changing modern day manufacturing. Overall, the talk offers a message of how the label “Made in the USA” can add a new shine to manufacturing’s old Rust Belt and what can be done to keep the steel industry great.
SESSION – Processing & Equipment Improvements
1:00 PM-4:00 PM
1:00 PM-1:30 PM
“Utilization of Thermo-mechanical Rolling for Improving the Utilitarian Properties of Electrode Wires,” by Karel Milan Čmiel and Radek Cieslar, Třinecké Železárny, Wade P. Krejdovsky, Primetals Technologies USA LLC
This article deals with the utilization of thermo-mechanical rolling (henceforth: “TMR”) on the continuous wire rod mill at Třinec Iron and Steel Works. The article describes in detail the utilization of TMR technology of electrode wire of steel grade 10MnSi7 (SG3). his grade is rolled at Třinec both by using conventional technology and by using TMR technology. By comparison of the qualitative results achieved with wires rolled by these two technologies, the contribution of TMR is documented in the case of this grade.
1:30 PM-2:00 PM
“Process, Precision, and Performance: The SMS Solutions for High-Quality and High-Productivity Wire Rod Mills,” by Mario Fabro and Larry Smith, SMS Meer GmbH
This paper covers the new technologies developed by the SMS Group to address the challenges of tomorrow for wire rod producers. Technologies presented range from Thermo Mechanical Rolling and precision three-roll sizing with the industry standard PSM®, to the efficient and cost effective wire rod finishing blocks MEERdrive®, to precise CCT conveyor design. Examples of these applications and results from recent installations at Burbach and Neunkirchen are also discussed.2:00 PM-2:30 PM
“Modernization of the Kroman Wire Rod Mill to Increase Productivity, Utilization, and Product Quality,” by Necdet Utkanlar, Kroman Çelik Sanayii AS, and Wade P. Krejdovsky, Primetals Technologies USA LLC
A modernization project was undertaken to improve product quality while increasing utilization and productivity. The project involved installation of a new Morgan Intelligent Pinch Roll and High Speed Laying Head, modifications to the existing controlled cooling conveyor, and replacing the coil reforming station. Resulting product and process improvements are presented, including increased tensile strength and uniformity, reduction in delays on the conveyor and reform tub, plus improvements in coil quality.
2:30 PM-3:00 PM
3:00 PM-3:30 PM
“Capital Projects and Continuous Improvement at Sterling Steel Company,” by Nichole Garza and Andrew Bettin, Sterling Steel Co.
This paper described two major capital projects and resulting improvements. The Pre-Finishing Mill (PFM) consists of two new rolling stands installed in the rod mill after stand 15. These stands provide the ability to decrease the reduction in other stands, which has resulted in large improvements in rod surface quality. The Electro-Magnetic Stirring (EMS) installed at the caster and subsequent continuous improvement actions has resulted in improvements to billet segregation, martensite formation, and internal cracking.
3:30 PM-4:00 PM
“H3 High-Speed, High-Quality, and High-Efficiency Wire Rod Mills,” by C. Fabbro, A. Taurino, A. Olsson, and A. Mestroni, Danieli & C. Officine Meccaniche SpA
Since the beginning of the 2000s, the technologies and methods to produce wire rod have undergone significant changes. Machine builders have been racing to provide reliable solutions processed by evolved automation systems in order to increase product quality with considerable energy savings and enhanced performance. This article focuses on the methods, machines, and processes used in the production of SBQ wire rod.
8:45 AM-9:00 AM
Welcome & Opening Remarks
SESSION – Property & Testing Advancements
9:00 AM-12:30 PM
9:00 AM-9:30 AM
“Quenched and Partitioned Steel Wires: Process, Characterization, and Properties,” by Christophe Mesplont and Walther Van Raemdonck, NV Bekaert SA
Steel wires with a microstructure containing martensite and retained austenite were produced with the Quenching and Partitioning (Q&P) thermal process, a modified version of the Quenching and Tempering (Q&T) process. The Q&P wires exhibited high “total elongation – at” x “tensile strength – N/mm²” product, above 20000 %. N/mm². This multiplication product is two to three times higher than with Q&T. The higher elongation was due to the TRIP (Transformation Induced Plasticity) effect during plastic deformation. The results reveal application possibilities especially where high energy absorption behavior is required.
9:30 AM-10:00 AM
“New Process Metallurgy Developments for the Production of Steel Wire Rods,” by Steven Jansto, CBMM North America Inc.
Improvements in mechanical property performance often result in higher production cost. Recent process metallurgy technology is applied in wire products to address this demand. The process influence is now balanced with improved wire rod microstructure, properties, and grain size consistency. The complementary benefit of micro-additions of niobium refines the microstructure, reduces scrap, and improves drawability and robustness. Case examples involve pre-stressed concrete wire rod, tire cord, and medium carbon spring steels.
10:30 AM-11:00 AM
11:00 AM-11:30 AM
“Bright Heat Treatment of Flat and Profiled Wire Made of Austenitic and Ferritic Stainless Steels,” by Igor Rogelj, Primoz Eiselt, and Franz Resch, Plasmait GmbH; and Willy Hauer, Howar Equipment Inc.
This paper outlines the latest high-output plasma heat treatment line for ferritic and austenitic stainless steel profiles and flat wires with typical dimensions up to 30 mm x 3 mm (1.18’’ x 0.12’’). It focuses on production line design that addresses the following key process features for efficient heat treatment of austenitic and ferritic stainless material: required temperature profile and cooling rates, tempering and slow cooling of ferritic materials, rapid cooling of austenitic grades, material handling and wire guiding through heat treatment line, and process gas alternatives and atmosphere requirements.12:00 PM-12:30 PM
“Evaluation of Mechanical Properties of Wire Rod by Shear Punch Test,” by Likhith Nalluri and Ramesh K. Guduru, Lamar University; and Roberto Perez, Leonardo Radicchi S. Cunha, Peter Power, Bhaskar Yalamanchili, and Thad Boudreaux, Gerdau Long Steel North America
For the first time, a miniaturized specimen testing technique, “shear punch test (SPT),” was implemented to study the mechanical properties of wire rods. SPT can predict tensile properties as well as localized variations in the mechanical properties. Therefore, the discs from the wire rods were tested at the center and mid-radius to investigate the variation in their shear strength correlating with their microstructures and possibly the chemistry. This paper presents those results.
12:30 AM-2:00 PM
SESSION – Keynote
2:00 PM-2:40 PM
“Our 3-D Printed Future: How to Position Yourself and Your Organization to Successfully Navigate This Historic Shift,” by Rick Smith, 3-D Printing Expert, Bestselling Author
3-D printing production will change the world more in this century then the industrial revolution has over the last 300 years. So says author and entrepreneur Rick Smith in this provocative and entertaining talk based on his upcoming new book. Smith lays out a compelling framework to explain the growth and inevitability of 3-D printing as it permanently displaces conventional manufacturing. He reveals a brave new future where objects are 3-D printed using plastics and steel, skin and stem cells, chocolate and Kevlar, where pipes are printed that can automatically repair themselves and batteries are printed the size of a grain of sand, where global supply chains collapse, and the wealth of nations is flipped on its head.
In pursuit of this radical future, Smith introduces audiences to some of the modern pioneers of 3-D printing while also moving further back in history to the fascinating cast of characters who shaped other great technological shifts. This talk answers two questions that strike at the heart of every leader in every organization: How will the future unfold in front of us? And how can we position ourselves and our organizations to successfully navigate this historic shift to our greatest benefit?
SESSION – Quality Monitoring
3:00 PM-4:30 PM
3:00 PM-3:30 PM
“Moving Toward Visible Difference and Beyond: Imaging-Based Surface Quality Control for Rod and Wire,” by Tzyy-Shuh Chang and Howard Huang, OG Technologies Inc.; and Jianjun Shi, Georgia Institute of Technology
Applications of rod and wire, particularly those subject to substantial processing, demand high surface quality to avoid product failure during processing or use. In recent years, imaging-based equipment has been applied not only to the hot rolling wire rod mills, but also in wire peeling and drawing facilities. The “image advantage” provides the foundation of visibility, a key capability for detecting and verifying very fine surface anomalies. Additionally, the visibility also facilitates timely identification of process/equipment issues such as roll and die wear, among others.
3:30 PM-4:00 PM
“Contour Measurement and Dimensional Surface Inspection of Long Products During Hot Rolling,” by Tom Campbell, LAP Laser LLC
“Contour Check Shape” is a new system for contour scanning and dimensional surface inspection of long product directly during hot rolling. This is an optical non-contact system which performs up to 1,000 measuring cycles per second. Several thousand measuring points are distributed across the entire surface of the stock, thus assuring high-resolution scanning of the entire profile. The system detects both rolling defects and surface defects automatically. It automatically classifies rolling defects which previously required interpretation by an experienced user.
4:00 PM-4:30 PM
“Advances in Measurement Techniques,” by P. J. Pugsley, Primetals Technologies Ltd.
Maximum yield of first quality finished product should be the aim of every mill. As yield is affected by many different variables, there is no single “quick and easy” fix to achieve this. This paper describes how advances in rotary and static measurement techniques for rolling mills can be combined to create a powerful new weapon in the constant battle to maximize yields.
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