Ferro Silicon Calcium Cored wire

Product Description:

No ImageCalcium Silicide cored wire is souce of Calcium for steel industries, which is used for Deoxidation, Desulphurization and Inclusion modification. Cored wire is prepared by, high grade of CaSi granules or powder, which is filled in U shaped steel sheath (Made of high quality of cold rolled steel strip), and this U shapes steel sheath is closed tightly, so called overlapping craft, with help of equipment. The encapsulated Calcium Silicide in steel sheath (called cored wire) is injected into the steel melt with help of wire injection system with the purpose of high recovery of Ca in steel than the virgin Ca / CaSi lumps addition into the ladle. The powder specification of Calcium siliside, which is used in cored wire, strip specification, & wire characteristics, is given below:

Chemical Composition:

Grade Powder Chemical Composition (%)
Ca Si Al (Max) C (Max) S (Max) P (Max) Fe (Min)
FeSiCa30 28-31 55-65 1.5 1 0.05 0.06 4.5
FeSiCa30+ 30-33 55-65 1.5 1 0.05 0.06 4.5
FeSiCa33 32-34 55-65 1.5 1 0.05 0.06 4.5
Grade Powder Specification
Ca Si Al (Max)
FeSiCa30 2.5 - 2.7 1030 -1200 -0.4 + 0.045
Grade Strip Specification
Diameter (e mm) Thickness)(mm)
EDD IS– 513 9 ± 0.5 0.30– 0.35 ±0.03
13 ± 0.2 0.30– 0.35 ±0.03
16 ± 0.2 0.35– 0.4 ±0.03

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Grade Wire Characteristics
Diameter (0, mm) Shape Powder Fill(gms/mt)
FeSiCa 9 ± 0.5 Round 105±10
13 ± 0.2 Round 230±10
16 ± 0.2 Round 390±10

Coil Specification (Flipping Coil â Horizontal & Vertical):

Details 9 mm Diameter  13 mm Diameter  16 mm Diameter   
F1-05 F1-10 F2-05 F2-10 F2-15 F2-20 F2-05 
Powder Weight (MT) 0.500 1.000 0.500 1.000 1.500  2.000  1.000

Coil Identification

All coils are colour coded and fixed with a detailed sticker clearly displaying details such as coil no., powder content, strip weight, gross weight density & length. A fluorescent sticker displays the name of the product in bold letters on the outer diameter of the coil.  

Strip Weight (MT) 0.490 0.980 0.315 0.630 0.945  1.260  1.710
Net Weight (MT) 0.990 1.980 0.815 1.630 2.445  3.260  1.710

Handling

No metal sling, chain or rod is to be used across the ID of the coil for handling as it may damage the coil. Use only polyester, synthetic slings, fork lift/tractor to handle the coil. The pallet is an integral part of the coil and it is to be removed till the coil is consumed.

Length (mtrs) 4760 9520 2172 4337 6521 8695 2631
Internal Diameter (mm) 650 650 650 650 650 650 650
External Diameter (mm) 1070 1190 1100 1200 1370 1420 1230

Shelf Life

Follow the shelf life period specified by MINEX

Height (mm) 630 900 630 900 900 1000 900

Packing:

Packing in flipping cage and mounted on wooden / mild steel pallet and strapped with pallet horizontally or vertically. All coils are wrapped in stretch film & palletized

To be stored in dry & covered area away from heat and moisture. Material Safety Data Sheet can be supplied on demand

No ImageCaSi is universal deoxidizing, desulphurising and Inclusion modifying agent used for manufacture every kind of steel as killed plain carbon steel, low alloy steel, high grade alloyed steel, stainless steel etc. (except low Si steel, where CaFe & CaFeAl Cored wire is used to get same effect). In combination with aluminium (FeAl / Al wire), it is used in cases where high demands are made on the degree of purity and the surface quality of steel. The addition of Calcium, and close control over the degree of addition, is an important step in the steelmaking process. There are various way to add calcium into steel melt. Usually calcium silicide lumps added into bottom of the ladle and steel melt (temperature 1500 N 1600°C) is poured into the ladle or Calcium silicide powder can be added by powder injection method through lance as shown in figure 1. :-

But it’s very costly and outdated process. In ladle addition of Calcium silicide lumps, the recovery of Ca is very low. Due to lower density (2.5gm/cc) of CaSi lumps its floats at the surface of melt and losses in oxidation and slag. Usually the recovery of Ca is only less than 10%.

Whereas in cored wire Injection system the recovery of calcium is 15 – 30% with precise control of composition. In CaSi cored wire, CaSi is encapsulated in steel sheath, when injected into steel it can go in depth of steel melt as shown in

In ladle addition of Calcium silicide lumps, the recovery of Ca is very low. Due to lower density (2.5gm/cc) of CaSi lumps its floats at the surface of melt and losses in oxidation and slag. Usually the recovery of Ca is only less than 10%.

No ImageNo ImageWhereas in cored wire Injection system the recovery of calcium is 15 – 30% with precise control of composition. In CaSi cored wire, CaSi is encapsulated in steel sheath, when injected into steel it can go in depth of steel melt as shown in figure2, where due to sufficient ferrostatic pressure, calcium bubbles slowly raise to surface and react efficiently in steel melt and also control of wire feeding with help of wire feeder at desired speed ensures high recovery, precise composition control and less fumes generation. Thus the cored wire injection into the steel is environmental friendly due to less fumes generation and economical due to high recovery and less heat rejection.

Recovery of Ca in steel melt depends on various factors as oxygen content & sulphur content into the melt, temperature, wire injection speed etc...

The addition rate of the Ca depends on the oxygen & sulphur concentration in steel and desired residual Ca content in steel. The residual Ca content in steel should be below the 20 ppm in order gets desired effect as Inclusion modification, improved castebility, reduced nozzle clogging etc. And also, the addition of calcium to the steel in an amount ensuring that Ca/Al > 0.14 and Ca/S > 0.7 leads to considerable decrease of the number and area fraction of long inclusions as well as their high plastic deformability.

The following advantages have been reported from Ca – treatment as:

  • To improve steel castability in continuous casting (i.e., minimise nozzle blockage during casting with consequential reduction in casting speed and possibly the formation of large aggregated alumina clusters in the solidified product).
  • To get good surface quality and good internal slag cleanlinessD To improve mechanical properties especially in transversal and through thickness direction, by modifying manganese sulphides to globular CaFMn sulphides, which are nearly nonFdeformable during rolling.
  • To improve steel machinability at high cutting speeds by forming a protective film on the tool surface that prolongs the life of the carbide toolD
  • To minimise the susceptibility of steel to reheat cracking, as in the heatFaffected zones (HAZ) of welds.
  • To prevent lamellar tearing in large restrained welded structuresD and
  • To minimise the susceptibility of highFstrength lowFalloy (HSLA) linepipe steels to hydrogenFinduced cracking (HIC) in sour gas or sour oil environment.

The following advantages have been reported from Ca – treatment as:

  •  To improve steel castability in continuous casting (i.e., minimise nozzle blockage during casting with consequential reduction in casting speed and possibly the formation of large aggregated alumina clusters in the solidified product).
  •  To get good surface quality and good internal slag cleanlinessD
  •  To improve mechanical properties especially in transversal and through thickness direction, by modifying manganese sulphides to globular CaFMn sulphides, which are nearly nonFdeformable during rolling.
  •  To improve steel machinability at high cutting speeds by forming a protective film on the tool surface that prolongs the life of the carbide toolD
  •  To minimise the susceptibility of steel to reheat cracking, as in the heatFaffected zones (HAZ) of welds.
  •  To prevent lamellar tearing in large restrained welded structuresD and
  •  To minimise the susceptibility of highFstrength lowFalloy (HSLA) linepipe steels to hydrogenFinduced cracking (HIC) in sour gas or sour oil environment.

No ImageAs During solidi!cation sulphur is selectively deposed at grain boundaries in forms of various sulphides and their solution (especially type II & III) and causes heterogeneity of mechanical properties of !nal products. Calcium change the sulphur release mechanism in such a way that the sulphur is bound to oxide or aluminate particles and not deposed as sulphide inclusions at grain boundaries during the steel solidi!cation. see microstructure - Alumina inclusions form calcium aluminates that can be as cores for precipitating “oxysulphide” inclusions (Figure 4). The outer layer contains calcium sulphide (or calcium sulphide with little manganese) when sulphur content is low or calciummanganese sulphide when sulphur content is higher.

The mechanism and stage of formation of the oxysulphides is not fully known, but the favourable in"uence of these complex inclusions for many products is well known i.e. improving the machinability of hardening and tempering as well as casehardening steels. The formation of oxide layer on the tool is optimized and results in longer tool life and in possibility to use higher cutting speeds. Better surface quality of the product is also attained. In addition, good castability is an important application of Ca-treatment. For some products, however, the Ca-treatment and hence modi!cation of inclusions must be avoided. For instance, well deformable silicate type inclusions are desirable for wire materials and undeformable inclusions should be avoided. In general, the properties of !nal products must be thoroughly considered when choosing the proper ladle treatment.No Image