Steel Manufacturing Process Quiz

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Questions and Answers

What is the primary purpose of the Asbestos Gasket in casting railway cast steel wheels?

To enhance the thermal conductivity of the casting process

To prevent the back flow of solidified metal

To support the weight of the molten metal

To act as a sealant between the drag and pouring tube (correct)

In which condition must the Clay Graphite Tapered Ingate Sleeves be fired?

At room temperature to preserve material integrity

At high pressure to enhance durability

In an open-air environment for even heating

In a reducing atmosphere to prevent oxidation (correct)

What function does the Ceramic Pouring Tube serve in the pouring process?

To allow for manual pouring by workers

To cool the molten metal

To serve as a measurement device for molten metal levels

To transport molten metal through controlled pressure (correct)

What is the primary function of Calcined Lime in the steel-making process?

To act as a flux for slag formation Signup and view all the answers

How is Ferro Silicon primarily used in the Electric Arc Furnace steel-making practice?

For enhancing the final chemistry of liquid steel Signup and view all the answers

What is the main role of Pouring Tube Glaze in the manufacturing process?

To fill the pores of the tube and make it air tight Signup and view all the answers

How is the Clay Graphite Stopper utilized during the metal pouring process?

It prevents back flow of molten metal after pouring Signup and view all the answers

Which component is crucial for achieving the desired manganese content in railway steel wheels?

Silico Manganese Signup and view all the answers

In the context of steel-making, what role does Graphite Powder/Granules serve?

To maintain the carbon content during melting Signup and view all the answers

What is the significance of maintaining a pressure of 52-56 kg/cm2 for the Clay Graphite Tapered Ingate Sleeve?

To provide a tight fit against the taper in the mould Signup and view all the answers

Which method is used to prepare the Clay Graphite Tapered Ingate Sleeve during the firing process?

Encasing it in a suitable medium to avoid oxidation Signup and view all the answers

What property does Magnaglo Powder exhibit under black light?

It fluoresces yellow-green Signup and view all the answers

What happens to the Clay Graphite Ingate Sleeves after each casting?

They are reamed using a grinding stone for proper seating Signup and view all the answers

What is the main purpose of using Fused Silica Powder in the steel-making process?

As a binder and stabilizer in graphite mould spray Signup and view all the answers

What is the maximum pressure used when pouring molten metal through the Ceramic Pouring Tube?

35 psi Signup and view all the answers

Which material is commonly added to liquid steel to improve its quality for casting railway wheels?

Silico Manganese Signup and view all the answers

In the inspection of cast steel wheels, Magnaglo Powder is used primarily to:

Locate fine surface and sub-surface discontinuities Signup and view all the answers

Which of the following consumables is specifically designed to act as a sealant during the casting process?

Asbestos Gasket Signup and view all the answers

What is the significance of the final chemistry with respect to Silicon for casting railway steel wheels?

It impacts the strength and longevity of the wheels Signup and view all the answers

Which material is considered a ladle addition in steel-making for achieving desired metal properties?

Ferro Manganese Signup and view all the answers

What is the range of hardness for the cast steel wheels that steel shots are used on?

255 to 363 BHN Signup and view all the answers

During which fiscal year was the average number of wheels cast per day highest?

2014-2015 Signup and view all the answers

What was the average number of heats per day in the fiscal year 2015-2016?

20.79 Signup and view all the answers

What is the rejection percentage for wheels cast in May of 2015?

7.51 % Signup and view all the answers

How many good wheels were produced per day in 2014-2015?

616 Signup and view all the answers

Which fiscal year experienced the lowest average number of good wheels per day?

2013-2014 Signup and view all the answers

What is the average number of wheels rejected per day in the fiscal year 2014-2015, based on a 6.083% rejection rate?

47 Signup and view all the answers

In the chart, what trend can be observed regarding the average wheels cast from 2013 to 2016?

Fluctuating without a clear trend Signup and view all the answers

What was the average number of wheels cast per day in the fiscal year 2013-2014?

680 Signup and view all the answers

What is the significance of using steel shots on cast steel wheels?

To improve surface finish and structural integrity Signup and view all the answers

Study Notes

Consumables for Wheel Shop

Consumables are used directly or indirectly in wheel manufacturing
Asbestos Gasket: Used as a sealant between drag and pouring tube in railway cast steel wheel casting. One gasket per wheel.
Ingate Sleeves (Clay Graphite Tapered): Fired/baked in a controlled reducing atmosphere. Kilns use a controlled heating rate per manufacturer's schedule. Encased in graphite, calcined petroleum coke, or similar during firing to prevent oxidation. Fixed in graphite drag during mould assembly for railway wheels. Retained in position by pressure (52-56 kg/cm²).

Additional Consumables

Ceramic Pouring Tube: Molten metal rises through the tube into the mould using controlled pressure (35 psi max.).
Pouring Tube Glaze: Used as a coating on the pouring tube to fill pores and make it airtight.
Clay Graphite Stopper: Made of clay graphite to prevent backflow of molten metal after pouring. Used in cast steel wheel manufacturing.
Calcined Lime: Used as a flux to create slag in steel making.
Ferro Silicon: Used in liquid steel tapping from electric arc furnaces. Composition is critical for railway steel wheels.
Silico Manganese: Ladle addition to liquid steel (electric arc furnace). Ensures Manganese and Silicon composition within required limits for railway wheels.
Ferro Manganese: Furnace addition used in steel making processes (electric arc furnaces) specifically for railway steel wheels.
Graphite Powder/Granules: Used in electric arc furnaces for melting scrap steel for railway wheels. Maintains carbon content during melting.
Magnaglo Powder: Dry, free-flowing, speckled brown/white magnetic powder; fluoresces yellow-green under black light (365 nanometres).
Fused Silica Powder: Used to prepare sprays for graphite moulds. Acts as an emulsion stabilizer and film former, etc.
Steel Shots: Cleaning and peening cast steel wheels. Hardness range of 255 to 363 BHN.

Wheel Shop Specifications

Average Wheels Cast Per Day: Data from 2013-2016, showing daily average wheel production amounts.
Average Heats Per Day: Data from 2013-2016, showing an average of heats per day.
Good Wheels Per Day: Daily output of wheels deemed acceptable.
Wheel Rejection %: Data for percentage of rejected wheels from 15-Apr to 15-Aug period.

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Description

Test your knowledge on various components and processes involved in steel manufacturing, particularly focusing on materials used in casting railway cast steel wheels. This quiz covers functions, properties, and applications of key materials such as clay graphite and ferro silicon.