Electric Arc Furnace Process Ladle Furnace Rolling Millsmete.metu.edu.tr/system/files/300...

References 1. www.safetysign.com 2. Scrap Specifications Circular, 2012, ISRI. 3. Steel Shop Process, Habaş A.Ş., 2008

Summer Practice METE 300 Fall 2012/2013 Yasin SEMİZ HABAŞ A.Ş.

Yavuz Ali TOPKAYA

Habaş A.Ş. is one of the major companies of Turkey, which produces industrial and medical gases, steel, electrical energy, heavy machinery, distributes liquified petroleum gas (LPG), liquified natural gas (LNG) and compressed natural gas (CNG). Habaş A.Ş. has a steel production plant at Aliağa, İzmir. Steel produces with EAF process from scrap at this plant. Products of this plant are; steel billets, wire rods, concrete reinforcement bars. Responsible Engineer: Halil KOCAOĞLU Phone: 05548534178 Work Safety

Every worker is held to an orientation and work safety program. Work safety is a very important

issue at this company because steelmaking is one of the most dangerous processes for workers and

accidents are inevitable.

The aim of the company is to have a zero accident and zero injury workplace. [1]

Important properties of preferred scrap: Cleanness; All grades shall be free of dirt, nonferrous metals, or foreign material

of any kind, and excessive rust and corrosion.

Off-grade material; The inclusion in a shipment of a particular, grade of iron and

steel scrap of a negligible amount of metallic material which exceeds to a minor

extent the applicable size limitations.

Residual alloys; Steel scraps shall be considered free of alloys when the residual

alloying elements do not exceed the following percentages: Nickel 0.45%,

Molybdenum 0.10%, Chromium 0.20%, Manganese 1.65%.

Deviations; Any deviations from the general classifications of iron and steel scrap

may be consummated by mutual agreement between buyer and seller. [2]

Recycling steel requires 60% less energy than producing steel from iron ore. 530 million

metric tons of ferrous scrap were consumed globally in 2010. Turkey is one of the leading steel manufacturer and Habaş A.Ş. is one the

leading steel manufacturer in Turkey.

Scrap Preparation Process

An example of scrap mix loading

Steel: 120 t

Charge weight: 130.4 t

Shaft volume: 114 m3

Basket volume: 97 m3

Total mix % t t/m3 HMS1 45.00 58.7 0.72 HMS2 12.00 15.7 0.60 Turnings 5.00 6.5 0.40 Shredder 15.00 19.6 0.70 Pig Iron 14.00 18.3 3.00 Bundles 9.00 11.7 0.70 Total 100.00 130.4 t – 169.6m3 0.77 t/m3

Electric Arc Furnace Process Scrap and some other materials turn to molten

iron at this step. There are two finger shaft furnaces at Habaş Steel Works which have

names EAF 1 and EAF 3. Finger shaft furnace is the most energy-efficient EAF at present. [3]

A schematic diagram of a finger shaft furnace, designed by Fuchs Systemtechnik

Technical properties of furnace

Furnace (molten steel) capacity 138 metric tons

Heat Size 120 metric tons

Permanent Molten Steel 18 metric tons

Electrical energy consumption: 300 – 315 kWh/t

Electrode consumption: 1.2 – 1.4 kg/t

Oxygen consumption: 25 – 30 Nm3/t

Fuel consumption: 6 – 8 Nm3/t

Charge carbon: 10 – 15 kg/t

Carbon powder: 5 – 7 kg/t

Tap-to-tap time: 40 minutes

Productivity: 1250000 – 1450000 metric tons/year

Electrode diameter 610 mm

Shaft volume 110 m3

Scrap basket volume 97 m3

Main Benefits of Finger Shaft Furnace - Up to 100% scrap reheating.

- Up to 120 kWh/t liquid steel electrical energy savings. - Approximately 40% reduced flicker factor.

- Up to 15% reduced electrode consumption. - Up to 2% increase of metallic yield. - Up to 25% lower dust emissions. - Up to 20% productivity increase.

Reactions of electric arc furnace

4 Al + 3 O2 ➝ Al2O3 / Si + O2 ➝ SiO2 2 Mn + O2 ➝ MnO / 4Cr + 3 O2 ➝ Cr2O3

S + O2 ➝ SO2 / 4Fe + 3 O2 ➝ Fe2O3 Fe + 0.5 O2 ➝ FeO / C + O2 ➝ CO2 2 C + O2 ➝ CO / 2CO + O2 ➝ CO2

Ladle Furnace

Continuous Casting Machine

The ladle furnace is used to correct the temperature and composition of liquid melt. This also allows the molten steel to be kept ready for use in case of a delay later in the steelmaking process. After treatment in the ladle furnace, furnace steel is reached its optimal chemical

composition. After ladle furnace steel can be directed to Continuous Casting Machine(CCM) for bloom and slab production or deairing equipment for steel degassing

processes.

Ladle furnace while tapping

Liquid steel must be cast into shapes so that it can be rolled. This is done by continuous casting machines that mould the

liquid steel into different sized shapes called slabs, blooms and billets. The process is continuous because liquid steel is

continuously poured into a 'bottomless' mould at the same rate as a continuous steel casting is extracted.

Types of steel products produced by continuous casting

New blooms from continuous casting machine

Rolling Mills Habaş has wire rod mill with an annual capacity of 500,000 tons : - 90 t/h capacity walking beam reheating furnace - 16 continuous rolling stands - 10 monoblock stands with a finishing speed of 100 m/sec. - Controlled cooling system (Stelmor) - Coil packing system capable of compacting and binding in 4 different places. - Master computer system to control every stage of production

Production Range : - Wire rods with a diameter of 4.5 to 16 mm in round and deformed. - Coil weight up to 1500 kgs. - The internal diameter of the coil is 850 mm and the external diameter is 1250 mm. - Coils are stocked in covered warehouses.

Cooling billets after rolling mills

There are two different testing laboratories at this plant. One of

these is a chemical laboratory and the other one is physical testing laboratory. In these laboratories

several analyses and testing processes is done regularly such as

water analysis, metallographic examinations, x-ray spectroscopy,

tensile test, bending test. esting etc. is done regularly. Every finished

product is tested here according to standards such as ISO, TSE which

certificates is shown.

One of the most important part of engineering in this plant is

trouble-solving. Because every machine works for 24 hours and

if an malfunction happens it effects every part of production,

so it should be immediately solved by engineers. Most

occuring troubles are; electrode breakage,electrical malfunctions, crane malfunctions, continuous casting machine stoppage etc.

21.99 19.18

15.6

10.74 9.21

6.39 4.35

2.56 2.3 1.79 1.79 1.28 1.28 0.77 0.51 0.26 0

5

10

15

20

25

Graph 1. Graph of electricity malfunction on EAF 1

and EAF 3 at april-may-june 2012

3 aylık duruş miktarı : 391 dakika 3 aylık döküm sayısı : 5025 döküm 3 aylık üretim tonajı : 623.750.033 ton 3 aylık döküme düşen arıza : 0.077 dk/dök

Shutdown time for 3 months: 391 minutes Casting quantity fo 3 months : 5025 casts Production for 3 months : 623.750.033 tons Malfunction per cast: 0.077 min/cast

Testing Laboratories

Troubles Some of the standard certificates which

Habaş A.Ş. have satisfied

Molding Box • Firstly, the pattern is made. It is a

physical model of the casting and usually made by wood, polystyrene and aluminum. In Akdas patterns are bought from another companies most of the time.

Figure1: A pattern • Secondly, core is made. It is usually

made of sand, which are placed into a mold cavity to form the interior surfaces of castings. Thus the void space between the core and mold-cavity surface is what eventually becomes the casting.

• Finally, preparing molding box consists of all operations necessary to prepare a mold for receiving molten metal. It usually involves placing a molding aggregate around a pattern held with a supporting frame, withdrawing the pattern to leave the mold cavity, setting the cores in the mold cavity and finishing and closing the mold.

Melting and Pouring The preparation of molten metal for casting is referred to simply as melting. Melting is usually done in a specifically designated area of the foundry, and the molten metal is transferred to the pouring area where the molds are filled. In Akdas Foundry, casting can be done at a capacity almost 45 tones at once. The firm uses induction furnaces which are Inductotherm branded. In foundry 2, the furnaces are at the capacities ; 10tones, 2x9tones, 3tones, 5tones and 2x1.5tones.

Figure2: Molten metal in the pot

Heat Treatment The term annealing refers to a heat treatment in which a material is exposed to an elevated temperature for an extended time period and then slowly cooled. Ordinarily, annealing is carried out to (1) relieve stresses; (2) increase softness, ductility, and toughness; and/or (3) produce a specific microstructure. In Akdas the processes available are, normilizing,

stress relieving, tempering, selective hardening,

differential hardening, and quenching.

Quenching in water is the most used one of the quenching processes in Akdas..

Figure3: A product is taken from furnace

Figure4: TTT diagram

Quality Control

In order to achieve the best quality, Akdas has many applications:

• In the laboratory, the firm has Charpy Impact Tester and Tensile Testing machine. So they can provide their customers stress strain curve and behaviour of materials in different temperatures.

• In the factory, the firm has Ultrasonic Test, Magnetic Particle Test, Liquid Penetrant Test units.

• In addition, Akdas is not able to apply radiographic test, yet, they have partner firms which apply this test for Akdas.

Figure5: Magnetic Particle Testing

References

1. www.akdas.com.tr

2. www.ndt-ed.org

3. Callister, W.D. (2007). Materials Science and Engineering

4. www.industrialmetalcasting.com

Akdaş Casting and Trade Company was founded in 1982 starting 500 tons/year capacity. After 30 successful years, now it has 2 smeltries, 2 processing factories and a welding construction factory at Sincan Organize Sanayi Bölgesi in Ankara. The foundation has 36000 m2 closed area, total area is 60000 m2. Akdaş Casting has 70 tons at a time capacity and 25000 tons per year. It produces low and high carbon alloyed steels, corrosion-resistant Mn steel, stainless steel, pig iron, grey iron casting.

Akdas has been manufacturing products in 7 major areas:

Automotive, Cement & Soil, Energy, Machinery, Mining &Crushing, Offshore & Marine, Steel Works

Contact: +90 312 267 18 80 [email protected]

Summer Practice METE 300 Fall 2012/2013

Mehmet Burak DAYIOGLU

Akdas Casting Ind. Trade Co. Assist. Prof. Dr. H. Emrah Ünalan

Week 1 • First two days of summer

practice, necessery education was given and equipments were supplied by the instructors. Moreover, technical trip was done.

Continuous Casting Unit: • Systematic informations were

given by the engineer. • Billet and slab production was

observed. • Tundish preparation steps also

examined.

Week 2 Meltshop: • In second week, with my group friend the meltshop was visited. • Detailed information about the steel making process was given by the engineers

Week 3 Blast Furnace:

• The first blast furnace (Cemile) and the second blast furnace (Ayfer) was viewed during the third week of my summer practice.

• Cemile was in rest, Ayfer was working.

• In the control rooms, information about computer systems was given by the engineer.


• Last week, the fourth blast furnace (Dilek) was viewed for two days.

• Dilek is the highest and most modern blast furnace in Europe.

Rolling Mills:

• Hot rolling operations was observed from beginning to end.

References 1.İsdemir Brochure 3. www.llanymynech.org.uk

2.isdemir.com.tr

• ISDEMIR being the third in terms of date of foundation, the biggest integrated Iron & Steel Plant of our country in terms of long product production capacity, is the only integrated facility of Turkey producing long and flat product with its 3.5 million tons/year hot rolling capacity commissioned in 2008. At ISDEMIR facilities being established with the intention of producing long products like pig iron, bloom, billet, construction steels in international quality standards; production is made with coke- sinter –blast furnace – steel mill – continuous casting and hot rolling processes.

• Volkan KIZILAY Billet & Slab Production Engineer E-mail: [email protected] Phone Number: 0532 350 46 38

Summer Practice METE 300 2012/2013 Serhat GÖKSU

İSDEMİR Assist. Prof. Dr. Hüsnü Emrah ÜNALAN

Week 1 - The first and second day Training Departmant gave us some

information about work and work place safety.

- Third day visited some departments of ISDEMIR Iron and Steel Co.

and every intern was sent to his/her department.

- In Wire Rolling Mill Deparment, responsible engineer made interns

to prensentation and told interns what is work and how is done.

Week 2 Wire Rolling Mill has 3 part. They are

business management, machine maintenance and electric part.

Operation room was explained Scarf process and Charging to

Furnace process observed Billet area was observed The process of wire rolling mill

was told • Work place was shown around in

wire rolling mill.

Week 3 There are 4 blast furnaces; namely,

Gönül, Ayfer, Cemile, Dilek • Only second and third blast furnaces

were visited because first blast furnace do not work and fourt blast furnace was repairing during intern interval.

• Sinter and raw material manipulation was observed and preparation of raw material was told.

• Coal preparation and Coke Manipulation Facility was observed.

• Working process of coke stockpiles and coke oven batteries are explained

Week 4 Meltshop has 2 department. These

departments are continuous casting and meltshop.

• Converter is visited and process of decarbonization has seen.

• Casting of billets and slabs were told by technician

• Tandish, melting pots and operation rooms were shown

References 1. http://www.dcud.org.tr/tr/users.asp?firma_id=23

2. http://www.isdemir.com.tr/wps/wcm/connect/IsdemirLibrary/Isdemir

• ISDEMIR being the third in terms of date of foundation, the biggest integrated Iron & Steel Plant of our country in terms of long product production capacity, is the only integrated facility of Turkey producing long and flat product with its 3.5 million tons/year hot rolling capacity commissioned in 2008. ISDEMIR is founded on 3 October 1970 in south of Turkey on the Mediterranean coast, in Payas (Yakacık) region, which is 17 km away from Iskenderun. On the date of its establishment, it was located on a total area of 16.75 million m2 (Plant area is 6.8 million m2) with its social facilities.

• Muzaffer İzgi [email protected] (0326) 7583341

• ISDEMIR’s mainly products are: Wire Rods, Pig Iron , Billets , Slabs , Hot rolled coil

ISDEMIR’s by-prodcuts are: Coke Coal, Oxygen Gase, Nitrogen Gase, Amonıum Sulphate Manure, Granulated Slag, Curude Benzene, Tar

Summer Practice METE 300 Fall 2012/2013 Eray Buğra Göktekin

İskenderun Iron and Steel Co. Prof. Dr. Rıza Gürbüz

Week 1

- The first and second day Training Departmant gave us some information about work and work place safety.

- Third day visited some departments of ISDEMIR Iron and Steel Co. and every intern was sent to his/her department.

- In Hot Rolling Deparment, responsible engineer made interns to prensentation and told interns what is work and how is done.

Week 2

Hot Rolling Department has six parts units. Slab Stock Area

and Mills Workshop Unit was visited.

- Alignment and giving id process for slabs observed.

- Scarf process and Charging to Furnace process observed.

- Cracks and corrosions in Mills are observed.

- Griding and reform of mills observed.

- Swarf and Babbitt metal is examined.

Week 3

Slab Reheat Furnace and Roughing Mills Unit was visited.

- Annealing process of slabs observed.

- The stabilization of temperature in furnace and how long slabs

can stay in furcane is examined.

- Exitance of slab from furnace is observed.

- Scale breaking process with presurized water observed.

- Plastic deformation of slabs is observed in Roughing Mills.

- Changing the back-up and work Mills is observed.

- Edger process is observed.

- The reducing the thickness of slabs and elongation of slabs is calculated.

- Coiling and unwraping of slabs in coilbox is observed.

- Scale cleaning and revising of slabs in coilbox are observed.

Week 4

Finishing Mills, Downcoilers and Coil Stock Area unit was visited.

- Cutting slab’s end and tail specific lenght is observed.

- Scale breaking process with water pumping is observed.

- Plastic deformation of slabs is observed in Finishing Mills.

- Giving final thickness to the slab with high technological applications is observed.

- Cooling of slabs with water in cooling table is observed.

- The cooling rate in cooling table is calculated due to company’s desires.

- Changing the finishing mills is observed.

- Coiling by downcoilers is observed.

- Bandaging the coils with special rape is observed.

- Quality controls of coil is made.

References

1. http://www.dcud.org.tr/tr/users.asp?firma_id=23

2. http://www.isdemir.com.tr/wps/wcm/connect/IsdemirLibrary/Isdemir


• Umut Ahmet Ay

[email protected] No: (0326) 7585752

ISDEMIR’s mainly products are: wire Rods, Pig Iron,Billets,Slabs,Hot Rolled Coil. ISDEMIR’s by-prodcuts are: Coke Coal, Oxygen Gase, Nitrogen Gase, Amonium Sulphate Manure, Granulated Slag, Curude Benzene, Tar

Summer Practice METE 300 FALL 2012/2013 SÜLEYMAN ERDİ GÜNDER

İSKENDERUN IRON AND STEEL CO. Ass. Prof. Dr. Emrah Hüsnü Ünalan

Week 1 Orientation:

• First week general information about the facility is given by instructers. • Rules and instructions

are given. • History of TAI is given. • Main buildings of facility

is observed which are; 10th Building Chemical Building Helicopter Unit

Week 2 First Clean Room:

• Second week first clean room was visited.

• Carbon fibers are laid-up by workers on the patterns.

• In this area parts of Boeing, Airbus and other aircrafts are manufactured.

• There is also produced sandwich panels with using honeycombs.

• All steps of the lay-up process was observed.

Week 3 2nd Clean Room & Autoclave:

• Third week second (new) clean room and autoclave was observed.

• In the second clean room generally glass fibers and kevlar is used.

• For detailed and big parts machine is used for lay-up the composite.

• Autoclave uses pressure beside the temperature in order to cure the composites.

Week 4 Tooling and Testing Facility:

• Excess resin and composites are cutted and grinding done at tooling.

• After the material gets its final form it is sending to dying facility.

• In testing area NDT is applied to material after autoclave.

• NDT machine uses water and sound wave to find the failure.

References 1) www.tai.com.tr 3) www.ndt-ed.org 2) www.tei.com.tr 4) www.talford.com •

• Designing domestic aircrafts and satellites and moderization of aircrafts and enhancing its software systems • Banu AKTİMUR Tel: (0312) 811 18 00/ 2568

Summer Practice METE 300 Fall 2012/2013 Kâzım Buğra GÜRBÜZ

Turkish Aerospace Industuries Prof. Dr. Vedat AKDENİZ

Vacuum Back Carbon Fiber

Honeycomb Structure TAI

Kevlar Autoclave

Carbon Lay-Up Machine

Ultrasonic NDT Machine

Week 1 • First two days of summer practice,

necessery education was given and equipments were supplied by the instructors. Moreover, technical trip was done.

Continuous Casting Unit: • The processes, risks and necessary

precautions were underlined by engineer.

• In continuous casting department, billet and slab production was observed.

• Steps of tundish preparation also examined.

Week 2 Meltshop: • In second week, with the approval of

my practice engineer the meltshop was observed.

• Torpedoes full of liquid pig iron coming from blast furnaces were examined.

• Steel making process was observed.


• In third week, for two days the first blast furnace (Cemile), for three days the second blast furnace (Ayfer) was viewed.

• Cemile was in rest, Ayfer was working.

• The systems in the control rooms was underlined by the engineers.


• In the final week, the forth blast furnace (Dilek) was viewed for two days.

• Dilek is the highest and most modern blast furnace in Turkey.

Hot Mill:

• Hot rolling operations was observed from beginning to end.

• ISDEMIR being the third in terms of date of foundation, the biggest integrated Iron & Steel Plant of our country in terms of long product production capacity, is the only integrated facility of Turkey producing long and flat product with its 3.5 million tons/year hot rolling capacity commissioned in 2008. At ISDEMIR facilities being established with the intention of producing long products like pig iron, bloom, billet, construction steels in international quality standards; production is made with coke- sinter –blast furnace – steel mill – continuous casting and hot rolling processes.

• Volkan KIZILAY Billet & Slab Production Engineer E-mail: [email protected] Phone Number: 0532 350 46 38

Summer Practice METE 300 Fall 2012/2013 Yakup Emre TANRIKULU

Iskenderun Iron & Steel Co. Prof.Dr. İshak KARAKAYA

References 1.www.isdemir.com.tr 3. www.steel.org

2.İsdemir Brochure

Week 1 • At first two days,

training department gave us information about safety factors.

• At day three, all of the interns were sent to their departments.

• In Quality Metallurgy Department, engineer gave a presentation about process and told how the work is done.

Week 2 • Spectral laboratory and physical&

mechanical test laboratory departments were visited.

• At spectral laboratory specimen recivement, preperation and examination were shown.

• Engineers teached how to use Optical Emission Spectrometer and X-Ray Spectrometer machines.

• Sinter and raw material manipulation was observed and preparation of materials to the usage shown by the responsible engineers.

Week 3 • Converter was visited and

decarborization process is observed.

• Continuous casting departmant was visited.

• Tandish , melting pots, water cooling system were observed.

• Casting of slab and billets were explained by engineer.

Week 4 • Blast furnaces were visited. There

were four blast furnaces: Ayfer, Gönül, Cemile, Dilek. However first blast furnce was in maintenance. Second and third blast furnace were visited.

• Hot rolling department is visited and hot rolling process was observed.

• Plastic deformation of slabs are observed. Slabs were shaped as coil and ready for usage.

References: 1.http://www.dcud.org.tr/tr/users.asp?firma_id=23

2.http://www.isdemir.com.tr/wps/wcm/connect/IsdemirLibrary/Isdemir


• Umut AYDIN • (0536)4946576 I • ISDEMIR’s mainly products are: Wire Rods, Pig Iron, Billets, Slabs, Hot Rolled Coil ,

• ISDEMIR’s by-prodcuts are: Oxygen Case, Amonium Sulphate Manure, Granuled Slag, Curude Benzene, Nitrogen Case, Coke Coal, Tar

Summer Practice METE 300 Fall 2012/2013 Ali Zafer YENER

İskenderun Iron and Steel Co. Prof. Naci SEVİNÇ

Week 1 : STEEL MILL

• Scrap Preparation: All collected scraps are separated depends on their ingredients.

• Electric Arc Furnace Scraps are melted in furnace.

• Ladle Furnace Molten ingredients are controlled

and arranged for customers’ order.

• Vacuum Degassing Slag and steel is mixed and amount

of H2 and O2 are reduced.

• Continuous Casting • Ingot Casting

Week 2 :ROLLING MILLS

•Large Section Rolling Mills

Blooming mill Billet Mill

•Medium Section Rolling Mills

Large section Rolling Mills are

generally done to ingot casting; whereas medium section rolling mills are done when smaller dimensions are desired.

Week 3 :CONDITIONING LINES

• Large Section Conditioning Line

1.Starightening Machine 2.Shot Blasting Machine 3.Ultrasonic Control Equipment 4.Surface Crack Testing 5.Packing

• Medium Section Conditioning Lines

Same procedure is done ,but specimens’ dimensions are different and smaller.

Week 4 : ATELIER and LABORATORIES

• Atelier In atelier basicly the welding processes

are observed.

• Laboratories

1. Mechanical Test Laboratories 2. Chemistry Laboratory 3. Metallography

ˆ ˆ ˆ ˆ ˆ

References www.asilcelik.com.tr

Asil Çelik is the largest quality steel producer of Turkey ,accepted globally as an accredited quality steel producer and produces 60% of Turkey’s total quality steel production.Asil Çelik has capacity of 485.000 ton/year crude steel and 410.000 ton/year end-product.

Contact Person in the Organization:Süleyman Eryüksel email:[email protected] Phone:0 224 280 62 03

Summer Practice METE 300 Fall 2012/2013 Ece ALPUĞAN

ASİL ÇELİK SANAYİ ve TİCARET A.Ş Academic Advisor: Prof.Dr. Cevdet KAYNAK

Week 1 Model Workshop

Model placement process is observed in model workshop. The model is placed by the lift and then the sand is covered the model. Also model burying process is observed.. Autocad and Solid Works drawings for the models and casts are observed The cast sand creation, machine and its use is observed here. The sand consists of regular sand, acid and resin. The fast cooling and hardening of cast sand is observed. Completed casts are examined as products. Used sands are examined as products.

Hands-on-work: I got into the cast and helped workers push the sand into the cast to avoid gas voids. I did it by pushing the sand via wooden sticks.

Week 2 Smelting District

Furnaces are observed. There are 7 arc induction furnaces in Akdas. Operating system of the furnaces, controlling panel of the furnaces are included. Smelting process of scraps are observed. Removal of slag and temperature measurement operations are observed. Casting process is observed. Charge calculations, addition of impurities and specimen taking operation is observed. Refractory coating, steel pot heating and hot metal transfers are observed. Liquid metal is examined with special glasses as product. Slag is examined as secondary product. Hands-on-work: I operated the smallest furnace(1.3 tons) for a while by charging scrap, increasing power to smelt. I removed slag from the furnace, measured the temperature , and tried to obtain desired composition by adding impurity materials. I, also used the control panel to rotate the furnace to pour hot metal into the steel pot.

Week 3 Quality Control and Heat Treatment

Quality control and measurement devices are observed. Faults in the products are observed. Different NDT techniques are observed. Welding processes are observed. Available fields for different NDT techniques examined (OT, MT, UT, PT). Repaired and welded pieces are examined as products. Snagged pieces are examined as products. Heat treatment process is observed. Heated austenite piece is examined. Quenching and normalizing processes are observered. Heat treated pieces are examined as products. Hands-on-work: I performed OT and MT personally. I did MT with a magnetic yoke hand gun and magnetic particle solution spray. Another worker helped me with ultra-violet light and we revealed a crack that we couldn’t see with OT.

Week 4 Laboratory

Tensile test machine and tension tests are observed. Charpy impact machine and toughness tests are observed. Spectrometer and its functions are observed. Abresive cutter and notch opener machine observed. Grinding and polishing machines are observed. Microscopic examination observed. Microstructures and stress-strain diagrams are examined as products. Hands-on-work: I grinded and polished specimens to prepare them for microscopic tests. I also used acid solutions to etch the surface of the specimens. With the help of the engineer, we have captured images of microstructures of the specimens that I have prepared.I measured the initial and final lengths and diameters of tensile test specimens. I prepared specimens for the toughness test with the notch opener machine.

References 1. Akdas. (No Date). Foundries. Retrieved from

http://www.akdas.com.tr/en/dokumhaneler.html in 10.10.2012

Summer Practice METE 300 Fatih SIKAN

Akdaş Casting Industries and Trade Company Prof. Dr. Yavuz Ali TOPKAYA

Akdas Casting Industries and Trade Company, occupies 55,000 meter square open and 111,000 meter square total for its 2 foundries and 1 factory in Sincan - Organized Industrial Region, Ankara. Akdas has 240 tons of liquid metal and 35,000 tons annual capacity, which makes Akdas one of the largest foundries in Turkey. Akdas started constructing a new heavy size foundry at 2010.

Full Adress : Batı Hun Cad. No 1 OSB-Sincan / Ankara 06935 Turkey Person on Contact: Gülsüm Çakır Tel : 312 267 18 80 E-mail : [email protected]

Products • Automotive

• Energy

• Cement

• Machinery

• Mining

• Steel

Week 1

13/08/2012 • Work health and safety • Facility and information of

security 14/08/2012

• Visiting the units • Learning the my unit rules and

regulations 15/08/2012 – 17/08/2012

• Meeting the employees • Learnig the scraps • How the scraps stored • How to fill the scrap ladles

Week 2 ARC FURNACE Furnace charge • 1. charge 150 tons • 2. charge 100 tons • 3. charge 50 tons Melting Preparation of furnace for another melting

Week 3 CONTİNUOUS CASTİNG • Preparation of ladle for liquid steel • To tranport the ladle to continuous

casting liquid steel comes continuous cating unit

Week 4

• Casting the liquid steel

• Cutting the steel bars

• Cooling the casted steel bars

References İÇDAŞ web page The notes from the summer practice

İÇDAŞ Çelik Enerji Tersane ve Ulaşım Sanayi A.Ş. is producing steel bars and high alloy steels since 1970. İÇDAŞ offers services with its Steelworks, Rolling Mills, Ports, Logistics company, Shipyards and Power Plant facilities located in Çanakkale-Biga and Istanbul-Güneşli

THE STEEL BILLET PLAIN AND DEFORMED CONCRETE PLAİN AND DEFORMED Semi-finished good REINFORCEMENT BARS WİRE ROD GROUP Cross-section range 100x100mm-200x200mm diameter range 8mm-60mm Diameter range 5.5mm-20mm(plain) Length range 5m-18m standard length 12m range 0.60-18m Diameter range 6mm-16mm(deformed) Standard packing weight 2tons range 0.5-5tons Package weight 200- 3000 kg coils

Summer Practice METE 300 Fall 2012/2013 Kıvanç ALKAN

İÇDAŞ Çelik Enerji Tersane ve Ulaşım Sanayi AŞ. Prof. Dr. Vedat AKDENİZ

Week 1 Steel Mill

Week 2 Rolling Mills

Week 3 CONDITIONING LINES

Week 4 Atelier and Laboratories

References

Summer Practice METE 300 Fall 2012/2013 Sertaç ALTINOK

Asil Çelik Sanayi ve Ticaret A.Ş Advisor: Prof Dr. Naci SEVİNÇ

Operations conducted in steel mill can be classified x groups that are :

•Scrap Preparation

•Electric Arc Furnace Operations

•Ladle Furnace Operations

•Vacuum Degassing

•Continuous Casting

•Ingot Casting

Figure 4: Continuous Casting

Figure 5: Ingot casting

Figure 1: Electric arc furnace.

The current rolling mill facilities, existing of a blooming mill, a billet mill and a finishing rolling mill, are equipped to produce long products up to diameter 152,40 mm. The blooming mill was modernized in 2003, operating with two duo-reversible strands and has a capacity of sheet. This equipment can also produce heavy flats until 430 mm width and operates with a rotating re-heating furnace and pit furnaces for ingots re-heating. A new finishing rolling mill is being installed at the Sumaré Plant. The equipment will start to operate at the end of 2006 and will increase the total rolled products capacity for finished products. Rolling mills used in the plant are: •Large Section Rolling Mills •Blooming Mills •Billet Mills •Medium Section Rolling Mills

Conditioning lines are basically separated into two large section conditioning lines and medium section conditioning lines The control and conditioning processes are done the Round Corner Square and Round materials rolled in the Large Section Rolling Mill. After steel goes through heat treatment processes and whether cooled at cooling grate or at annealing hole before packing materials should be gone through these processes. Conditioning Lines are seperated two parts:: •Large Section Conditioning Lines •Medium Section Conditioning Lines

Figure 10: Straightening machine Figure 11: Shot Blasting Machine

Figure 6: Large Section Rolling Mills

In atelier, components that would be used in factory are processed by machines like milling machine and turning. Moreover, some special components of cutting tools are processed too. On the other hand, 3 basic welding processes are made in atelier. Welding by using oxygen gas, arc welding and submerged arc welding. Laboratories are seperated into 2 different sections which are mechanical and chemical laboratories. In mechanical laboratories bending test machine, tensile test machine, hardness test machines, Charpy-impact test machines are present. In chemical laboratories several tests are conducted in order to control whether the castings’ ingredient percent values are close to the customers.

Figure 15: X-ray equipment.

Asil Çelik produces hot rolled, heat treated, fully conditioned alloyed, non-alloyed, high-alloyed round, square, hexagonal, flat, grayder blade steel, mainly from scrap metals supplied from domestic and global markets in compliance with the technical specifications. Contact Person: Süleyman ERYÜKSEL email: [email protected] Tel: 02242806203

1. Photographes retrived from www.asilcelik.com.tr

Figure 2: Ladle Furnace.

Figure 3: Vacuum Degassing. Figure 7 Blooming Mills

Figure 8: Billet Mill Figure 9: Medium Section Rolling Mills

Figure 13: Surface Crack Testing Machine

Figure 12: Ultrasonic control equipment

Figure 16: Test Machines

Figure 14: Packing equipment

Week 1 • Education about the company that was

given by the employees working in the related units.

Week 2: Clean Room • In the clean room prepreg lay-up and metal

bonding of aircraft parts for the projects like JSF/F-35, Skorsky CH60-S70, Anka, Boeing AW-139

• Temprature, humidity and dust particles are controlled continuously in this room.

• Prepreg lay-ups and vacuum bag moldings of

these projects are observed and done. • Prepreg lay up of test specimens are done and

sent to the autoclave.

Week 3: Autoclave • After the lay-up process composite materials are

sent to the curing area which includes autoclave and curing oven. In this area polymerizaton cycles are controlled.

• Connecting and calibrating the thermocouples and

vacuum hoses in the autoclave is observed and done.

• Tool cleaning and taking of the composite materials from tools are observed and done

• The polymerization cycles of composite materials are observed and controlled by a computerized system.

Week 4: Tooling , Core Machining • “Tools”, are the molds that used in assembling of the

aeronautical structures . Tool Design and Manufacturing Department is responsible for the design and manufacture of composite tools required by the production units.

• Tool manufacturing with wet lay-ups, trimming and use of cutting tools are observed

• In the core machining area cut and finish operations of

metallic and non-metallic cores which are used in sandwich parts are performed. Than cleaning operations of cores are done.

References 1. Notes and presentations provided by the company 2. http://www.tai.com.tr/en 3. http://www.compositesworld.com/articles/tooling

• Established in 1984 for the co-production of F16 aircraft with USA, now TAI Turkey's center of technology in design, development, modernization, manufacturing, integration and life cycle support of integrated aerospace systems, from fixed and rotary wing air platforms to UAVs and satellites.

• Banu AKTİMUR

Summer Practice METE 300 Fall 2012/2013 Sıla Ece ATABAY

Turkish Aerospace Industries, Inc. Prof. Dr. Vedat AKDENİZ

Wet Lay-Up: Wet lay-up is the oldest method used to manufacture composite materials. In this method the successive plies of reinforcing material or resin impregnated reinforcement are placed and worked on/in a mold . Cure takes place at room temperature by applying a catalyst-promoter or heat in oven. Prepreg Lay-up: Prepregs are pre-impregnated fiber reinforcements or textiles that are used to manufacture composite materials. The lay-up process is done in clean rooms. Wet lay-up process is widely replaced by prepregs. Vacuum Bag Moulding: The sheet of flexible transparent material is placed over the lay-up on the mold and sealed. Vacuum is applied between the sheet and the lay-up in order to remove the entrapped air while curing.

18.06.2012

Work health and safety

Facility and information security

20.06.2012

Flight systems and integration

Manufacturing engineering and capabilities and duties of it

22.06.2012

A brief introduction about the composite and metal bonding (CAMB) building then visit to the building and moved onto the first work place; clean room

21.06.2012

Tool manufacturing process

Machining

Sheet metal unit

Chemical and metallurgical processes

Composite technologiesdirectorate

19.06.2012

Facilities and technical services

Flight path briefing

TAI intern briefing

Introduction of product and FOD

http://www.tai.com.tr/en

Week 1 • Briefing

Week 2 • Clean Room oHumidity, temperature, dust

controlled area. Respectively, 45±10 % R.H., 21 ± 3 ˚ C, 10 micron.

oPrepreg lay-up, metal bonding and vacuum bagging of the projects JSF/F-35, Skorsky CH60-S70, Anka, Boeing AW-139 are done in Clean Room.

oVacuumed products are sent to autoclave to be cured.

Week 3 • Tooling oTooling is manufacturing aids such as

cutting tools, dies, fixtures, gauges, jigs, molds, and patterns of a specialized nature which are limited in use to a specific production line.

oTool manufacturing, wet lay-up, use of molds and dies were observed.

Week 4 • Autoclave oThis area has both autoclave and oven. oAfter lay-up process, composite materials

are taken to be cured, where curing process are done in either autoclave or oven.

Curing Cycle

References 1.Notes and presentations by TAI 2. Notes taken during summer practice 3.http://www.businessdictionary.com/defin

ition/tooling.html

• Established in 1984 for the co-production of F-16 aircraft with the USA, now TAI became Turkey’s center of technology in design, manufacturing, and life cycle support of integrated aerospace systems.

• Banu AKTİMUR (Process Leader) e-mail: [email protected] Phone: 0312 811 1800 / 2568

Summer Practice METE 300 2012/2013 Simge BAKIR

TAI (Turkish Aerospace Industries, Inc.) Assist. Prof. Dr. Yunus Eren KALAY

Hand Lay-up: The plies of reinforcing material are placed and worked on or in a mold by hand. Curing process takes place at room temperature by applying a catalyst-promoter or heat in oven Vacuum Bagging / Autoclave Molding:. After applying vacuum between the sheet and the lay-up, lay-up is placed in autoclave, where both pressure and heat are applied. Resin Transfer Molding (RTM):Dry fibers are placed into tool and the resin is pumped under low pressure through injection ports into the tool.

13.08.2012 • Safety, Health, Information Security 14.08.2012 • Technical Services, Facilities, TAI Intern Briefing, Introduction to Production and FOD 15.08.2012 • Flight Systems, Capabilities of Manufacturing Engineering

16.08.2012 • Tool Manufacturing, Machining, Sheet Metal, Chemical & Metallurgical Applications, Composite Technologies 17.08.2012 • Visiting the Composite and Metal Bonding Facility, Starting With Clean Room, 220

mailto:[email protected]

Week 1 ( MOULDING AND CORE MAKING ) Moulding : It is one of the most important part of casting. Moulding is the process of manufacturing by shaping pliable raw material using a rigid frame or model called a pattern. In Akdaş moulding operation is made manual and green sand moulds are used. Figure 1. Closed Sand Mould. Core making: A core is a device used in casting and moulding processes to produce internal cavities and reentrant angles. The core is normally a disposable item that is destroyed to get it out of the piece. They are most commonly used in sand casting. For core making process , mainly two types of sand are using in this company. These are categorized like resin bounded sand ; shell sand.

Figure 2. Green Sand Cores.

Week 2 (CASTING) Casting is the main part of the production. The

choice of pot is identified with respect to the tonnage and the casting style of the workpiece which will be casted. Then the pots are heated.

Also the lining reddens. The metal which is approved is taken the pot by helping of hoists.

The casting amount of the pot records to related forms and the pot is approached the

basin of degree. The temperature of the metal in the pot is measured and compare with the

temperature in the workpiece production form and recorded too. The samples in the

workpiece production form are taken for spectral analyze and tensile test. In order to keep under the control of rate of casting the runner basins are filled and start the casting.

Also the outwards of gas are fired so as to ease the outgassing.

Figure 3. Casting Pot Figure 4. Casting Process

Week 3 (HEAT TREATMENT) Annealing: For annealing process , high furnace ,

which has two burner heat controlled with a capacity of five tones , is using in this company. Annealing is a generic term used to denote a heat treatment wherein the microstructure and , consequently , the properties of a material are altered.

Figure 5. Annealing Furnace. Normalizing: Normalizing is a type of heat

treatment applicable to ferrous metals only. It differs from annealing in that the metal is heated to a higher temperature and then removed from the furnace for air cooling. The purpose of normalizing is to remove the internal stresses induced by heat treating, welding, casting, forging, forming, or machining. Stress, if not controlled, leads to metal failure.

Tempering: The other heat treatment process that done in this company is called tempering. Tempering is the general term of the quenching , in other words , fast cooling. Fan quenching , oil quenching , water quenching are the tempering types

Figure 6. Water Quenching.

Week 4 (QUALITY CONTROL-NONDESTRUCTIVE TESTS) Penetrant testing: Penetrant solution is applied to the

surface of a precleaned component. The liquid is pulled into surface-breaking defects by capillary action. Excess penetrant material is carefully cleaned from the surface. A developer is applied to pull the trapped penetrant back to the surface where it is spread out and forms an indication. The indication is much easier to see than the actual defect.

Figure 7. Penetrant Testing. Magnetic Particle Testing: A magnetic field is established in

a component made from ferromagnetic material. The magnetic lines of force travel through the material, and exit and reenter the material at the poles. Defects such as crack or voids cannot support as much flux, and force some of the flux outside of the part. Magnetic particles distributed over the component will be attracted to areas of flux leakage and produce a visible indication.

Figure 8. Magnetic Particle Testing. Ultrasonic Testing: Ultrasonic Testing (UT) uses high

frequency sound energy to conduct examinations and make measurements. Ultrasonic inspection can be used for flaw detection/evaluation, dimensional measurements, material characterization, and more. To illustrate the general inspection principle, a typical pulse/echo inspection configuration as illustrated below will be used.

Akdaş was founded in a small rental area with a capacity of 500 tons/year in 1982. Today it has a total of 34 200 m2 closed area and 52.000 m2 open area occupied by two foundries and one machining factory production in the

three plants are operational. Turkey's largest with a capacity of 42 tons of liquid metal casting plants, and 18,000 tons of annual production, more than 65% of it is exported. Akdaş Casting Industry , besides being capable of producing a wide range of casting products in line with customers' demands , manufactures the following parts for the industries listed below: Construction Industry: Wearing parts of earth moving machinery such as shoes , teeth and blades , concrete plant parts. Mining Industry: Parts for jaw crushers , hammer crushers , impact crushers and cone crushers. Cement Industry: Mill liners , hammers , furnace parts and cooling plates. Machine and Chemical Industry: Various parts.

Summer Practice METE 300 Fall 2012/2013 MERVE BESCI

AKDAŞ CASTING AND TRADE CO. YUNUS EMRE KALAY

Week 1 • Job Seminar • Steel Plant Trip • Junk Yard

• Materials Preparing • Electric Arc Furnace

• Melting Operations • Phosphorus Refining • Slag Foaming

First week it is examined first steps of steel production.

This is electric arc furnace

Week 2 • Ladle Metallugy

• Ladle Furnace • VOD Operations • VOD Unit

Second week, it is examine that

basic operations in ladle furnace. Ladle furnace is so ideal for setting the chemical compositions of steel.

This is the ladle furnace.

Week 3 • Ladle Metallurgy

• Homogenization

• Temperature Settling

• Deoxidation

• S Rafination

• Stirring the Ladle

Third week, it is observed chemical operations in ladle metallurgy.

Week 4 • Continuous Casting Operations

• Clean Steel and Steel Noozles • Inclusions • Casting Tundish Ladle

• Laboratory • Spectrometers • X-Ray devices

• Rolling Mill • Types of Rolling Mill

• Rod Mill • Coil Mill • Profile Rolling Mill

Fourth Week, it is observed the last steps of production of steel.

References • http://www.kromancelik.com.tr/

Kroman Demir-Çelik A.Ş. Founded at 25 June 1966 at Gebze in Kocaeli. The Company has two parts in production : steel plant and rolling mill. The company produces semi-steel products yearly 1.100.000 tones of steel. Adress: Emek mah. Aşıroğlu cad. No:155 Tel: 0262 679 20 00 Fax: 0262 653 26 76

Summer Practice METE 300 Fall 2012/2013 Halil İbrahim Binici

Kroman Demir Çelik A.Ş. Naci SEVİNÇ

Week 1 Briefing The fist 4 days passed with education that was

given by the engineers working in the related unit.

.First Day

-Work Health and Safety - Facility and Information Security

. Second Day

-Flight path and intern briefing -Introduction of product and FOD

. Third Day

-Flight systems and integration -Manufacturing engineering and capabilities and

duties of it

. Forth Day

-Tool manufacturing process -Machining -Sheet metal unit -Chemical and metallurgical process -Composite materials

Week 2 Clean Room

. The temperature, humidity and dust are controlled at 21 centigrade, 45

percent of R.H. and 10 micron maximum, respectively in Clean Room.

. Prepregs are pre-impregnated fiber reinforcements or cloths that are used to manufacture composites. The lay-up process can only be done in clean rooms.

. All materials such aspregpregs, adhesives and chemicals must be hold in the cold storage conditions during their rest of time. Therefore, the freezers which it’s temperature is kept at minus 18 centigrade are introduced in Clean Room to keep all these materials.

.Various aircraft parts for the projects like JSF/F-35, Skorsky CH60-S70, Anka, Boeing were observed and lay-ups were done

with the help of vacuum bagging process.

Week 3 Autoclave After lay-up operations in Clean Room, composite

and metal bonding parts are send to the Curing Area which includes autoclave and oven facility with

Computerized process control. In this area, polymerization cycles are controlled. The autoclave features the latest technology for

computerized control and data logging. Curing is closely controlled in a certain temperature, pressure and vacuum cycleadapted to the type of material.

Week 4 Tooling .Tooling used in manufacturing industries to

cut or shape material using a press. Like molds, dies are generally customized to the item they are used to create. Products made with dies range from simple paper clips to complex pieces used in advanced technology.

• Tool manufacturing, trimming,use of molds,dies and cutting tools were observed.

References: 1.Notes and presentation provided by TAI 2.http://www.tai.com.tr

. TUSAŞ Aerospace Industries, Inc. (TAI), the center of technology in design, development, manufacturing, integration of aerospace systems, modernization and after sales support in tukey, was established on 15

May 1984. . Banu AKTİMUR is contact person in the organization. . Hand Lay-up/Contact Molding, Vacuum Bagging/Autoclave Molding Method and Resin Transfer Molding(RTM) are applied process for manufacturing composite materials at TAI. - Hand Lay-up/Contact Molding: The plies of reinforcing material are placed and worked on or in a moldby hand. Curing process takes place at room temperature by applying a catalyst-promoter or heat in

oven. - Vacuum Bagging/Autoclave Molding Method: The sheet of transparent material is placed over the lay-up on the mold and sealed. Vacuum is applied between the sheet and the lay-up. After that bagged lay-

up is placed in autoclave and both pressure and heat are applied to cure the resin-impregnated materials. - Resin Transfer Molding(RTM): Dry fibers are placed into and the resin is pumped under low pressure through injection ports into the tool. Both the mold are resin can be heated as needed for the

application.

Summer Practice METE 300 Fall 2012/2013 DENİZ CERAN

Turkish Aerospace Industries, Inc. Assist. Prof. Dr. Y. Eren Kalay

Week 1 • The first 4 days passed with

education that was given by the engineers working in the related unit.

• A short introduction and visit to the Composite and Metal Bonding Facility (CAMB). Moved on to the first work place; Tooling.

Week 2 Tooling • Tooling is manufacturing aids such

as cutting tools, dies, fixtures, gauges, jigs, molds, and patterns of a specialized nature which are limited in use to a specific production line.

• Tool manufacturing, trimming,use of molds,dies and cutting tools were observed.

• Tool production with wet lay-up was observed and done.

Week 3 Clean Room • Prepreg lay-up and lay up of adhesive-boned

structures like prepreg honeycomb cores are made in Clean Room where temperature, humidity and dust particles are continuously controlled.

• Prepreg lay-up and metal bonding for various aircraft parts for the projects like JSF/F-35, Skorsky CH60-S70, Anka, Boeing AW-139 were observed, and lay-ups were done.

• Helped with vacuum bag moulding processes

for these projects.

• A test specimen with prepreg lay-up was done, sent to autoclave, and results of it were observed.

Week 4 Autoclave • After lay-up, the composite parts must be cured.

Curing takes place either in an oven or autoclave. • Autoclaves are used by the majority of commercial

aircraft companies to manufacture composite structures.

• The polymerization cycles of composite materials are

observed and controlled by a computerized system.

References 1. Notes taken in internship 2. Notes and presentations provided by the company 3. http://www.hindawi.com/journals/ijae/2011/985871/

Established in 1984 for the co-production of F16 aircraft with USA, now TAI is Turkey’s most state-of-art industrial facility for

manufacturing to aircraft assembly. Banu AKTİMUR

Summer Practice METE 300 18.06.2012-13.07.2012 Mete Batuhan DURUKAN

Turkish Aerospace Industries, Inc. Assoc. Prof. Dr. Caner DURUCAN

Wet Lay-Up: Wet lay-up is the oldest method used to manufacture

composite materials. In this method, fibers are laid over a mould surface that has been coated with a release agent and resins are impregnated by using brushes into these fibers.

Prepreg Lay-up: Prepregs are pre-impregnated fiber reinforcements or cloths that are used to manufacture composites. The lay-up process can only be done in clean rooms. The use of prepregs widely replaced wet lay-up.

Vacuum Bag Moulding: Non-adhering plastic film, usually polyester, is

sealed around the layup material and mold plate. A vacuum is slowly created under the bag forcing it against the lay-up. This draws out entrapped air and excess resin thus provides better adhesion.

18.06.2012

Work health and safety

Facility and information security

19.06.2012

Facilities and technical services

Flight path briefing

TAI intern briefing

Introduction of product and FOD

20.06.2012

Flight systems and integration

Manufacturing engineering and

capabilities and duties of it

21.06.2012

Tool manufacturing process

Machining

Sheet metal unit

Chemical and metallurgical processes

Composite technologies directorate

Week 1

Cartridge Case Production

Week 2

Bullet Production

Week 3

Quality & Assurance

Week 4

Tool-Device-Jig Workshop

References


Cavit EYÖVGE

MKE Gazi Cartridge Factory

Advisor: Prof. Dr. C. Hakan GÜR

Cartridge case production is a complex process composed of several deep drawing, cutting, and heat treatment steps. The base material for cartridge case production is brass, which is called as ‘cartridge brass’ for cartridge case production and has a composition of 70% Cu – 30% Zn. Brass is used for cartridge case production due to its characteristic specifications; such as high corrosion resistance, high ductility etc. Production steps of a cartridge case, microstructure and specific properties of the brass used in fabrication are provided below in figures 1, 2, and 3, respectively.

Figure 3: Phase and ductility diagrams of cartridge brass.

Figure 2: Microstructure of cartridge case brass in 400x magnification.

Figure 1: Cartridge case production steps as a flowsheet.

The bullet is the damage causing part of the cartridge propelled by a firearm. A bullet consists of two major parts which are core and jacket. The core material is generally lead (Pb) for normal bullets but in some specific bullet types; such as armor piercing bullets, steel -lead mixture is used. The other part, jacket, reduces the effects of extreme frictional force that may possibly cause fracture of the gunbarrel. The production steps of the bullet and several bullet types are provided below in figures 4 and 5.

Figure 4: Bullet production steps as a flowsheet..

In the “MKE Gazi Cartridge Factoy”, all products coming to the plant and fabricated in the plant are examined before they are sent for any application. These tests are for guaranteeing the security of the laborers during the fabrication process and the quality level and workableness of the finished products. Any item failed at quality assurance tests are rejected for the further applications. Some of the quality & assurance tests are: 1. Hardness test 2. Aging test 3. Neutralization test 4. Leakage test 5. Tensile test 6. Microstructural observation Results of a tensile test and a hardness test are provided below in figures 6 and 7.

0

20

40

60

80

100

120

0 2 4 6

Hard

nes

s (H

RB

)

Distance From Closed End (cm)

Upper Limit

Lower Limit

Figure 6: 9-Point hardness test result of a cartridge case.

Figure 7: Tensile test result of a cartridge case. Figure 5: 7.62mm ammunition with different

bullet types.

The tool-device-jig workshop applies required heat treatment processes to several metals used in the factory. The aim of the heat treatment is adjusting the hardness degree of metals. Some heat treatment processes applied by the tool-device-jig workshop are: 1. Tool steel heat treatment 2. High speed steel heat treatment 3. Water hardening steel heat treatment Heat treatment procedure of high speed steel is provided below in figure 8. Other than heat treatment processes, grinding operations for puncheons or workbench parts are also conducted in the tool-device-jig workshop. According to the time limitation or detail level of the illustration of the part that will be grinded, CNC machines or optical grinding machines are used. CNC machines require detailed illustrations whereas optical grinding machines do not. Working mechanism of optical grinding machine is provided below in figure 9.

Figure 9: Working mechanism of optical grinding machine.

Figure 8: Time-transformation diagram for the production of high speed steel.

MKE Gazi Cartridge Factory meets the requirement of the weapon ammunition of Turkish Army, Turkish Police Organization, and the internal market. Products of the factory are

cartridges, primers, chemicals, and cartridge links. Fabrication techniques include cold extrusion, cutting, deep drawing, and heat treatment processes.

Contact Person: A. Sedat ÖZTÜRK (phone: 0312-211 0162/2151-2351 email: [email protected])

1. Ammunition types for 7.62mm. GlobalSecurity.org - Reliable Security Information. Retrieved from http://www.globalsecurity.org/military/systems/munitions/bullets.htm

2. High speed tool steel transformation. ASM International Homepage | The Materials Information

Society.. Retrieved from http://www.asminternational.org/content/ASM/StoreFiles/06022G_Sample.pdf

Week 1: Work Preparation The projects which was

organized with computer aided design programmes are gained and divided into posses which show more details with the particular dimensions. Next, these posses are analysed by the draftperson and manufacturing department in the company. Manufacturing and quality control department personnels work on both drawing and technical processes together by showing ultimate attention. These posses and their particular dimensions in the drawing project are so important that the product has highly qualified manufactured in a succesful way.

Week 2: Machining Department 1) Sandblasting is a general term used to describe the

act of propelling very fine bits of material at high-velocity under high pressure to clean, etch and smooth a rough surface.

2) Turning is a process which realized with the single point-tool apparatus that produces cylindirical pieces. Generally it is a workpiece that runs and turns around itself and composed of suitable tools. Milling is a metal removing process that tools machine turning around itself and workpieces having motion of linear are combined together.

3) Computerized Numerical Control (CNC) is the machining operation with the aid of computer. CNC machines work hard works and angle operations easily due to computer controlling.

Week 3: Non-destructive Testing Techniques A number of non-destructive test (NDT) techniques have

been developed that permit detection and measurement both internal and surface flaws. Such techniques are used to examine structural components that are in service for defects and flaws that could lead to premature failure; in addition, NDT’s are used as a means of quality control for manufacturing processes.

1)Visual Inspection Test 2)Penetrant Testing

3)Magnetic Particle Testing 4)Eddy Current Testing 5)Radyographic Testing 6)Ultrason Testing

Week 4: Welding Techniques 1) Shielded Metal Arc Welding (SMAW) 2) Gas Metal Arc Welding (GMAW) 3) Gas Tungsten Arc Welding (GTAW) 4) Flux Cored Arc Welding(FCAW) 5) Submerged Arc Welding (SAW)

References: 1) www.nurolçelik.com.tr 2) The guide notes obtained from Derya Büyükbaş

Nurol Machinery and Industry Co. Inc. Steel Industry Co. Steel Works ranks among the top leading Turkish companies as a result of its completion inside and outside the country of significant projects with a high sense of quality through works it has accomplished in industrial facilities, power plants, airports, stadiums and manufacturing and assembling of hangar steel structures, as well as works in contracting and automation of all kinds of mechanical electrical facilities. The manufacturing plant which is located in Ankara on a 75,000 sq.mts of land with 16,000 sq.mts of indoor space has an annual production capacity of 12,000 tons of steel construction and technological machinery-equipment.Nurol Steel Construction Division is suitable for the processes applied; every kind of steel construction and technological equipment, surface works, metal forming, automatic shot blasting, automatic profile cutting/drilling line, automatic beam welding line, CNC pipe cutting/working.

Quality Control and Assurance Chief : Derya BÜYÜKBAŞ ( [email protected] 0312 814 37 10)

Summer Practice METE 300 Fall 2012/2013 Öznur GELLECİ

Nurol Machinery and Industry Co. Inc. Steel Construction Division Prof.Dr. Cevdet KAYNAK

During ultrason testing, there is a specific curve on the screen of controlling machine and if there is an intersection between this curve and ultrasonic reflection lines obtained the material, welding error will be identified by this method.

Summer Practice METE 300 Fall 2012/2013 Öznur GELLECİ Nurol Machinery and Industry Co.

Inc. Steel Construction Division Prof.Dr. Cevdet KAYNAK

Week 1 Pole production was the first observed and examined.

• Steel sheets up to 35 mm are cut by under cooling liquids CNC machineries.

• Steel sheets are bended by press brake.

• Automatic welding is carried out by Automated Submerged Arc Welding (SAW) longitudinally.

• Manual welding is carried out when there is a need for detailed welding.

Bending Machine Welding

Week 2 Quality control proceses of poles are observed .

• At the laboratuary, tensile test , charpy impact test and chemical composition test are done.

• Inspectors from MITAS and also from other companies work during the whole production process.

• When welding process finished non-destructive tests like ultrasonic test, magnetic test are done.

UT MT

Week 3 Galvanization process and process details are examined. • Galvanization is the process of

applying a protective zinc coating to metal to prevent rusting and corrosion.

• Hot-Dip galvanizing is a coating method performed by dipping iron and steel products to a molten zinc bath at 450°C,

• Hot -Dip galvanizing process‘ steps are: oil removal (washing), surface cleaning with acid treatment, rinsing, fluxing, drying, galvanizaion, cooling and passivation.

Hot-Dip Galvanization

Week 4 Inspection of galvanized poles is observed.

• For the optimum coating quality defined in the standards, steel composition should be given below:

Si% < 0.04 or 0.15 < Si% < 0.25

C% < 0.25, P% < 0.05, Mn% < 1.3

Si% + (2.5xP%) < 0.09

• Coating thickness in zinc coated materials is inspected by means of electronic micrometer.

• In addition to these acid peeling test, bending test are done.

References • http://images.google.com/ • http://www.mitaspole.com/ind

ex.php • http://www.mitastelecom.com/

• MİTAS was established in 1955 in Ankara. The main fields of the company are lighting poles, energy transmission lines, GSM poles, advertisement poles, bolt and nut production, and hot-dip galvanizing. Further to these in the company subgroups like MİTENG work on desing of some components produced in the company. MITAS carries out these activities in its total 82,000 m2 manufacturing facilities, of which 42,000 m2 is indoor with an annual capacity of 20,000 tons, exports to more than 110 countries all around the world.

• In MITAS, poles with polygonal and round conical section are welded with proper method of welding an then hot dip galvanized in the 14 m length tank, with fully-automatic centrifugal galvanizing unit, which is the only one in Turkey.

Contact person: Selçuk SAKINMAZ (Management Representative & Quality Manager) e-mail: [email protected] telephone: 0312 2962000

Summer Practice METE 300 Fall 2012/2013 Özlem GERÇEK

MİTAŞ Pole Industry and Trade Inc. Prof. Dr. Naci SEVİNÇ

References

• TAI was established by Turkish and US partners for the co-production of F-16 aircraft in Turkey and became the center of aerospace systems. Tai manufactures aircrafts, their parts and satellites with the capacity of produce composite and metallic equipment Tolga BALCI ([email protected])

.

Summer Practice METE 300 Fall 2012/2013 Berfu GÖKSEL

TAI Prof. Dr. Rıza GÜRBÜZ

Week 1 : Training Week

First days of the week, briefings about the history of

TAI,

what are made in TAI ,occupational health and

safety ,

and security are given.

On the following days production, composite

materials and tool manufacturing are

introduced. Tour is organized to the 10th building.

Week 2 Tooling In tooling department tools are

prepared to make products.

There are different types of tool

• Nickel Tools : The machining is easy and thermal expansion is

low

• Steel Tools: The machining is not easy as the machining of nickel but thermal expansion is low.

• Aluminum Tools : The machining is easy but thermal expansion is

bigger than other metal tools.

• Composite Tools : The composite tools are obtained

with lay-up process. The thermal expansion is the most ideal one

for composite manufacturing

A Representative Steel Tool

A Representative Composite Tool

Week 3 Clean Room Clean room is where composite and metal bonding applications are done. After composites are placed they undergo vacuum pumping to make sure that composites are stacked each other without air bubble. During the lay up dust-free environment should be provided, since then clean rooms have controlled atmosphere.

Precision Milling Machine, which is used in F35 planes, and

Automated Fiber Placement Machine are in this room

Clean Room

Automated Fiber

Placement Machine

Precision Milling

Machine

Week 4 Autoclave After the composite and metal bonding applications products are sent to the autoclave. Autoclave is where products are cured with high pressure and heat. The curing cycles are taking hours. In the autoclave pressure is supplied with nitrogen gas. Both temperature and pressure are equal everywhere in the autoclave. Temperature is measured by thermocouples. After vacuum-pumping thermocouples are attached to the products. There are four autoclaves with different sizes at TAI. After the autoclave products and tools are seperated, then prouducts are sent to routing and coaitng.

Autoclave

1. www.tai.com.tr 2. http://www.engineershandbook.com/MfgMetho

ds/autoclavemolding.htm

Week 1 In the first week, Tooling

section of the CAMB(Composite) building is observed. In tooling, sensitive composite molds(Tools) for composite materials are produced. Materials used for the processes range from carbon fiber to kevlar.

-Carbon F. and Kevlar Clothes- -A Carbon fiber tool for composite Materials- In general, several fibeclothes and epoxy resin are used in manifacturing tools. Then tools are vacuumed and sent into autoclaves.

Week 2 Cleanrooms are specially

designed rooms to provide certain conditions for aircraft parts.These rooms are temperature, pressure, dust and humidity controlled. Sensitive conditions are necessary for production of most aircraft composite parts.

Ply cutters cut the prepregs in desired shapes, then layers of prepregs(composite fibres where epoxy resin is already present) are applied on metal molds. The processes involves several vacuuming operations and finally curing in autoclave furnaces.

Week 3 Another cleanroom is cleanroom

number 2. In this area, JSF/F-35 aircraft parts are produced.The cleanroom has an automatic fiber laying machine.All production conditions are applied here too.

Most composite parts have

honeycomb sandwich structure(Core) in them. Cores are very light and greatly strengthen the composite material.

-Structure of F-35 motor intake produced in cleanroom 2-

Week 4 Autoclave furnaces are the furnaces

used for curing the prepared composite materials. Sensitive presssure and temperature control enables precise production of important aircraft parts.

-A composite material ready for curing in Autoclave furnace- TAI has 5 autoclaves With different size and capabilities ranging from 232 to 450 C in temperature and 145 to 250 psi in pressure.

References TUSAŞ- Havacılık Sanayiinde Kompozit

malzeme uygulamaları,2012

Turkish Aerospace Industries Inc.(TAI) located in Kazan,Ankara manifactures aircraft parts and vehicles for both Turkish and other aviation industries around the world .

Responsible Engineer: Banu Aktimur.

Summer Practice METE 300 Fall 2012/2013 Faruk KIRILMAZKOL

Turkish Aerospace Industries Inc. Prof. Dr. İshak KARAKAYA

Weeks 1-2-3 Laser Cutting & Drilling: Process in which sheet parts are cut, and holes are created with Nd-YAG lasers. Faster and cheaper than other cutting techniques. Sheet parts with thickness up to 4-5 µm are cut. Electrical Discharge Machining(EDM): Nonconventional electrochemical material removal process as a result of sparks formed between electrodes and workpiece. In TEI, there are three types of EDM: fast hole drill EDM, wire- cut EDM and sinker EDM. Chemical Milling (Chemmill):Chemical material removal process in which sheet engine parts are milled in strong acid solutions. Important parameters are solution temperature, acid type and concentrations, part thickness. During my internship, I prepared a report concerning problems widely encountered in chemical milling process and what can be solutions to these problems. Brazing: Joining process in which parts made from different materials and in different sizes can be joined. Braze solution is injected between two parts and cured in vacuum furnace, the step where diffusion

occurs.

Weeks 4-5-6 Electrochemical Machining (ECM): Electrochemical material removal process for production of "blisk", bladed+disk. In process, electrolyte passes between electrodes (molding blocks) and workpiece. Workpiece take mirror shape of molding blocks. Differences from EDM are to consist of electrolyte and not to be processed by sparks. Inertia Weld: Type of welding process. Spool, a compressor module consisting of numerous disks and a shaft, is produced by this method. Two parts are welded together by means of diffusion, which is formed as a result of friction between rotating part in contact with other part. Sermetel Coating & DryLube: Sermetel is applied for corrosion protection of carbon steel engine components. Parts are coated with an aluminum chromium powder mixture. Dry lube is solid greasing of areas between two matched parts. Parts are coated graphite film which eliminates galling and seizing, and reduces friction under heavy loads. I calculated First Time Yield (FTY) for 6 months in 2012 for sermetel operation within the scope of 6 Sigma strategies. I observed inspection methods in Non-Destructive Testing and Metallography & Chemical Lab. departments throughout these weeks. I also performed contact ultrasonic inspection manually.

Weeks 7-8 Nickel & Chrome Plating: Coating process for corrosion protection, and also for maintenance & repair operations of used engine parts. By electrochemical means, nickel, or chrome, are deposited onto workpiece in nickel, or chrome, solution tanks. In TEI, nickel plating is more widely performed than chrome plating. Macro Etch & Blue Etch Anodize, Black Oxide: Macro etch is NDT method to observe the imperfections on the surface of the parts. It has the same mechanism with metallographic etching. Blue Etch is also NDT method for the same purpose, but it is only used for titanium parts. Black oxide is a coating process that provides corrosion protection for low alloy steels. Alkaline Cleaning: Removal process of deburr, oil, chemicals remaining after chemical processes and dirt from the parts’ surfaces in order to prepare a clean surface to further operations. I performed an experiment to observe corrosion rate of alloy steels in chloride environment and I prepared a report by its results.

Weeks 9-10 Heat Treatment: Comprises solutionizing, ageing, stress relieving and brazing processes in vacuum furnaces. Shot Peening: Process in which the stress at the surface of the parts is relieved to increase fatigue strength of the parts. Shots which are made up of mild steel or cast iron are sprayed towards the parts with certain velocity at a specific angle. Parts take opaque apperance and rough surface structure. Thermal Spray Coatings: Process where matched and gear parts are coated with harder and wear- resistant materials for wear protection. Grit blasting step is extremely important for thermal spray coating quality. Grit blasting is a process in which Al2O3 grits are sprayed toward workpiece in order to provide rough surface for better adhesion of coating. In TEI, there are 2 types of thermal spraying; HVOF and plasma spaying. During my intership, I translated glossary of terms and certain chapters from ASM Handbook of Thermal Spray Technology into Turkish (~120 pages). Also, I manually performed grit blasting operation of a fan shaft engine component.

References 1. Retrieved from http://www.runsom.com/Electrical-Discharge-Machining.html

2. Retrieved from http://trsavunma.com/?q=node/40951

3.Retrieved from http://www.galvanoplastie.fr/modpub/modules/cms/upload/dir_3/medium_368a

49bc08dcfca7bb580bbb01f17eab.jpg

4.Retrieved from http://theyo.com/yoyo/yoyo-mods-maintenance/62225-

sandblast-question.html

5.Retrieved from http://www.fischer-wesnigk.de/index.php?loc=HVOFpulver

TEI is established in 1985 with the partnership agreement signed by Turkish partners (53.78%) and General Electric (46.22%). TEI’s Turkish partners are TUSAS-Turkish Aerospace Industries INC., Turkish Armed Forces Foundation and Turkish Aeronautical Association. The products manufactured in TEI are steel, aluminum alloy, titanium alloy and superalloy fan disk, turbine and compressor disks and exhaust parts of civil and military aircraft egines. Contact person: Erkan ÜNSAL, Special Process Leader Phone: +90 222 211 23 67 E-mail: [email protected]

Summer Practice METE 300 Fall 2012/2013 Seda OTURAK

TUSAŞ Engine Industries, Inc. Advisor: Prof Dr. Amdulla MEKHRABOV

Figure 1. Wire-Cut EDM Process. [1]

Figure 2. Swirl frame

component produced by

brazing.

Figure 3. Blisk during inspection. [2]

Figure 4. Blue-etched parts. [3]

Figure 5. Manual grit

blasting booth. [4]

Figure 6. HVOF process. [5]

Week 1

Orientation week

First two days giving information

about the history of TAI and

trainings involve security and

Occupational health done.

Remaining three days

detailed information about

products of TAI are given.

Also 10th building is visited.

Week 2

Tooling

According to the order from firms or

designs tools are made at tooling,

then aircraft parts are made from

these tools. There are different

types of tools; nickel tools,

aluminum tools, steel tools and

composite tools.

This week sheet metal is also

visited.

Week 3

Clean Rooms

Clean rooms have a low level of

pollutant such as dust , aerosols

particles and have higher pressure

than outside in order to quality of

products. Manufacturing composite

products ,lay up process , vacuuming

take place in there.

Ply cutter machine ,mechanical fiber

placement machine and precision

milling machine are also in clean

rooms.

Week 4

Autoclave Products that undergo vacuuming come to

autoclave. In autoclave the products are

exposed to high pressure and high

temperature. Temperature is quantified by

way of thermocouples. After autoclave d

products are controlled and seperated

products that are faulty.

References


Didar TÜRKCAN

TAI

Prof.Dr. Ali Yavuz Topkaya

TAI , established in 1984 , has grown to become largest aircraft manufacturer in Turkey , and is emerging as a globally recognized.

Tolga BALCI ([email protected])

www.tai.com.tr

www.pronal.com/en/composite,manufacturing,products.

php

Week 1 (Desulphurisation Plant): Aim: To reduce sulphur level in pig iron in torpedo via injection

method. Injection Methods: Mono-injection:CaO Co-injection:Mg + CaO

Also, in both injection methods CaF2 is used to increase refractory usage time.

Figure 1:Desulpurisation Process Figure 2: Lance After Desulpurisation

Reasons of Desulphurisation:

– Embrittlement during manufacture and use

– The incresaed requirements of steel quality

– Reduced Scrap Quality and increasing cost high quality iron ores (low sulphur content iron ore)

Capacity of Desulpurization Plant: 81 torpedo/day (2 conveyors)

81x 110 = 8910 tons pig iron/day (average)

Blowing Time: Blowing takes approximately 19-20 minutes in mono-injection method. In co-injection method, blowing takes approximately 25-26 minutes. Mg is used to decrease blowing time in co-injection method.

Figure 3:Control Monitor Figure4:Desulpurisation Result Monitor

Actions taken for Sulphur Reduction at Erdemir Steelmaking Plant:

Increase in hot blast temperature,

High top pressure at Iron Blast Furnaces,

Increase in sinter percantage in burden,

Action to decrease Al2O3 in Iron ore ( Lumps and Fines),

Use partial Briquette blended coal charge (PBCC).

Week 2 (Calcination Plant) Aim: To produce lime (CaO) from limestone CaCO3 by burning at the Double Shaft Furnaces. Metallurgical lime produced in lime kiln is used in Basic Oxygen Furnaces (B.O.F.). Lime fines are used in the sinter plant. Capacity:The capacity of the 3. and 4. Kiln Furnaces are 300 tons/day and 600 tons/day respectively. Double Shaft Furnaces: These typically consist of a pair of shafts, operated alternately. Each of these furnace make 114 cycles per day. The furnaces work the principle of Counter Current Operation, which means solids and gases move opposite direction. Figure 5:Principle of the Furnaces[3] Figure 6: Double Shaft Furnace [4]

Fuels Types: Natural gas, Fuel, Coke gas. Figure 7: Calcination Process [5] Calcination of limestone CaCO3: CaCO3 CaO + CO2 ΔH= +42.5 kcal/ gram.mole (Strongly Endotermic)

Week 3 (Basic Oxygen Furnace (B.OF)) Aim : 1) To oxidize mainly carbon, and the other elements such as Si, Mn, P by given pure oxygen to pig iron. 2)To remove the formed oxide inclusions from the hot metal by slag makers such as lime and dolomite. Technical Descriptions:There are 3 converters in Erdemir B.O.F plant. The average capacity of them is 3 300 000 tons/year. The blowing time of O2 is approximately 15-16 minutes. LD-S types of converters have the ability of blowing and mixing simultaneously. Argon is used for mixing. Also addition of some elements such as Ferro Vanadyum, molybdenium is possible. Main Reactions at B.O.F. Process: 1) 2Mn + O2 2MnO (In Slag) 2) Si + O2 SiO2 (In Slag) 3) C + O2 CO2 (g.) 4) C + ½ O2 CO (g.) 5) 4P + 5O2 2P2O5 (In Slag) 6) 4Fe + 3O2 2Fe2O3 (In Slag) Figure 8: Scrap Charging Procee Description: 1. The converter is one-fifth filled with steel scrap. Molten iron is added

until the converter is full. Filling the converter with the ingredients is called charging.

1. Process 2. Process 3.Process 4.Process 5.Process 2 . The converter is then stood upright and an oxygen lance is lowered down into it. The lance blows 99 percent pure oxygen onto the steel and iron, causing the temperature to rise to about 1700°C. This melts the scrap, lowers the carbon content of the molten iron and helps remove unwanted elements. 3. Fluxes (burnt lime or dolomite) are fed into the converter to form slag which absorbs impurities of the steelmaking process. Near the end of the blowing cycle, which takes about 20 minutes, a temperature reading and samples are taken. The samples are tested and a computer analysis of the steel is given within six minutes. 4. The converter is tilted again and the steel is poured into a giant ladle. This process is called tapping the steel. In the ladle furnace, secondary metallurgy is applied to the steel. ( Addition of some alloying elements) 5. After the steel is removed from the converter, the slag, filled with impurities, is poured off and cooled. [6] Figure 9: Pig Iron Charging

Week 4 (Secondary Metallurgical Process (SMP)) Aim: To obtain the wanted material composition before continuous casting. The desired

composition can be achieved by adding elements, compounds or wire feeding such as Al and Ca-Si wire feeding.

Technical Descriptions: Heating operation is done by Electric Arc Furnace (E.A.F).This Furnace has the capacity of 13800 kV and mixing and heating can be done simultaneously.. Temperature is the main parameter in this system before continuous casting. It is mainly determined with respect to C and Mn composition in the steel. Firstly, liquidus line temperature is determined by C and Mn composition. The leaving temperature at SMP 15 °C higher than this temperature before continuous casting.

Process Descriptions: After the B.O.F Plant, the steel is delivered to the secondary metallurgy plant in

which secondary steel making processes are applied to make fine adjustments to the steel composition.

In the secondary metallurgy plant, according to the temperature and chemical composition of the steel the following processes are applied:

• Argon purging • Heating-cooling • Alloying • Ca-Si injection • Decarburizing under vacuum In this way, the steel is refined such that it becomes suitable for the planned casting

quality and continuous casting conditions. Figure 10:Decarburizing Under Vacuum [7] Figure 11: Pig Iron Before SMP (Slag Comp. Low) Figure 12:E.A.F. at Process E.A.F after Process Steel at E.A.F. Steel after SMP

REFERENCES: [1].http://en.erdemir.com.tr/aboutus [2].http:// en.erdemir.com.tr/ProductFacilities

[3].http://en.wikipedia.org/wiki//Lime_kiln

[4].http://www.polysiusuna.com/news/lime.expertise.html [6]-[7]. Erdenir Tanıtım Sunusu

[5]. http://www.sciencedirect.com/science/article/pii/S0360544211001010

Ereğli Iron & Steel Works Co. (ERDEMIR) was founded in 1960, and started to produce crude steel in 1965. The main products of Erdemir are Hot-Rolled Flat Steel products Cold Rolled Sheets and Coils, Galvanized/Galvanealed Sheets and Coils, Electrolytic Tin Plate and TFS. [1]

Hot Rolled Coils, Sheet And Heavy Plates: Hot rolled products are obtained via continuous casting process of rectangular shaped slabs, which are then hot rolled into 1.50-20.00 mm thickness range. Cold Rolled Products:Cold rolled materials have homogeneous physical properties throughout the whole coil and their surface smoothness, width and thickness consistencies are perfected to meet industry expectations. Galvanized / Galvannealed Products: Hot dip galvanized steel products are obtained by continuously coating both sides of cold rolled materials with a layer of zinc. Tinplate Products: Electrolytic Tinplate is a cold-rolled low carbon mild steel sheet or coil manufactured in 0.12-0.60 mm thickness and coated on both surfaces with tin in various coating weights. [2]

İsa Keskin Process Engineer at Steelmaking Plant e-posta: [email protected] Telephone Number: 0372 329 30 40

Summer Practice METE 300 Fall 2012/2013 Emrah Yalınız

Ereğli Iron & Steel Works Co.(Erdemir) Steelmaking Plant

Assist. Prof. Dr. H. Emrah Ünalan

Week 1 Steel-Mill Desulphurization Basic Oxygen Furnace Process Secondary Metallurgical Processes RD Vacuum Degassing Facility Continuous Casting

Week 2 Plate Mill Normalization Furnace Hot Strip Mill No.1 Slab Reheating Furnaces Combination mill Strip Mill Hot Strip Mill No.2

Week 3 Cold Mill No.1 Acid Regeneration Plant Batch Annealing Line Continuous Annealing Line Electrolytic Tinning Cold Mill No.2 Continuous Pickling/Tandem Line Continuous Annealing Line Continuous Galvanizing Line

Week 4 Quality Technology &Metallography Laboratories

and Specification Optical Spectrometers X-Ray Diffractometer Thermal Analyze Equipments Specimen Preparation/Analysis Equipment Tensile and Hot Tensile Test Machines Load, Bending, Drop-Weight tear testing and

Charpy impact, Surface Roughness Measurement and Hardness Testing Devices

Optical Microscopy, SEM-EDS Gleeble Dilatometer

References

Erdemir is the largest Iron and Steel Works company and the only integrated flat steel producer with its crude steel production capacity of over 3 million tones/year. By producing steel in conformity with the international quality standards using modern technology, Erdemir provides inputs for various sectors varying from pipe and profile, machinery ship-building, packing, to automotive and by-industry and home and Office equipment, and creates added value for economy.

Summer Practice METE 300 Fall 2012/2013 Şimal Cemre YAMAN

Ereğli Demir ve Çelik Fabrikaları T.A.Ş Prof. Dr. Cemil Hakan GÜR

Contact Person : Dr. Oktay ELKOCA Hot Rolling Mills

Metallurgy and Product Development Chief Engineer

Tel: 0 372 329 34 52 E-mail:

[email protected]

Image9: Scanning Electron

Microscope

Image10: H13 Tool Steel on

Optical Microscope

Image1: Basic Oxygen Furnace

Image2: Continuous Casting

Image3: Defects on Slabs

Image4: Hot Stril Mill No.2

Image5: Normalization Process

Image6: Defects on Hot Worked Material

Surface

Image7: A sheme of Cold Mill Plant

Image8: Final Cold Worked Product

www.erdemir.com.tr

Week 1

References www.cemtas.com.tr

Summer Practice METE 300-Fall 2012/2013 ÖZGÜN ÇEPELİOĞULLAR

ÇEMTAŞ ÇELİK ve MAKİNE A.Ş. Prof.Dr.Cevdet Kaynak

Çemtaş Çelik ve Makina Sanayi A.Ş is one of the biggest qualified steel producer in Turkey. Every year Çemtaş produces over than 350 000 tones of qualified steel for automotive and with many different qualities for many different applications in the industry. Çemtaş Çelik ve Makina Sanayi A.Ş. Established in 1970 on a 110000 m2 area in Bursa Organized Industrial District with the help of merge of Industrialists, businessmen, small craftsmen and public entrepreneurs. Full address of the Conpany: Organize Sanayi Bölgesi A.O.S. Bulvarı, NO:3 16159 BURSA Contact Person in the Organization Tel: 224 243 12 30 e-mail:[email protected]

St37-2 Structural Steels St(42,44,50,60,70)- Structural Steels SAE 1010 - 1090- Carbon Steels Case Hardenıng Steels Quenched And Tempered Steels Mıcro Alloyed Steels Free-cuttıng Steels Sprıng Steels Carbon Tool Steels Staınless Steels Boron Steels

PRODUCTS

Steel Plant Area observations;

Electric Arc Furnace Ladle Furnace Vacuum Degassing Wire Injection Station Continuous Casting

Machine Accumulation of dust

are examined in steel plant area with engineers.

Figure 1. Electric Arc Furnace

Week 2 Rooling Mill observations;

Qualified Steel Rolling Mill Reheating Furnace Sandblasting Machine Sensitive Straightering

Machine Surface Crack Tests

examined with rolling mill engineers.

Figure 2. Cooling bed at Rolling Mill area

Week 3 In week 3 quality department is examined.

Destructive tests

Non-Destructive Tests

Week 4 In the last week of my summer practice, I had chance to make general observations both ın production parts, quality department and research and development studies in the area. Raw material procurement area Servo test “road bend stabilizer

bar” fatigue tests. General observations at Steel Plant

and Rolling Mill area.

WEEK 1 : ROLLING MILLS

In the first week at rolling

mills unit, rehating

furnace, the oxide layer

removing, rolling mills,

continuous rolling mill,

cooling platform, cutting

and packaging are

observed. During this

period, there was the

production of lamellar

and round steels.

WEEK 2: STEEL PLANT

In the second week at steel plant

the tundish, continuous casting,

ladle furnace and electric arc

furnace are observed. Plant was

producing 160x160 mm ingots

during this period.

WEEK 3: QUALITY & CONTROL UNIT

Third week, in quality&control unit

there were 2 different control tests. In

destructive tests, spectrometer

analysis, jominy test, charpy impact

test, tensile and hardness test, sulphur

print test and metallography

applications are observed. In non-

destructive tests, surface crack test,

ultrasonic inspection test and portable

spectrometer are observed.

WEEK 4: SCRAP UNIT & STABILIZER BAR

In the last, 4th, week, scrap ( raw

material ) producement area,

stabilizer bar (newest investment)

and different sorts of scrap is

observed. Also, general

observations at Steel Plant, Rolling

Mills Unit and Quality&Control unit

are made.

References: 1) www.cemtas.com.tr 2) The guide notes obtained from İrfan Ayhan

Çemtaş Makine ve Ticaret A.Ş. İs one of the biggest quality steel suppliers in Turkey. ÇEMTAŞ has nearly 300 000 tonnes steel production every year in different kinds. ÇEMTAŞ usually produces the parts used in automobile companies or like. ÇEMTAŞ was established in 1970 on a 110 000 m2 area in Bursa Organized District as a joint stock companyFull address of the Company: Organize Sanayi Bölgesi A.O.S. Bulvarı, NO:3 16159 BURSA

Contact Person in the Organization Tel: 224 243 12 30 E-mail:[email protected]

Summer Practice METE 300 Fall 2012/2013 Öznur GELLECİ

Nurol Machinery and Industry Co. Inc. Steel Construction Division Prof.Dr. Cevdet KAYNAK

Summer Practice METE 300 Fall 2012/2013 Murat İLERİGELEN

ÇEMTAŞ Machinery and Industry Co. Inc. Prof.Dr. Ali KALKANLI

ÇEMTAŞ STEEL PLANT

ROLLING MILL UNIT

QUALITY & CONTROL UNIT

SCRAP UNIT

THE COMPANIES THAT ÇEMTAŞ A.Ş. WORK WITH

Week 1 Several important

information have been given about TAI such as; •Occupational health •Facility and information

security •Flight line briefing •FOD

Week 2 During second week of the

summer practice composite tool manufacturing and routing have been observed.

The steel tool are came tooling before send clean room

Routing of excess side of the composite are done at the routing department.

That is first and the last step of production have been observed at the second week.

Week 3 Clean rooms have been observed

during the third week

Naturally it is most important place for composite manufacturing.

It should be under positive pressure to keep the room clean.

Also temperature is fixed at 22 C.

Lay-up process includes not only man power but also machines

Structural parts of some important famous firm such as;

Boeing, Airbus, F-35 are produced in here.

Week 4 Autoclave and painting place of the

building have been observed at the last week.

In order to fasten the polymeric reaction of prepeg the roasting is a vital step.

It should be done under pressure which is determined by type of prepeg used.

Lastly after routing those materials need to be painted to avoid corrosion.

References

1. www.tai.com.tr

2. Human resources manegement of TAI

TUSAŞ Aerospace Industries is the center of technology in design development manufacturing integration of aerospace systems

modernization and after sales support in Turkey. There are several products manufactured and process applied such as composite part production, sheet metal production, machining, chemical and metallurgical process(heat treatment), detail piece painting and assembly. Banu Aktimur ([email protected])

)

Summer Practice METE 300 Fall 2012/2013 DOĞA DOĞANAY

TUSAŞ-TÜRK HAVACILIK VE UZAY SANAYİİ A.Ş Assoc. Prof. Dr. Arcan Dericioğlu

http://www.tai.com.tr/

Week 1 ( Steel plant proceedings ) ELECTRIC ARC FURNACE

The basic set-up of the electric arc furnace consists of a furnace shell with a roof on top. The furnace shell is lined with ceramic bricks (carbon bonded magnesia bricks) insulating the furnace from the liquid steel. On the upper side walls and on the inside of the roof, water cooled elements are used instead of ceramic insulation. These water cooled panels are positioned so there will be no direct contact with the liquid steel. Before the melting and heating operations start, the furnace is charged with recycled steel scrap using a scrap basket that has been carefully loaded at the scrap yard. After scrap charging, the roof is closed and three graphite electrodes are lowered towards the scrap. The electrical power is switched on and on contact electrical power is transformed into heat as arcing takes place between the electrodes and the solid feedstock. As the scrap melts, a liquid steel pool starts to form at the bottom of the furnace.

Melting: The melting stage in the EAF starts when the operator switches the furnace power on after charging the first basket. From that point and onwards the operating conditions of the EAF changes throughout the heat, starting with melting of cold scrap and ending with superheated liquid steel at a temperature above 1650 °C as it can be seen from Figure 1.

Tapping: Tapping of the furnace is initiated by the operator when the processing in the furnace is finalized and the target temperature has been reached as it can be seen from Figure 2. Tapping should be performed as fast as possible in order to save time.

Figure 1: Melting Figure 2: Tapping

Casting: Casting is the last statement at steel plant. Different kinds of carbon steel and alloy steel are casted into the moulds as it can be seen from Figure 3.

Figure 3: Casting

Steels Which Are Produced in Steel Plant: low-carbon steels ( 1010, 1040, … ), high-carbon steels ( 1090, 10100, … ), case hardening steels ( 3315, 4120, 8620, … ), hot work tool steel .

Week 2 ( Forging workshop doings )

3000-TONS PRESS 3000 tons press is controlled by a person in the main control centre. A

hydraulic system runs up and down movements. 3000 tons press can beat with a maximum 19-ton blocks of. All kinds of carbon-steel and alloy steel can be forged. Steel blocks are shaped such as round and square. Annual forging capacity could be 800 tons. Maximum 10.000 mm steel can be forged. 3000-tons press can be seen from Figure 4.

Figure 4: 3000-tons press

GFM ( CONTINUOUS FORGING PLANT )

GFM provides fully automatic or manually forging on steel blocks that are produced in steel mill. There is a returns-based annealing furnace which belongs to GFM. There are four forging hammer on GFM bench. These hammers can be opened up minimum 90 mm and maximum 450 mm. These four hammers can beat totally 3200 tons to the forging material. Hammers can be changed according to the diameter of the material. The annual forging capacity of GFM continuous forging plant is 12.000 tons / year. Maximum forging length is 10.000 mm. GFM can be seen from Figure 5.

Figure 5: GFM Figure 6: Harness parts

HAMMER BENCH

Hammer bench is a workshop where free forging and forging-in-pattern processes are applied. Thanks to forging-in-pattern method, various parts are produced from all kinds of carbon and alloy steels. The products are;

• Harness parts belonging to DDY ( Devlet Demir Yolları ) as it can be seen from Figure 6, • Screw shaft, • Piston rod, • Traction couplings, • Flange of the barrel of a heavy weapon system.

Week 3 ( Heat treatment ) ANNEALING

Annealing involves heating the steel to a designated temperature and holding it for a specified period of time before cooling. Different annealing processes use different annealing temperatures, holding times and cooling rates to achieve the final microstructure and properties required. Annealing furnace can be seen from Figure 7.

Figure 7: Annealing furnace Figure 8: Water quenching

NORMALIZING Normalizing is the heating of steel to above its critical temperature followed

by an air cool. The piece is usually left somewhere warm ( like near the forge ). Normalizing is a quick method of softening a piece to the point where one could heat treat ( harden and temper ) it for use. From Graph 1, normalizing program of AISI 4340 Steel can be seen.

Graph 1: Normalizing program of AISI 4340 steel

QUENCHING ( HARDENING ) Hardening can be performed by rapid cooling, which is also known as

quenching. During quenching, there is insufficient time for the diffusion-controlled decomposition of austenite to ferrite and pearlite. Instead, a diffusionless transformation takes place, in which martensite is formed. Martensite is a very hard phase, therefore the steel becomes very hard and brittle. Quenching, therefore, is usually followed by a tempering treatment to regain some toughness and ductility in the steel. There are three types of quenching which are salt bath quenching, water quenching ( as it can be seen from Figure 8 ) and oil quenching.

TEMPERING

After quenching, the steel microstructure will typically comprise martensite and retained austenite. Tempering is used to reduce the detrimental effects ( e.g. extreme brittleness ) caused by hard martensite without losing the beneficial properties gained during quenching. A wide range of tempering temperatures may be used, depending on the application and steel grade and, therefore, the final properties required.

Week 4 ( Quality control )

TENSILE TEST

Tensile test, also known as a tension test, tests a material’s strength. It is a mechanical test where a pulling force is applied to a material from both sides until the sample changes its shape or breaks. It is a common and important test that provides a variety of information about the material being tested, including the elongation, yield point, tensile strength and ultimate strength of the material. Tensile tests are commonly performed on substances such as metals in MKE.

CHARPY IMPACT TEST

Charpy impact test, also known as the Charpy V-notch test, is a standardized high strain-

rate test which determines the amount of energy absorbed by a material during fracture. This absorbed energy is a measure of a given material’s notch toughness and acts as a tool to study temperature-dependent ductile-brittle transition. It is widely applied in MKE, since it is easy to prepare and conduct and results can be obtained quickly and cheaply.

DYE PENETRATION TEST

This test is a very easy method to determine the surface cracks. Red BT-68 spray is

tightened to the surface of the material. In 15 minutes the dye is impregnated with the cracked region of the material. Then White BT-70 spray is tightened to the surface of the material. Thus, it is possible to see all regional cracks after second spray.

ULTRASONIC INSPECTION

Ultrasonic testing uses high frequency sound energy to conduct examinations and make

measurement. Ultrasonic inspection can be used for flaw detection / evaluation, dimensional measurements, material characterization and more. A typical ultrasonic inspection system consists of several functional units, such as the pulser, transducer and display devices. A pulser is an electronic device that can produce high voltage electrical pulses. Driven by the pulser, the transducer generates high frequency ultrasonic energy. The sound energy is introduced and propagates through the materials in the form of waves. When there is a discontinuity ( such as a crack ) in the wave path, part of the energy will be reflected back from the flaw surface. The reflected wave signal is transformed into an electrical signal by the transducer and is displayed on the screen. From the signal, information about the reflector location, size, orientation and other features can be gained. As it can be seen from Figure 9, there is a 4.11 mm diameter crack inside the steel block.

Figure 9: Ultrasonic inspection machine

References [ 1 ] http://www.mkek.gov.tr

MKE Heavy Weapon & Steel Factory was established in between 1932-1937. It is the first and the only factory

which produces heavy weapons and quality forged steel material. It produces 105 mm tank gun, 155 mm howitzers, 60 mm, 80 mm, 120 mm mortars. In addition, ammunition materials, various types of forged steel materials, barrel materials, breech, breech ring materials, tube forged piston and cradle materials can be produced [ 1 ].

MKE Heavy Weapon & Steel Factory has 123.982 m² covered and 682.730 m² open area. It has AQAP-2120 and ISO 9001-2008 quality assurance system certificate [ 1 ].

Steel Plant Engineer: Fatih Kayı ( [email protected] 0 534 614 52 95 )

MKE Heavy Weapon & Steel Factory is suitable for below processes applied: • Steel plant proceedings: All kinds of carbon steel and alloy steel can produced from electric arc furnace by casting. • Forging workshop doings: The steel blocks can be forged by 3000-tons press or GFM ( Continuous Forging Plant ). • Heat treatment: The materials can have superior qualities after annealing, normalizing, quenching, tempering, stress-

relieving and surface treatments respectively. • Quality control: Before marketing, the materials are checked by quality control methods such as tensile test, charpy

impact test, dye penetration test and ultrasonic inspection.

Summer Practice METE 300 Fall 2012/2013 Rasim ERİŞ

MKE Heavy Weapon & Steel Factory Prof. Dr. Naci SEVİNÇ

Week 1 – Molding and Melting

When the model of a product is determined, the molding process is started. Wooden or polysytrene patterns are produced, then the patterns are used to produce molds. Molds are built from sands. In Akdaş Casting, there are eleven induction furnaces having 44 tons of capacity in total. Scrap is melted in these furnaces at high temperatures up to 1700ºC.

Week 2 – Mold Opening and Cleaning

After solidification, the cast piece is seperated from mold sand and flasks. Then, extras like risers and gating system are cut by oxygen and LPG torch and sent to scrap yard. Next steps are rough grinding and blasting.

Week 3 – Heat Treatment In Akdaş Casting, there are 6 natural gas fired heat

treatment furnaces all equipped with plc controls (4x4 m, 4.5x4 m, 2.5x2.5 m, 3x2 m, 4x6 m, 2.5x2.5 m). In these furnaces, 5 types of treatment processes applied : Normalizing, Water Quenching, Air Quenching, Tempering, Stress Relieving.

Week 4 – Quality Control For Akdaş Casting quality is very important, that is why at

every stage of production some inspections are done. Chemical Analysis: Spectral Analysis. Destructive Tests: Tensile test, Pendulum Impact Charpy

Test, Hardness Test. Non-destructive Tests: Liquid penentrant test, Magnetic

particle test, Ultrasonic test.

References http://www.akdas.com.tr/

Akdaş is a casting co. which carries out its production in two foundries and two machining shops in Organized Industrial Zone of Sincan with a total area of 36.000 m^2 having liquid metal capacity of 42 tons and 25.000 tons of annual production.

Contact Person: Gülsüm Çakır. No: 0 312 267 18 80 e-mail: [email protected] Production Areas: Various parts of automotive, cement, soil, construction, energy, food, machinery, mining and crushin, off shore and marine, steel works.

Summer Practice METE 300 Fall 2012/2013 Ömer Ulaş Kudu

Akdaş Casting and Trade Co.Inc. Abdullah Öztürk

Week 1 Observation in Body Area;

Spot Welding Application,

Stud Welding Application,

Remote Laser Welding,

Arc Welding.

Week 2 Stamping Area;

Processes, namely blanking, embossing, bending, flanging and coining,

Hot and cold stamping operations were observed.

Parts like gas tank cap and doors and all parts of the body are produced in here from sheet metals.

The Stamping Area also provides stamped sheet metal for Eskişehir factory.

Week 3 Quality Laboratories;

Tensile test was performed with the help of operators.

Week 4 Spot Weld Inspection;

Non-destructive Spot Weld Inspection

Destructive Spot Weld Inspection (Teardown) were observed.

REFERENCES http://www.fordotosan.com.tr/

The company’s main purpose is the production of light commercial vehicles. It is considered as the “main base of commercial vehicles of Ford” by the Ford Motor Company. Although the main purpose seems to be producing vehicles, this is not the only area of the company’s works. Ford Otosan also produces dies for stamping sheet metals to parts of the vehicles. It was established on 1.600.000 m2 land, and it hosts to nearly 500 engineers and 2000 workers in general.

Full Address of the Company: Denizevler Mah. Ali Uçar St. No:53 İhsaniye/Gölcük/Kocaeli

Contact Person in the Organisation: Gökhan TAN Tel:0 262 315 55 26

e-mail: [email protected]

Summer Practice METE 300 Fall 2011/2012 Başak AKÇA

Ford Otomotiv Sanayi A.Ş. Name of the Advisor: Cevdet Kaynak

Figure 2. Stamping Area

Figure 1. An image from Body Area

Figure 3. A stress-strain graph obtained from tensile tests

Hardness Test Compression Test Cup Test

Figure 3. An image from Production Line

Figure 4. Probes

Figure 5. Spot Weld Inspection with Ultrasonic

Names of the Suppliers of Sheet Metals;

•Borçelik,

•Arcelor Mittal,

•Erdemir,

•Voestalpine,

•Posco,

•Thyssen.

Week 1 o In the first week some

educational programs in order to inform the people about the general rules ,the process taking place in manufacturing products and some projects studied in TAI are studied.

o In addition some trips in which the TAI building are shown,are organized in the last day of the week.

Week 2 Clean Room o The hand lay-up is a manual process

for manufacturing monolithic type structures or sandwich structures made with pre-preg material.

o Hand lay up is seperated into two catagories which are wet and prepeg lay up but mostly prepeg used in hand lay up method in TAI.

o In (wet lay up) the liquid resin is poured to the reinforcement material which is hown in Figure 2.

o In prepeg lay up prepegs are laid out with a proper direction shown in Figure 3.

Week 3 Autoclave o It is a pressure tank in which the

composite tool having cured under pressure and vacuum.

o In autoclave molding materials with high fiber densities are produced without any air pocket.

o However; there must be long cure cyles because autoclave is so big that is hard to heat and cold.

o Cure cyles of temperature pressure and vacuum with respect to time is shown in the Figure 4.

Week 4 Core Cut & Tooling o Cores which are based on the

honeycombs are used in aircraft technology since 1940 due to its low weight and high strength.

o It composed of three parts which are surface molding (fiberglass, titanium, stainless steel),cores and adhesives. In order to obtain the desired property cores should be shaped which is shown in Figure 6.

o In addition to the core cut preparing of tools ,essential for the hand lay up is learnt in fourth week of the summer practice

References 1)Notes taken in internship 2)Notes and presentations provided by the company 3)

. Turkish Aerospace Industries, Inc. TUSAŞ Aerospace Industries, Inc. (TAI) was established on 15 May 1984 in order to manifacture F-16 planes.Then in 2005 The Turkish Aircraft Industries, Inc. (TUSAS) and TUSAS Aerospace Industries, Inc. (TAI) merged under the roof of TAI. Contact Person: Banu Aktimur (Tel:+90 312 811 1800)

Summer Practice METE 300 Fall 2012/2013 Bengisu Yaşar

Turkish Aerospace Industries, Inc. Assist. Prof. Dr. H. Emrah Ünalan

Wet Lay up, Prepreg Lay-up, Vacuum Bag Moulding ;In addition ,the products are

manufactured by the automated tape layup are observed

Third 2.5 Weeks: Actual

Cleaning Tests and Laser

Welding of the Parts

Cleaned

In the light of the parameters that have been determined by the preliminary tests, actual parts have been cleaned at various temperatures, concentrations and times. After the parts cleaning process was done, the samples have been laser welded and sent to metallography lab for cross sectional welded area analysis.

First 2.5 Weeks:

Orientation and

Company Trainings,

Literature Research

for the Project

During the first quarter of the internship, various orientations and chats with experienced people in their fields have been organized and offered by the company. In addition, various departments of production have been visited for observation of the actual metallurgical related processes. Those orientations and visits include:

• Occupational Security

• Six Sigma and Bosch Production System (BPS)

• Chats with departmental managers

• Visits to soft machining, quality management, heat treatment, coating and cleaning departments

Second 2.5 Weeks:

Preliminary Tests for

Low Temperature

Cleaning Project

In the scope of the 10 week summer practice program at RBTR Bosch Bursa plant, an engineering project has also been assigned to the selected interns. In this manner, investigation of the potentials and risks that are underlying at low temperature cleaning processes and their effect on critical chain processes such as laser welding, force fitting, nitriding etc. has been examined. For this project two new cleaning chemicals have been offered and their preliminary tests for parameter range determination has been conducted.

Fourth 2.5 Weeks:

Metallography Laboratory

Reports and Final Presentation The cross sectional welded area analysis reports have been

obtained from the metallography laboratory. The results have been examined precisely and low temperature cleaning is found to be feasible for laser welding process. The outcomes of the experiment have been gathered for a final presentation (including a brief cost analysis) to present the outcomes to the highest degree managers of the plant.

References

1. http://intranet.bosch.de

• Robert Bosch Bursa/Turkey plant is the world leading producer of the latest generation Diesel Injection Systems for commercial vehicles and industrial transportation solutions. Besides

the usual metal processing steps, production of these injectors include high tech. processes as well. These processes include: Electro-erosion drilling, carbon coating, laser welding,

nitriding, etc.

• Contact Person in the Organization: Azra Martin e-mail: [email protected] Tel: 0224 219 25 00


Bilen Aküzüm Robert Bosch Diesel Systems Turkey (RBTR)

Advisor: Assist. Prof. Dr. Emrah Unalan

Week 1 Composite Parts Production Unit

was the designated unit for this practice. The processes observed in this week were those which are related to insulation of rocket/missile cases. The main objective of the set of processes for insulation is to render the case resistant to extremely high temperatures reached as a result of combustion of propellant(s). The most widely used material for this purpose is epoxy-fed glass weave composite material (Pre-Preg) whose production stages were experienced in the flesh.

An Application of Pre-Preg Material

Week 2 The unit observed this week was

Mechanical Production Unit. Among many operations performed by the unit, flow forming and chip removal were the ones that are observed most closely.

Flow forming is used to reduce the wall thickness and increase the length of tubes, cases, etc.. without changing the inside diameter.

Chip removal is the removal of unwanted portions from a block of material in the form of chips so as to obtain a finished product of desired size, shape and finish.

A high-tech CNC Machine, a widely used tool in chip removal processes

Week 3 Continuing with Mechanical

Production Unit, another closely observed operation in ROKETSAN was heat treatment.

Heat treatment is the operation of heating and cooling a metal in its solid state to change its physical properties. In ROKETSAN; heat treatment process has 4 main stages; pre-heating, austenitizing, quenching and tempering. Which include heating the part up to some +900°C and cooling down to alter some physical properties for desired specifications.

A part in austenitizing stage of the heat treatment process

Week 4 In this week, along with Composite Parts

Production and Mechanical Production Units, some other departments were visited and overview ideas were acquired. These departments include;

• Information Processing • Maintenance and Repair • Project Engineering, Planning • Quality Test Laboratories

References: summer practice notes www.roketsan.com.tr

ROKETSAN, which is established upon a decision of Turkish Defense Industry Executive Committee at 1988 to be the leader of national missile and rocket programs, is now one of the strategic centers of Turkey’s defense industry that produces technology.

Some of the processes applied in ROKETSAN: Flow Forming, Insulation, Heat Treatment, Chip Removal

Summer Practice METE 300 Fall 2012/2013 Burhan Can YİĞİT

Roketsan Missiles Industries Inc. Assist. Prof. Dr. H. Emrah ÜNALAN

ROKETSAN Cirit, one of the products whose production stages observed most closely

Summer Practice METE 300 DİLEK SEZER

ERDEMIR PROF. DR. MACİT ÖZENBAŞ

• Ereğli Demir ve Çelik Fab. T.A.Ş

Erdemir Group which owns 80% of iron ore reserves in Turkey is one of the major players of iron and steel industry with industrial facilities in Turkey and Romania. The parent company of the group is Ereğli Demir ve Çelik Fabrikaları T.A.Ş. (Ereğli Iron and Steel Company), which is the largest flat steel manufacturer of Turkey, located in Karadeniz Ereğli in Zonguldak. OYAK, one of the biggest groups of Turkey, acquired Erdemir group on 27th February 2006.

References 1. Summer practice notes 2. www.erdemir.com.tr

3. Summer practice pictures 4.tr.wikipedia.org/wiki/Erdemir_Demir_Çelik_A.Ş

Week 1 After hot rolling procedure the products are rolling at room

temperature in order to get final products with a desired thickness and a width also mechanical property which the customer wants. In Erdemir there are 2 cold mill plants. The basic difference between 1st cold mill plant and 2nd cold mill plans is that 2nd cold mill plant has continuous working system. Traditional cold mills consist of five difference line. These production lines are improved to continuous lines. Then, thanks to the enhanced technology , production quality and efficiency raised. This means that the materials which is came from hot rolling process are subjected to more rapid process. This provides much more production. ,

PRODUCTION LINES ACID AND TANDEM LINE (CPL/TANDEM) CONTINUOUS ANNEALING HATTI (CAL) COLD SHEARS LINE (IRSL) CONTINUOUS GALVANIZATION LINE (CGL)

Week 2 No. 1 cold mill plant has 2 pickling line. In pickling line surface of the steel coils are cleaned by using HCl solution. No. 1 line started-up on 1978 and had 2 modernizations on 1992, 2006. Also it has a production capacity of 600000 tones/year. No. 2 line started-up on 2004, it has a production capacity of 400000 tones/year. After cleaning the surface of the steel in pickling line, the steel get desired shape in the tandem mill started-up on 1967 and had 3 modernizations on 1975, 1987, 2006. Moreover it has a production capacity of 450000 tones/year. The products of No.1cold mill plant is coated with the tin whether it is wanted by the customer. There is an electrolytic tinning line started-up on 1999 which has a production capacity of 250 000 tones/year (total). PRODUCTION LINES ACID LINE TANDEM LINE CLEANING LINE ANNEALING LINE TEMPER LINE COLD SHEARS HOT SHEARS TIN COATING LINE CHROME

Week 3 Blast furnace is a type of metallurgical furnace used for smelting

to produce metals, generally iron. The necessary charge to produce molten pig iron consists of iron-bearing materials (iron pellets, iron ores, iron sinters), coke, and flux. The charge is introduced into the furnace at the top. Blasts of heated air from large blast stoves, and in most cases gaseous, liquid, or powdered fuel, are injected into the furnace through openings (tuyeres) at the bottom of the shaft just above the hearth ladle. As the hot air encounters the coke, the coke is burned along with the injected fuels, producing the necessary heat and reducing gas to remove oxygen from the ore in the reduction process. As the iron melts, it descends and accumulates in the ladle. The unwanted materials different than the iron make slag which can be used in cement industry. The molten pig iron and slag are drained from the ladle through the tapping holes. The gas that exits from the top of the furnace goes through a cleaning process. The pig iron which is the raw material of the steel has a composition of: Fe: %94.0-96.0,Si: %0.60-1.20,Mn: %0.50-0.70,C: %4.20-4.50,P: %0.07-0.10.

The composition of the slag which is produced in blast furnace is: FeO: %0.20-0.70, SiO2: % 36.0-38.0, MnO: %0.70-1.50,Al2O3: %13.0-15.0, CaO: % 37.0 - 40.0,MgO: % 4.00 - 8.00 , S: % 0.80 - 1.20, Na2O: % 0.20 - 0.40, K2O: % 0.50 - 1.00, TiO2: % 0.70 - 1.50.

Week 4 Pig iron obtained from blast furnace has approximately %4 carbon, that amount of carbon is not suitable for engineering applications so that before the casting hot metal should be decarburized. BOF removes this excessive amount of carbon and another important function of BOF is dephosphorization, also; some other impurities are removed by basic oxygen furnaces. Basic oxygen furnaces also optimize temperature of hot metal. Pig iron brought by torpedo cars is charged to BOFs. Blowing oxygen from top to the furnaces oxidation reaction occurs in the furnace, these reaction are exothermic reaction and produce heat more than process need. To prevent the excessive rising of the temperature scraps are charged to the furnace from scrap stock area so that the thermal balance is achieved. Oxidation reactions in the BOF: C + ½ O2 → CO Si + O2 → SiO2 2P + (5/2)O2 → P2O5 Mn + ½O2 → MnO Fe + ½O2 → FeO 2Fe + (3/2)O2 → Fe2O3 The slag and waste gases are valuable and stock to use in some other applications. The hot metal with optimized composition is forwarded to secondary metallurgy units.

Secondary Metallurgy

Steel which is produced by BOF at the temperature of 1650-1700°C pours into the ladle and transfers to the secondary metallurgy plant by the help of the crane in order to refine the steel one more time. In secondary metallurgy, molten steel with regard to the temperature and the composition; the argon mixing, heating-cooling, alloying, Ca-Si injection or vacuum degassing are done to get the planned steel grade by the customers. In Erdemir there are 2 ladle furnaces in secondary metallurgy plant. No.1 ladle furnace started-up on July 1993 has capacity of 1700000 tones/year. No.2 ladle furnace started-up on August 2007 has a capacity of 1700000 tones/year.

Week 1 In the first week of the

summer practice,education related to the general rules, working principles and manufacturing capabilities were studied with an education program.

Educational programs studied in this seminar are work health and safety rules general information about TAI (vision and mission of TAI) ,the parts of the building and their responsibilities in manufacturing products.

Moreover, all of the building of TAI campus and their responsibilities in the production were mentioned.

Week 2 Clean-Room Clean room is a place that the

composites are manufactured under 21°C and %40-60 humidity.The important point of the clean room is that it should not contain more than 25 micron dust particles.The diagram shown in the Figure 1 demonstrates the suitable conditions for variable composites products.

Prepreg lay-up and metal bonding for various aircraft parts for the projects like JSF/F-35, Skorsky CH60-S70, Anka, Boeing AW-139 were observed, and lay-ups were done.

Week 3 Autoclave Autoclave is the next step of the

hand-layup process. After vacuum bag is done (which is

shown in the right)it is cured under so high pressure and temperature with vacuum with kong cycles.

Curing processes are done in ovens or autoclaves.Being pressure in the autoclaves causes more efficient process so that most of the composite producing companies prefer autoclaves.

Week 4 Core Cut & Tooling Cores which are used in sandwich panel

structure is high strength and low weight materials in which it is sticked to the walls with special adhesives.In order to obtain the desired properties cores should be cut hexagonal and ox shape with some apparatus shown in Figure 2.

In addition tooling which is the preparation step for the production of hand layup composites tool by cleaning is explained in the last week of the internship.

References 1)Notes taken in internship 2)Notes and presentations provided by the company 3)

Turkish Aerospace Industries, Inc. The processes applied and the products manufactured in the summer practice TAI was established by Turkish and US partners in 1984 for Thanks to the processes such as wet layup,prepeg layupautoclave molding,automated

taped lay up ,the products shown in below manufactured the coproduction of F16 aircraft

Contact People: Banu AKTİMUR ,Kemal ŞEHZADEOĞLU(Tel:+90 312 811 1800)

Summer Practice METE 300 2012/2013 Doğancan Sarı

Turkish Aerospace Industries, Inc. Prof.Dr. Ahmet Macit Özenbaş

Week 1→Clean Room • At this area, the temperature, humidity

& dust are controlled at 21 ± 3 ˚ C , 45 ± 10 %R.H. and 10 micron maximum, respectively.

• The lay-up operations both for metal bonding parts and for composites are held in this clean room area. After the lay-up, vacuum bags to be introduced in the autoclave for polymerization are also prepared in this area.

Week 3→Autoclave • After the lay-up operations in

clean room, composite and metal bonding parts are forwarded to the Curing Area.

• The area has an autoclave with auxiliary utilities and a cure oven. A certain amount of land is reserved to be able to install a second autoclave.

.

Week 4→Tooling • Construction of aircraft, spacecraft, missile parts,

aerospace tooling, automobiles, and sporting goods equipment is rapidly moving to carbon fiber-reinforced thermoset and thermoplastic resins, resulting in a higher strength-to-weight ratio, higher stiffness, and less susceptibility to corrosion and fatigue.

• Tooling must be low in cost, rigid, durable, and thermally stable, offering a low coefficient of thermal expansion (CTE), and, in many cases it must also be lightweight, in applications such as aerospace composite tooling.

References: 1. Notes and informations provided by TAI 2. http://www.cfoam.com/tooling.htm

• TAI, the center of technology in design, development,

manufacturing, integration of aerospace systems, modernization and after sales support in Turkey, was established on 15 May 1984.

• Kaan BAŞTÜRK/ Banu AKTİMUR

Processes Applied and/or Products Manufactured in the Organization • Hand Lay-up: The plies of reinforcing material are placed and worked on or in a

mold by hand. Curing process takes place at room temperature by applying a catalyst-promoter or heat in oven.

• Autoclave Molding Method: Vacuum is applied between the sheet and the lay-up. Lay-up is placed in autoclave and both pressure and heat are applied.

• Resin Transfer Molding (RTM):Dry fibers are placed into tool and the resin is pumped under low pressure through injection ports into the tool. Both the mold and resin can be heated as needed for the application.

Summer Practice METE 300 Fall 2012/2013 Ece FERİZOĞLU

Turkish Aerospace Industries, Inc. Prof. Dr. C. Hakan GÜR

Week 1 The first 4 days given education by the engineers working in the related unit.

Week 1 • Anode Casting: It is the first

step of the copper wire production and it is pyrometallurgical refining of the blister copper. Anode casting prepares the copper for electrolytic refining as casting anodes. Anode casting consists of 6 steps which are charging, smelting, oxidation, reduction (Copper Poling), heating and casting.

• Electrolysis (Electrolytic Refining): It is the second step of the copper wire production. Electrolysis can be divided into three steps which are preparation of the initial (cathode) plate, obtaning cathode copper and analysis of anodic mud.

Week 2 Wire Rod Casting: • Southwire Continuous Casting

(SCR): the input of the process:cathodic

copper, turnings, billets, clean defective wires.

Capacity of the process: 12.5 tons of copper wire per hour.

• Contirod Continuous Casting The input of the process: cathodic

copper, turnings,billets, clean defective wires.

Capacity of the process: 12.5 tons of copper wire per hour.

• Outokumpu Continuous Casting The input of the process: electro-

refined cathodic copper.

Week 3 Wire Drawing: • Production 1: It consists of heavy,

medium, fine gauge wire drawing units, flat wire and bus-bar drawing units and plating units.

• Production 2: It consists of multiwire

drawing unit and stranded wire drawing units.

• Production 3: It consists of superfine

gauge wire drawing unit, wire rope production unit, plating by dipping unit and braided wire production unit.

Week 4 • Tube Production: In this plant, copper

tubes and bus-bars are produced from copper billets which are produced at

Billet Casting unit. • Laboratories: 1.Physics Laboratory 2.Chemistry Laboratory 3.R&D Laboratory

References: • http://www.sarkuysan.com/tr • Copper Wire Production,Sarkuysan A.Ş.

The essential objective of the foundation of Sarkuysan is to meet the country’s demands for copper by refining the mined blister copper smelting it domestically and preventing the loss of the precious metals in the electrolytic refining process. Final products which are obtained after the processes applied in the Sarkuysan are copper rods, wires, bus-bars, and tubes.

Contact person in the organization: Murat DEMİR, e-mail: [email protected], Tel: (0-262) 653 26 04

Summer Practice METE 300 Fall 2012/2013 Elif ÖNER

Sarkuysan Electrolytic Copper Industries Inc. Student’s Advisor: Caner DURUCAN






Week 1 ‘Scrap’ and ‘Electric Arc furnace

(EAF)’ units are visited in the first week. In scrap unit, classification of scrap and transportation of scrap are observed. In electrical arc furnace unit; processes of charging and melting of scrap, Phosphorus refining, seperation of slag are observed. Also cooling system of Electric arc furnace are observed during melting operation. After all processes are underwent, molten steel is poured into ladle furnace by using EBT tapping system which makes pouring operation easier.

Sketch of an electric arc furnace is illustrated in Figure 1.

Week 2 ‘Ladle furnace’ unit is visited in the

second week. Vacuum operation for degassing of steel, buoying of inclusions by the help of Argon gas, alloying operation by stirring, S refining by synthetic slag and accumulation of inclusions are the processes underwent in ladle furnace.

The main aims of ladle metallurgy are to arrange the homogeneity of temperature of steel, provide deoxidation, control the inclusions, evacuate gas, provide clean steel, refine sulphur, and save the working time of electric arc furnace.

Sketch and picture of a ladle furnace can be seen in Figure 2 and Figure 3 relatively.

Week 3 ‘Continuıus Casting’ unit is visited in the

third week.Continuous Casting is the process whereby molten steel is solidified into a "semifinished" billet, bloom, or slab for subsequent rolling in the finishing mills. Steel from the electric arc furnace is tapped into a ladle and taken to the continuous casting machine. The ladle is raised onto a turret that rotates the ladle into the casting position above the tundish. Referring to Figure 4, liquid steel flows out of the ladle into the tundish, and then into a water-cooled copper mold. Solidification begins in the mold, and continues through the First Zone and Strand. In this configuration, the strand is straightened, torch-cut, then discharged for intermediate storage or hot charged for finished rolling.

Week 4 ‘Rolling Mill’ unit is visited in the fourth week of

summer practice.180X180mm, 160X160mm and

130X130mm section billets from the casting

department are passed through the Rolling line.

At the end of this operation the desired quality

and size semi-finished and finished products are

obtained.

Picture of rolling mill can be seen in Figure 5.

References 1. http://www.steel.org/en/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Electric%20Arc%20Fur

nace%20Steelmaking.aspx

2. http://www.steel.org/~/media/Files/AISI/Making%20Steel/Article%20Files/learning_2ndrefining.ashx

3. http://www.metsoc.org/virtualtour/processes/steel/Casters.asp

4. http://www.kromancelik.com.tr/

Kroman Steel Company was founded on 25 June 1966 in Darıca,Kocaeli, in order to produce market steel and iron products and semiproducts. It is located on 300 000 m2 land and it has 110 000 m2 closed facility. Primary and secondary metallurgical processes are applied such as Electric Arc furnace processes, Ladle furnace processes,Continuous Casting and Rolling operations. At the end of these processes, long steel products are achieved such as billets, wire rods and spoolers.

Contact Person:Gökhan TUĞYANOĞLU (Refractory Preparing Chief)

E-mail: [email protected]

Phone number: 0262 679 20 00

Summer Practice METE 300 Fall 2012/2013 EMRE CAN TEMEL

KROMAN STEEL COMPANY Prof.Dr. NACİ SEVİNÇ

Figure 1 Figure 2 Figure 3 Figure 4

Figure 5

http://www.steel.org/en/Making Steel/How Its Made/Processes/Processes Info/Electric Arc Furnace Steelmaking.aspx

http://www.steel.org/en/Making Steel/How Its Made/Processes/Processes Info/Electric Arc Furnace Steelmaking.aspx

http://www.steel.org/~/media/Files/AISI/Making Steel/Article Files/learning_2ndrefining.ashx

http://www.metsoc.org/virtualtour/processes/steel/Casters.asp

http://www.kromancelik.com.tr/

http://www.kromancelik.com.tr/

Week 1 Firstly, some information about rules

of factory, general processes, directorates and occupational health and safety are given for three days. Then, engineers showed the both factory which are foundary and machininng factory. They told how prosseses are going on by showing and introducing departmens and machines. According to our department and the summer practice’s content we were classified and distributed to the sections. I completed my summer practice in Erkunt Foundary 1. I had enough time to observe 4 sections which are coreroom, melting, molding and cleaning departments in the foundary.

Week 2-3 In second week, I was assigned in the

coreroom. I had 4 days to observe the procedure in detail. Core dressings are used to satisfy a space in a product and are placed in the mold cavity. I learned core making machines’ properties, how core sand is prepeared, what core sand’ ingredients are and their expected properties, how core dressings are attached each other, in order to attach what kind of things are used, why core dressings are painted and finally how they are dried.

Week 2-3 After that I was assigned in the melting

section. Melting procedure consists of solidification, alloying, homogenization and processes for preparing casting. I learned in this section the properties of induction ovens, procedure of gray cast iron and ductile cast iron, what their ingredients are. For melting, vaccination is important. Duties of vaccination is also important. Microstructures of gray cast iron and ductile cast iron are observed.

When melting and producing core dressings are finished, molding operation starts. Feeders, breast, model, filters are used for molding. There are three molding lines for casting Gustav Zimmerman, Kunkel wagner and Furan.

Week 3-4

These operations are observed. Important points and

features that should be considered are learned. Finally in cleaning part, molding boxes are opened. In order to clean sand, runners and chips pieces are sent cleaning department. By using grinding machine and blasting machine, pieces are cleaned. Blasting machine sprays high speed steel balls shots. So, parts will be free from sand. Then, these pieces are controlled visually. In grinding line, cleaning of the runners, taking of chips, doing necessary corrections on core prints are done by handmade machines which has flex stone. According to customer’s request, painting can be done in different colors. Finally if operation is wanted, pieces are send to the machine factory.

References

http://www.erkunt.com.tr/site/

Erkunt Industry Inc. was established as a pattern-shop in 1953. It started to invest for machining of castings in 1959. After 50 years of production, Erkunt Tractor Industry Inc. was established with domestic capital for the dream of home made tractor in 2003. Erkunt Industry Inc. is working for automotive supply industry. It produces parts for tractors, heavy construction equipments, trucks, generators and ships. The mission of the company is to supply castings, machined parts and components to the automotive industry requiring high quality and precision to meet the ever-changing market demand, determining technical and environmental standards with a corporate profile that has a high awareness of social responsibilities, assuring continuous satisfaction of the shareholders.

Contact Person: Arzu Uyar (Expert in Director of Human Resources and Personal Communications) [email protected] 0312 397 25 00 / 2602

Summer Practice METE 300 2012/2013 GAMZE ÖNELKE

Erkunt Industry Inc. ALİ KALKANLI






Week 1: Laboratory Tests, which are made in Çemtaş, are below; Chemical Analysis (Ladle and Product/ ARL4460) Mechanical tests (Tensile / EN10002-1, Notch Impact

/ DIN 50115 or EN 10045-1) Jominy / EN ISO 642 Hardness (Rockwell / EN ISO 6508-1, Brinell / EN ISO

6506-1 Austenitic Grain Size Determination (ASTM E112 or

EN ISO 643) Micro Cleanness (ASTM E45 or DIN 50602) Macro Etching (Billet and Product / ASTM E381) Decarburization Depth Determination (EN ISO 3887) Banding (Various automotive specifications) Blue Brittleness / SEP 1584 Upset Test Step Down Test (JIS G0556) H Measurement (LECO) N/O Measurement (LECO) C/S Measurement (LECO) Figure 1. Microscope Sulfide Shape Determination (SEP 1572)

These tests are done according to the needs and requirements of the customer. Test results are given

on the quality certificate. In Çemtaş, quality certificates can be given according to EN 10204 3.1.

and EN 10204 2.2. standards.

Figure 2. Charpy Impact Figure 3. Chemical Test Analysis

Week 2: Steel Plant The Steel Plant at Çemtaş is consist of three different units. Their name called as a process order are Electric Arc Furnace,

Ladle Furnace and Continuous Casting Machine.

1) Electric Arc Furnace : EAF is a steel making furnace, in which steel scrap is heated and melted by heat of electric arcs striking between the furnace electrodes and the metal bath.


2) Ladle Furnace : Liquid steel is tapped into ladle where it is alloyed and refined by automatic alloying system, argon bubbling and vacuum degassing applications.

Figure 5. Ladle Furnace

3) Continuous Casting Machine : The aim of the CCM controlled by computer is to cast liquid steel as billet after the alloying process and the other processes are completed.

Figure 6. Continuous Casting Machine

Week 3: Rolling Mill Rolling Mill is the production unit, in which the billets produced in

the steel plant is rolled to the customer required sections and sizes in the range of standards.

Figure 7. Rolling Mill Unit Figure 8. Shot Blasting

Unit and Straightening

Quality steels should be rolled with modern technology and high production yield. So ÇEMTAŞ has modernized the Special Quality Steel Rolling Mill in 1998 with wide range of different sections and sizes. Çemtaş Special Quality Steel Rolling Mill is a must for the production of high quality steel with the capacity of 210.000 tons/year and automation systems of level 1 and level 2.

Figure 9. Cooling Bed Figure 10.Surface Defect

. Testing Device

Week 4: General Observation ÇEMTAŞ produces materials; According to International Standards EN BS DIN JIS SAE ASTM AFNOR According to the specifications of main automotive manufacturers

According to the specifications of the companies. Additionally, materials are also produced according to the specific analysis and characteristics required by the customers.

Reference ÇEMTAŞ Webpage

Çemtaş, a joint stock company, was organised to operate on an area of 101.000 m2 in the Bursa Organised Industrial Zone by a group of industrials, businessmen, small craftmen and public entrepreneurs of Bursa on 27.01.1970. The aim of company is that produce manufacture steels in compliance with TS, DIN, AISI, SAE norms and also produce specific request as “Arc Furnace based Qualified Steel Manufacturer”.

Human Resources Manager: İbrahim UYANIK ( insankaynakları@cemtas.com.tr )

There main process are applied at ÇEMTAŞ; Steel Plant Processing : Scrap is changed to be formed liquid steel. After refined, liquid steel is shaped and solidified in CCM.

Rolling Mill Processing: The billets produced in the steel plant is rolled to the customer required sections and sizes in the range of standards

Laboratory: Several tests are applied to produced steel according to obtain the needs and requirements of the customer. Test result are given on the quality certificate according to EN 10204 3.1. and EN 10204 2.2. standards

Summer Practice METE 300 Fall 2012/2013 Gözde Ceren NARSAP

Çelik Makina Sanayi ve Ticaret A.Ş. Prof. Dr. Amdulla MEHRABOV

Week 1 Composite and Metal Bonding CAMB facility at TAI started with the

introduction of CASA CN-235 Light Transport Aircraft Project. TAI made a decision for the improvement of its technological capacity and capability in aerospace industry by CAMB building.

The design of the TAI CAMB facility was mainly based on the documents & information received from Construcciones Aeronautics S.A. (CASA) and Lockheed Fort Worth Company (LFWC). The equipment, the layout and work flows for CAMB are depended on the possibility of having new projects and state of art technology in CAMB.

Figure 1 : Camb Building. Figure 2 : Metal bonding area.

Week 2 Clean Room Area Clean Room was designed to be CLASS

100.000 in accordance with FED. SPEC-209 and has a dimensions of 38 m x 30 m with a height of 4 meters. The temperature, humidity and dust are controlled at 21 ± 3 ˚ C , 45 ± 10 %R.H. and 10 micron maximum, respectively. All materials such as prepregs, adhesives and chemicals must be hold in the cold storage conditions during their rest of time. Therefore, the freezers are introduced in Clean Room to keep all these materials in the required conditions. The temperature of the freezer is kept at -18 ˚ C. Moreover, there is a refrigerator whose temperature is kept at plus 4 ˚ C.

Figure 4 : Freezer.

Figure 3 : Clean Room Area.

Week 3 Autoclave and Owen Area &

Demolding Area After the lay-up operations in clean room,

composite and metal bonding parts are send to the Curing Area which includes autoclave and owen facility with computerized process control. In this area, polymerization cycles are controlled.

The autoclave features the latest technology for computerized control and data logging. Curing is closely controlled in a certain temperature, pressure and vacuum cycle adapted to the type of material.

The maximum attainable temperature is 400 ± 2˚C. The pressure is automatically controlled and can reach up to 17 atm. It has some more auxiliary units like nitrogen systems, air compressors and water cooling systems. The heat up and cool down rate is 1 to 5.5 ˚ C / min.

Figure 5 : Autoclave.

Week 4 Non-destructive Control, Ultrasonic and X-Ray Inspection & Assembly Area 286 square meters area is available for non-

destructive testing and dimensional measurement of composite and bonding parts. Also some destructive tests are applied in the separate Process Control Laboratory by Quality Control Department.

34 m. long and 20m. wide area is for assembly operations. Some detail parts are assembled in this area after curing operations. Miscellaneous cutting and fastening elements are used depending on the type of the assembly work. Also, there is a five ton overhead crane in this area.

Figure 6 & 7 : NDI (non-destructive inspection ) area.

References - http://www.compositesworld.com/zones/autoclave-technology

- http://www.compositesuk.co.uk

- http://www.cleanroom-system.com

TAI is an universal defence and aerospace company that improves and performs advanced technological applications based on the national resources and global knowledge. Composite & metal components of Turkish and some other country’s aircraft’s and helicopter’s are produced in that factory.Contact molding,Vacuum bagging,Resin transfer molding & hand lay-up are the some of the fabrication techniques. Contact Person : Banu AKTİMUR ( phone : 0312 811 18 00 / 2568 ) e-mail: [email protected]

Summer Practice METE 300 Fall 2012/2013 H. Burak ÜNSAL

Turkish Aerospace Industry,TAI Prof.Dr. Yavuz Ali TOPKAYA

http://www.compositesworld.com/zones/autoclave-technology



http://www.compositesuk.co.uk/

http://www.cleanroom-system.com/



Week 1 - 2: Steel Making Shop Electric Arc Furnace (EAF) refractory lined in steelmaking shop. A.S.E.A model

Sweden made EAF has 25 tons capacity and 12.5 M.V.A power rate. The units are; scrap preperation unit and electric arc furnace. The general processes are charging, melting, refining, de-slagging, casting. The kinds of steels produced in steelmaking shop are: Carbon Steels (Ç1010, Ç1117, Ç1060, C15, C45, Ç1090, Ç10110, ,…) Alloyed Steels (Ç4140, 34NiCrMo6, Ç3415,……) Case Hardening Steels (Ç3315, Ç4120, Ç8620, 16MnCr5….) Cold and Hot Work Tool Steels (Ç7245, Ç3150, H13, Ç7430, 56NiCrMo7,…..)

Week 3: Forging Shop All kinds of carbon and alloy steel

ingots can be subjected to open-die forging. There are 3000tons press,wheel ring making unit, closed die forging, GFM continious forging system and heat treatment units. Wheel rings are

also produced by cooperation of 3000 tons

press and ring rolling unit with various sizes

for TCDD.

Week 4: Quality Assurance Units

Five main mechanical testing are performed in MKE Heavy Steel &Weapon; Tensile Test, Hardness Test, Impact Test, Portable Ultrasonic Control, Dye Penetretion Test.

References http://www.mkek.gov.tr/english/foUretimYerleri.aspx?iKodUretimYeri=4

http://www.gfm.at/gfm/en/index.html

MKE Heavy Weapon & Steel Factory was established in between 1932 – 1937. It is the first and the only factory which produces heavy weapons and quality forged steels. MKE Heavy Weapon & Steel Factory has AQAP-2120 and ISO 9001-2000 Quality Assurance System Certificate. It also has the establishment Safety and Security Clearance Certificate. The main produces are; 155mm 52 calibre weapon system, 60mm command mortar, 81 mm UT-1 and NT-1 mortar, 120mm HY1-12 mortar, 105mm M68 Tank gun, forged products, 155mm L-39 weapon system, 155mm 52 calibre weapon system , all kinds of carbon and alloy steel except high speed steels and stainless steels 30.000 tons/year and, 2.000tons/year ESR Block.

Summer Practice METE 300 Hasan Mert Eryılmaz

MKE Heavy Weapons & Steel Factory Assist. Prof. Dr. H. Emrah Ünalan

Week 1 ( HOT ROLLİNG PLANTS )

Erdemir has 2 hot rolling plants. Slabs produced in CCP are forwarded to these hot rolling plants using rail transportation. Slabs are taken in the slab ovens to reheat up to rolling temperature (approx. 1200oC).After rolling operations rolled products heated in the normalizing ovens up to 920oC. Capacities of hot rolling plants are 3.650.000 tons and 1.150.000 tons per year Hot rolling process is a hot shaping Line process which the slabs are rolling when they are heated about the rolling temperature The hot rolled coils produced in this Hot Rolling plant have a thickness of 1.5- 12mm and width of 700-1530mm. In this plant there are 2 slab furnaces. The Marked Slab

Week 2 ( COLD ROLLİNG PLANTS )

Erdemir has 2 cold rolling plant.Cold rolling is the last process in production line. Some of the hot rolled products come to cold rolling plants to be given last properties before using for several industries. Cold rolling plants have three main parts: [1]

•Continuous Acidification/Tandem: In acidification line, scale on the steel is removed then goes to Tandem Rolling to be cold rolled from 1.8-4.5mm down to 0.4-2.0mm. •Continuous Annealing; Cold rolled steel comes from the Continuous Acidification/Tandem line is cleaned from acid and oil on it by alkali and electrolytic cleaning unit. In oven unit internal structure defects and stresses are removed by a couple of heating and cooling process . •Galvanization line: Hot Dipped Galvanization is applied in this unit. Galvanized steels are cromated or oiled for passivation so that zinc coating is protected

Week 3 ( STEELMAKİNG PLANTS) Steelmaking Plant has two main section in it, convertors (BOFs) and secondary metallurgy plant. Steelmaking Plant is the plant that needed composition of the steels ordered by customers is achieved. Erdemir has 3 Basic Oxygen Furnaces with capacity of 120 tons of each and some secondary metallurgy units such as ladle heater, ladle mixer, chemical heater and gas removing under vacuum. CCP SMP Basic Oxygen Furnaces; Pig iron obtained from blast furnace has approximately %4 carbon, that amount of carbon is not suitable for engineering applications so that before the casting hot metal should be decarburized. BOF removes this excessive amount of carbon and another important function of BOF is dephosphorization, also; some other impurities are removed by basic oxygen furnaces. Basic oxygen furnaces also optimize temperature of hot metal Oxidation reactions in the BOF: Continuous Casting Plant C + ½ O2 → CO [2] Continuous casting is very important Si + O2 → SiO2 in production line of Erdemir. Mn+1/2O2 → MnO so production continuous for 24 Fe+1/2O2 → FeO hours.Continuity in CCP is important 2Fe+(3/2)O2 → Fe2O3 for the whole process BOF Secondary Metallurgy Plant; In the secondary metallurgy plant (SMP) •The heating argon gas is blown for homogenization •Also alloying elements for different steel qualities are added in the secondary metallurgical plants. Erdemir has the capability of producing 300 type quality of steel

Week 4 (Laboratory ) Tensile Test A tensile test, also known as a tension test, tests a material’s

strength. It is a mechanical test where a pulling force is applied to a material from both sidesuntil the sample changes its shape or breaks. It is a common and important test that provides a variatiy of information about the material being tested, including the elongation, yield point, tensile strength and ultimate strength of the material. Tensile tests are commonly performed on substances such as metals, plastics, wood and ceramics.

sample cutting sample

Metallography Tensile Machine

[3] Metallography is the science and art of preparing a metal surface for analysis by grinding, polishing, and etching to reveal microstructual constituents. After preparation, the sample can easily be analyzed using optical or electron microscopy. A skilled technician is able to identify alloys and predict material properties, as well as processing conditions by metallography alone.

1020 Ferlite + Perlite 0.7 C thin Perlite

References [1] http:// www.erdemir.com.tr

[2] http://www.mpe-us.com/images

[3] http://www.wisehero.com/metallography-test-report/ /

Erdemir (Ereğli Iron and Steel Works Corporation), was located an area of approximately 4 square kilometers at Kdz.Eregli / Zonguldak, began production in 1965, the only

integrated flat steel producer in Turkey with a total annual crude-steel production capacity of 3,0 million tones. Today Erdemir, reaching to 3 billion revenue and 15,000 employees, has became a group of companies with its subsidiaries.(Chief Engineer [email protected] 0372 329 38 38 )

Summer Practice METE 300 Fall 2012/2013 Mustafa Anıl Yıldırım

EREĞLİ IRON & STEEL WORKS CO.(ERDEMİR)

Prof. Dr. Naci SEVİNÇ

http://wisehero.com/metallography-test-report/







Week 1

Quality Control Zone Here in Emek Boru quality control covers

all the activities starting from raw material inspections continuing with all production processes till to transportation that guarantee a 100% reliable production according to customer specifications and related standards.

Within the scope of quality system these activities are carried out at three main stages including ; incoming materials, processes and finished product.

1. Destructive Testing After the ordered length is achieved, the

pipe is cut to length. Due to the production standards, samples are cut for the mechanical and chemical tests which are chemical analysis, tensile test, Charpy impact test, guided bend test and hardness test. The base is specified for the tests. Test unit is prescribed quantity of pipe that is made to the same specified outside diameter and specified wall thickness, by the same pipe manufacturing process, from the same heat and under the same pipe manufacturing conditions.

Week 2

Quality Control Zone 2. Non-Destructive Testing The following testing methods are

observed respecctively: a.Pipe Visual and Dimensional

Inspection b.Manual Ultrasonic inspection c.Ultrasonic Inspection d. Radiographic Inspection of Weld and

Fluoroscopy e. Magnetic Particle Testing f. Liquid Penetrant Inspection

Week 3

Manufacturing Zone

This section is main part of the factory that the raw material (coil) is converted into the main material (bare pipe). In the company, there are 3 production lines. In this production lines, steel pipes with arc welding are produced with the diameter from 219.1 mm to 3048 mm. In order to give a beter form to steel roll, after the pre-bending, the plate is given a pipe shape by boom and rollers. The pipes whose measument controls are made and whose welding parameters are set are welded by submerged-arc welding externally and internally. In the meantime, the laser control of the internal weld seam is monitored during production. Skelp-edge milling unit, skelp-end weld, submerged-arc welding, welding monitoring system with laser and ultrasonic lamination control system become a part of the process which steel rolls are transformed into the pipes.

(Submerged-arc welding)

Week 4

Isolation Zone The coating depatment is the last process that is done to the

pipes finished to be conducted manufacturing operaions. First of all, the pipes which pass all of the destructive and non-destructive inspections come the sanding section in the coating department. This process is the preparation stage for the coating of the pipes. This makes the paint or other coating types a contribution to beter hold.

1. The Surface Blast Cleaning (Pipe Surface Preparation) 2. Three Layer Polyethylene Coating

3. The Internal Concrete Lining

4. The Epoxy Paint Coating

References 1. Retrieved from:

http://www.ndted.org/EducationResources/CommunityCollege/Ultrasonics/Introduction/description.htm

Emek Boru is built on an area of 70000m2 in Sincan Organized Industrial Zone

Spiral welded steel pipe production Hande YILMAZ – 0312 267 02 25 – [email protected]

Summer Practice METE 300 Fall 2012/2013 Merve Gizem ÖZDEN

Emek Boru Machinery Industry and Trade Inc. Prof. Dr. Ahmet Macit ÖZENBAŞ



Week 1

Machining Process:

To understand the machining operation and to learn the machines which are found in FORD-OTOSAN, “crankshaft” production processes are studied in this part. Crankshaft is produced in Crankshaft Production Line in Engine Field Directorship. Thus, all operation and machining processes are examined and piece’ production details are investigated.

Week 2

Press Operation:

Press machines are visited. Machines names are Siemperkamp press machine, Hydraulic press machine, Akbant twist press machine and Chassis press machine. These machines are used for shaping the steel.

Week 3

Thermal Process:

Pieces which be exposed to thermal process are known their chemical properties and molecule structure. In part, carbonazing, neutralization, cementation and sandy.

Process that apply in thermal process according to piece’s length, thickness, surface hardening, chemical properties and deep of the toughness.

Some workbench is established in Ford Otosan Factory. These are existing by Ipsen ovens. Except these ovens, EMA , induction machine, water-giving, sanding, tempo and bathrooms are exist.

Week 4

Welding and Quality Assurance:

Welding process is doing in chassis press and welding line. Engine front travers in chassis press and pipes in welding line are welded.

MIG under gas welding is common used in factory. In addition to this oxiacidion welding is used if it is necessary. There are one robotic welding machine, six welding machine in welding process center and five welding machine in chassis press.

Chemistry and materials laboratory has Wilson hardness test machine, metals cutter, materials analyses microscopes and micro structure microscopes.

References 1. http://www.tpub.com 4. http://www.americanmachinetools.com

2. http://engineeringwork.webs.com 5. http://hechaforklift.en.alibaba.com

3. http://www.siempelkamp.com.br 6. http://www.veracruzmanufacturing.com

Ford Otosan İnönü Factory’s products are Ford Cargo trucks, Dover engineers, Transit minibuses & pick-ups, 2.5DI engines, MT-75 transmissions and Transit rear axles.

Contact person: Ömer Ersoy ALANYALI (Phone: 02222132210 E-mail: [email protected])

Summer Practice METE 300 Fall 2012/2013 Mustafa Mete ÖZDÖNGÜL

Ford OTOSAN Motor Company Prof. Dr. Naci SEVİNÇ

Figure1: Crankshaft Figure2: Crankshaft CNC Machine

Figure3: Siemperkamp Press Machine

Figure4: Hydraulic Press Machine

Figure5: Chassis Press Machine

Figure6: Ipsen Oven Figure7: Carbonizing Balance Machine

Figure8: Wilson Hardness Figure9: Optical Emission Spectometer Figure10: Robotic Welding Machine

WEEK 1 [2]:

On the first week in ERDEMİR, it was passed by learning the facility. First two days, some presentations and instructions were shown by the responsible people about the company and the job security. Then we are distributed to our departments: mine was’ Blast Furnace II ‘ Zübeyde. This week was passed by learning the parts of the Blast Furnace Zübeyde. Castinghouse, sieve field, stack of the furnace, conveyor system (charging process) and control room was seen. Especially, castinghouse (foundry) was visited almost everyday to see drilling process of tap hole and to see how the pig iron produced. To obtain pig iron refractory mud is used to close the tap hole and after a certain time accumulated pig iron is led to flow with the help of tap hole gun which helps drilling the solidified mud.

Castinghouse : It is the part of the furnace that pig iron is taken from the heart of the furnace and pouring to the laddles to send desulphurization plant before going steelmaking plant (BOF).

Sieve Field: The field that raw materials are controlled and only the only correct sized materials coming from raw materials field via conveyors are send to the charge bands to charge into the furnace.

Stack of Furnace : In this part, copper cooling plates that are cooled by sea water are set.

Control Room : Every part of the blast furnace is watched and controlled by computer-based program.

Figure 1: Castinghouse (Foundry) Figure 2: Seperation of Hot Metal & Slag

Figure 3: Charge Conveyor Figure 4: Control Room

Figure 5: General View of Blast Furnace I ‘Ayşe’

WEEK 2:

In this week, foundry was still be visited to understand the process in details. Blow pipes, cooling system and stoves were examined deeply. By chance, the situation was occured that furnace had to be stand at least 5 hours, since the furnace was new relined. During this five-houred standing –actually sometimes regular standings are done be cause of the necessity ; however this was an unexpected standing- the summit of the furnace and stacks were seen and also inside of the furnace and the distribution chute were seen. It was totally an amazing experience seeing inside of the fully charged furnace. It was blue and white flames inside of the furnace – of course it were top of the throat part of the furnace- where it was about over 250 Celsius centigrad degree. Beyond the parts of the blast furnace, other plants were also be visited that are coke and sinter plants.

At sinter plant, dust and the little raw materials particles, that means they are iron-rich particles, are gained together and heated . As a result of this , much bigger sinters are produced to use in blast furnace.

On coke plant, the coals are carbonized oxygen-free furnace about 16-18 hours at 1100 centigrad degree. Then the coke is quenched than sent to the hoppers to charge blast furnace.

Figure 6: Blowpipes

Figure 8: Quenched Coke

Figure 7: Coke Batteries

Figure 9: Sinter Stack from Top of Zübeyde

WEEK 3:

During third week; steelmaking plant, harbour and raw material manipulation department were examined. In steelmaking plant three Basic Oxygen Furnace (BOF) were present. All BOFs had 120 tonnes capacity.

The steelmaking process is oxygen blowing system actually. Approximately 15 minutes oxygen blowing process was done for every pig iron torpedo coming from desulfurization plant. The purpose of this process is to reach the wanted Carbon value in iron. Oxygen; reacts other impurities (more reactive elements than iron) and as a result produces BOF slag. The steel is still liquid form and after secondary metallurgical applications it is transferred by railway to the continuous casting plant in order to produce slabs.

Harbour is the place where importation and exportation are done. Especially, for pellet importation and steel product (hot or cold rolled coils) exportation are the main works of harbour.

Raw materials and manipulation department is the place where all needs or all stocks or all demands are planned. After planning raw materials are transfered to the related department by help of conveyor system.

Figure 11: Oxygen Blowing in BOF

Figure 10: Hot Metal Adding BOF

Figure 12: Scrap Adding Due to Temperature Control

Figure 13: Pellet Heap

Figure 14: Conveyor System

Week 4 [3]:

On the last week, very intense schedule were done. Continuous casting plant, cold rolling plants and hot rolling plants are visited and examined.

At continuous casting plant, the liquid steel was pouring the tundish and the help of puppet and the cooling system the liquid steel is tranformed to the slab. These slabs were transferred by railway to the hot rolling plants.

In hot rolling plant; these slabs were made thiner and thiner up to 1.50 mm with the order of custumers. These hot rolled sheets were making coil to tranfer easily to any location, since a single sheet was about the 12m length. It is possible to sell hot rolled steels to another purchasers; however if the purchaser brand wants to much more thiner steel sheets or galvanized steels. Cold rolling process is done for this purpose .

At cold rolling plants, hot rolled steel sheets were rolled again and again in the cold rolling line up to 0.2 mm thickness.Of couse in the case of demanding; galvanized or electrolytic tinplate were also prepared in cold rolling plant.

Figure 15: Hot Rolling Figure 16: Hot Rolling Line

Figure 17: Technical Sheme of Casting Figure 18: Hot Slab Figure 19: Cold rolling

References

1) http://en.erdemir.com.tr/

2) Yüksek Fırın Prosesi, Erdemir Yayınları,1991

3) Prof. Dr. Tekin, E. (2006). Türkçe-İngilizce Metalbilim ve Gereçbilim Karşılıklar Sözlüğü. Ankara: Erdemir Eğitim Müdürlüğü Yayınları.

Summer Practice METE 300 Fall 2012/2013 ONUR ÖZ

ERDEMİR T.A.Ş. Assoc. Prof. Dr. Fehmi Arcan Dericioğlu

ERDEMİR T.A.Ş. is an one of the biggest integrated steel plant in Turkey. It has harbour, sinter, coke, steelmaking, continuous casting, hot rolling and cold rolling plants and also has blast furnace. In 2006, Erdemir Group has been carrying on its activities since February 27, 2006 with the guidance of OYAK’s experience at international markets.

PRODUCTS [1]:

• Hot rolled products are obtained via continuous casting process of rectangular shaped slabs, which are then hot rolled into 1.50-20.00 mm thickness range. THE RESPONSIBLE ENGINEER : Gökhan Turanlı

• Cold rolled flat steel products are offered in 0.20-2.00 mm. thickness range, and they are obtained by re-rolling hot rolled coils without any heat treatment. E-MAIL ADRESS : [email protected] TEL NO : 0372 329 52 95

• Hot dip galvanized steel products are obtained by continuously coating both sides of cold rolled materials with a layer of zinc.

• Electrolytic Tinplate is a cold-rolled low carbon mild steel sheet or coil manufactured in 0.12-0.60 mm thickness and coated on both surfaces with tin in various coating weights.

Week 1

References www.cemtas.com.tr

Summer Practice METE 300-Fall 2012/2013 ÖZGÜN ÇEPELİOĞULLAR

ÇEMTAŞ ÇELİK ve MAKİNE A.Ş. Prof.Dr.Cevdet Kaynak

Çemtaş Çelik ve Makina Sanayi A.Ş is one of the biggest qualified steel producer in Turkey. Every year Çemtaş produces over than 350 000 tones of qualified steel for automotive and with many different qualities for many different applications in the industry. Çemtaş Çelik ve Makina Sanayi A.Ş. Established in 1970 on a 110000 m2 area in Bursa Organized Industrial District with the help of merge of Industrialists, businessmen, small craftsmen and public entrepreneurs. Full address of the Conpany: Organize Sanayi Bölgesi A.O.S. Bulvarı, NO:3 16159 BURSA Contact Person in the Organization Tel: 224 243 12 30 e-mail:[email protected]

St37-2 Structural Steels St(42,44,50,60,70)- Structural Steels SAE 1010 - 1090- Carbon Steels Case Hardenıng Steels Quenched And Tempered Steels Mıcro Alloyed Steels Free-cuttıng Steels Sprıng Steels Carbon Tool Steels Staınless Steels Boron Steels

PRODUCTS

Steel Plant Area observations;

Electric Arc Furnace Ladle Furnace Vacuum Degassing Wire Injection Station Continuous Casting

Machine Accumulation of dust

are examined in steel plant area with engineers.


Week 2 Rooling Mill observations;

Qualified Steel Rolling Mill Reheating Furnace Sandblasting Machine Sensitive Straightering

Machine Surface Crack Tests

examined with rolling mill engineers.

Figure 2. Cooling bed at Rolling Mill area

Week 3 In week 3 quality department is examined.

Destructive tests

Non-Destructive Tests

Week 4 In the last week of my summer practice, I had chance to make general observations both ın production parts, quality department and research and development studies in the area. Raw material procurement area Servo test “road bend stabilizer

bar” fatigue tests. General observations at Steel Plant

and Rolling Mill area.

Summer Practice METE 300 Fall 2012/2013 Recep ÖREK

Ereğli Iron & Steel Works Co. (ERDEMİR) Blast Furnace (AYŞE)

Prof. Dr. Macit Özenbaş

Erdemir was founded in 11st May 1960 ,and the first crude steel produced in 1965. Hot Rolled Flat Steel Products, Cold Rolled Sheets and Coils, Galvanized /Galvanealed Sheets and Coils, Electrolytic Tin Plate and TFS are the main products. Engineer: Can Öden ([email protected]) 0507 205 74 74

Ereğli Iron & Steel Works Co. (ERDEMİR) is suitable for below processes applied: •Hot rolled products are obtained via continuous casting process of rectangular shaped slabs, which are then hot rolled into 1.50-20.00 mm thickness range.

•Cold rolled flat steel products are offered in 0.20-2.00 mm. thickness range, and they are obtained by re-rolling hot rolled coils without any heat treatment.. •Hot dip galvanized steel products are obtained by continuously coating both sides of cold rolled materials with a layer of zinc. •Electrolytic Tinplate is a cold-rolled low carbon mild steel sheet or coil manufactured in 0.12-0.60 mm thickness and coated on both surfaces with tin in various coating weights.

Week 1(Sinter Plant) There is a sinter plant in Erdemir to prepare sinter for blast

furnace from powdered ore and flue dust. Sintering process is important because it has significant effect on the efficiency of blast furnace. The product sinter must have the properties of ideal input material for blast furnace in response of permeability, density, size and chemical composition

Figure 1: Sinter Chimney

Figure 2: Sintering

Graph 1: Sintering Cycle

Week 2(Coke Plant) There is a coke plant in Erdemir which is founded to response the

coke need of blast furnaces. There are three furnaces in the coke plant of Erdemir. The first two furnaces were built in 1964 and each one has 37 batteries. Third furnace was built in 1978 and has 87 batteries. Total annual production capacity of coke plant is around 1100000 tons.

Figure 3: Coke Process

Figure 4: Coil on forge

Figure 5: Coke Plant

Week 3(Steel Plant) It was modernized in 1995. Its capacity is around 3.4 million tons per

year. The pig iron that comes from blast furnace goes to converters after mixing with some amount of scrap. Converters have a capacity around 120 tons output steel. The converters are basic oxygen furnace. The oxygen oxides the impurities and let them go to slag .

Figure 6: Scrap charging

Figure 7: Casting after BOF

Figure 8: Steel Plant

Week 4(Continuous Casting) • Continuous casting is the link between blast furnace- steel plant and the rolling. • There are 4 continuous casting machines in Erdemir. • The product of continuous casting is as a name of slab with proper sizes for rolling. • The continuous casting has the advantage of continuous production as the name suggest.

• It becomes possible with carefully calculated solidification rates. • The outer shell becomes solid where the inner parts are still liquid. • By this way the plant can cast slabs with all lengths.

Figure 9: Continuous Casting Machine

Graph 2: Casting Curve for Al

References:

1. http://www.erdemir.com.tr

2. ERDEMİR guidebook

HEAT TREATMENT ANNEALING-TEMPERING: Annealing is

made in annealing furnaces that have a temperature which transforms steels to austenite phase. In this phase the steel remains 80-90 minutes and get a homogeneous microstructure. So that it removes the internal stresses. After annealing, parts are quenched either in oil or water. Then the parts are charged to tempering furnace that has a temperature between 200-600˚C.

INDUCTION HARDENING: Induction

hardening is used to harden a specific surface of machine parts and uses electric energy.

It is recommended for preventing wear during application of blades or drill points for example.

CEMENTATION: Cementation process is

carburization of iron in a furnace. Actually it is made for hardening the surface of the machine part.

ISOTHERMAL ANNEALING

HOT FORGING FORGING: Forging is another process to produce

machine parts which is faster than casting. And also forged steels have different mechanical properties. Pressing machines are used to shape the hot steels.

FORGING DIES: Forging dies are placed into

the pressing machines to obtain the desired shape. Dies are made of hot working tool steel and shaped by machining processes.

CASTING PATTERN MAKING SHOP MOLD MAKING: Mold is important because gives a

shape to molten metal and controls the parameters of casting process.

MELTING CASTING: Ladles are used for casting to carry the

molten material to cast into the molds. COOLING AND SHAKE-OUT: The solid part is

extracted from the mold after cooling.

CUTTING AND NORMALIZING

MACHINING AND QUALITY CONTROL MACHINING: Machining is a process to shape the metal

parts by drilling or cutting by lathes, milling machines and drills.

HARDNESS TEST: Rockwell and Brinell Hardness Testing Machines.

CRACK CONTROL: By UV or Ultrason. TENSILE TEST IMPACT TEST CHEMICAL ANALYSIS MICROSTRUCTURE DETERMINATION DIMENSION AND COORDINATE MEASUREMENTS

References 1. www.cimsatas.com

ÇİMSATAŞ IS AN INDUSTRIAL COMPANY AND A PART OF ÇUKUROVA GROUP. THE COMPANY HAS ESTABLISHED IN MERSİN IN 1972 AS AN INTEGRATED FACILITY ON A 84.000 m² AREA TO PRODUCE CONSTRUCTION MACHINES. FROM 1981 TO 1994 ÇİMSATAŞ MANUFACTURED LOADERS WITH CATERPILLAR INC. LICENSE. NOW PRODUCES AUTOMOTIVE AND CONSTRUCTION MACHINE PARTS TO DOMESTIC AND FOREIGN COMPANIES LIKE BMC, RENAULT, OTOYOL, MERCEDES-BENZ, LIEBHERR AND KNORR-BREMSE.

CONTACT PERSON: ÖZDEŞ AKKAYA E-MAIL: ozdes.akkaya@cimsatas PHONE NUMBER: 324 221 84 00 – 132

ÇİMSATAŞ PRODUCES AUTOMOTIVE AND CONSTRUCTION MACHINE PARTS BY CASTING, FORGING, HEAT TREATMENT AND MACHINING PROCESSES. ALLOY STEELS AND CAST IRON USED AS MATERIALS TO PRODUCE PARTS. ÇİMSATAŞ BUYS THESE MATERIALS AS BLOCKS FROM ASİL ÇELİK, BURSA.

Summer Practice METE 300 Fall 2012/2013 RIZA MAHFUZ YARGICI

ÇİMSATAŞ ASST.PROF.DR. H. EMRAH ÜNALAN

Week 1 In the first week, chemical

analyses and metallographical examinations are done in laboratory services.

• Chemical Analyses : Analyses for ferrous and

nonferrous alloys, and chemical analyses for quality control are made by automatic machines and wet analyze methods.

• Metallograpical Examination :

Ferrous and nonferrous alloy’s microstructures are examined for their mechanical properties.

Week 2 In the second week ,some small

molding and casting shops and some factories ,which are Emek Boru and Makim, are visited.

• Emek Boru :The production of

spiral welded steel pipes with qualified material and outstanding quality is achieved.

• Makim : Investment casting is used for manufacturing materials.

Week 3 In the third week ,chemical analyses,

mechanical tests and metallographical examinations are done in laboratory services.

• Mechanical Testing : One of the primary aims in

mechanical property tests is to determine conformance or non-conformance to specifications. The data may thus serve as an index of the quality of a product in comparison with the data obtained from other sources. Such data may also be used to compare a given material with other materials and in conjunction with other factors, may assist in the replacement improvement of a material.Mechanical testings include hardness, tension,compression,bending and microhardness testings .

Week 4 In the fourth week, Akdaş Döküm is

visited and chemical analyses and mechanical testings are made.

• Akdaş Döküm : High-low alloy and plain carbon steels,

stainless steels, wear resistant manganese steels, Ni-hard, white casting irons and grey, nodular cast irons are produced according to the standards by experienced personnel in this company and it has also got the ability to produce pre-machined and machined pieces upon customer request.

References • http://www.emekboru.com.tr/ • http://www.akdas.com.tr/

With the first aim of supporting Small and Medium Industries KOSGEB, the Small and Medium Industries Development Organization,was established in April 12, 1990 by Ministry of Industry an Trade, KOSGEB.The second aim of the KOSGEB is making some analyses on materials for companies. Contact Person :M. Tarık FERİZOĞLU e-mail : [email protected]

Summer Practice METE 300 Fall 2012/2013 Selvihan KILIÇ

KOSGEB (SMALL AND MEDIUM INDUSTRY DEVELOPMENT ORGANİZATION) Prof. Dr. Ali KALKANLI

2.http://www.akdas.com.tr/ 2.http://www.akdas.com.tr/ 2.http://www.akdas.com.tr/ 2.http://www.akdas.com.tr/

1.http://www.emekboru.com.tr/

http://www.akdas.com.tr/





http://www.emekboru.com.tr/


Core Production

Core is a part placed inside the mold in order to produce complex shapes.

Cores are produced by hotbox or coldbox method.

Coldbox method involves amine gas and acids to bind the sand together

Hotbox method involves heat in order to produce a core.

Both products from these methods require paint for extra durability.

Mold Production

Mold is the main body which creates the shape of the cast material.

Sand molds are used in order to achieve low cooling rates.

In automated systems, pulverized coal, bentonite clay and sea sand is used for mold sand

In Furan line, binder resin, bentonite and sea sand is used.

Molds are produced by pressing the steel or aluminum model into the sandboxes.

Filters, rizers and ventilation chambers are manually installed in both of the production techniques.

There are two automated systems called as Künkel Wagner and Gustav Zimmermann.

Smelting

3 line frequency and 2 medium frequency, total 5 induction furnaces are used for smelting processes.

Line frequency furnaces are used for pouring and medium frequency furnaces are used for melting.

Pouring temperature is in 1390-1440 C temperature interval.

Supercooling is examined to prevent carbide and bainite formation.,

Spectroscopy is used before pouring the melt metal

Laboratory and Quality Control

Laboratories mainly use optical microscope for phase analysis.

Nodular and gray iron phases are examined for their graphite sizes.

Matrix percentage is examined for ductility and strength of the material.

Spectroscopy is mainly used for carbon content of product metal.

Spectroscope uses OES (Optical Emission Spectrometry).

Sand inclusions and gas entrapment are the most common defects in the material.

References 1.Döküm fabrikası–1. (n.d.). Retrieved from www.erkunt.com.tr 2.Erkunt Sanayi A.Ş. Mesleki Eğitim Kitapçığı. Maçacılık, Kalıpçılık, Ergitme, Temizleme, 28. 3.Principle of optical emission spectrometry. (n.d.). Retrieved from http://www.shimadzu.com/an/elemental/oes/oes.html

Erkunt is one of the leading gray and nodular cast iron producers in Turkey.

Casting and machining of motor blocks, cylinder headpieces, brackets, brake parts, flywheels, campanes, and other truck and automobile pieces .

Engineer of Quality Control and Improvement; Yiğit Boran 05326314060

Summer Practice METE 300 Fall 2012 Sencer AYDIN

Erkunt Sanayi A.Ş. Assistant Prof. Dr. Hüsnü Emrah ÜNALAN

Picture of Coldbox Method [1] Picture of Hotbox Machine [2]

Picture of Automated Molding Machine [3] (Gustav Zimmermann)

Picture of a smelter, pouring metal

into a crucible [4]

Picture of the Spectroscope[5]

http://www.erkunt.com.tr/

Week 1 : Sinter Plant

In sinter plant, ores which cannot be charged to the blast furnaces directly because of their sizes are mixed then using limestone and dolomite as flux, ores are prepared in a suitable way both chemical and physical for blast furnace operations. The capacity of the sinter plant in Erdemir is 2.000.000 tons per year. Also in the sinter plant, some waste materials such as blast furnace gas, rolling plant scale and steel plant slag are used. Since sinter has porous structure, it increases the surface area of blast furnace and efficiency. Picture 1:Sinter stack Picture 2:Sinter feeder Picture 3: Sinter product Picture 4: Dwight - Lloyd sinter machine Picture 5: Sinter personnel

Week 2 : Coke Plant & Raw Material

Manipulation Plant & Lime Plant

In coke plant which was founded to response the coke need of blast furnaces, coals from different sources are heated to 1400 C in coke batteries to intensify the carbon content of coal. With this way coals give highest energy when they burned in blast furnace. In raw material manipulation plant, ores from different sources are landed from ships and stored. Sinter and blast furnace blends are prepared according to engineers’ demand and feeded. In lime plant limestone is calcined in furnaces to produce lime which used different areas in factory.

Picture 6 : Coke batteries Picture 7 : Active coke battery Picture 8 : Iron ore stock Picture 9: Calcination furnace

Week 3 : Blast Furnace & Steel Making Plant

Continuous Casting Plant

There are two blast furnaces in Erdemir which are named Ayşe and Zübeyde. In blast furnaces iron ore transforms to pig iron by reduction of iron. Since pig iron has poor mechanical properties, it is converted to steel by blowing oxygen in basic oxygen furnaces in steel making plant. Excess amount of carbon and other impurities in pig iron are eliminated during steel making process. Mechanical properties of steel much more better than that of pig iron. Continuous casting is the link between steel plant and the rolling. The product of continuous casting is slabs with proper sizes for rolling. Continuous casting becomes possible with carefully calculated solidification rates. The outer shell of slab becomes solid where the inner parts are still liquid.

Picture 10: Ayse and Zubeyde

Picture11: Basic oxygen furnace during blowing

Picture 12: Slab ( Continuous casting product )

Week 4 : Hot Rolling Plant & Cold Rolling

Plant

After continuous casting process, steel slab is rolled into 1.5-20.00 mm thickness range by passing through a pair of rolls as shown in figure 1. Before hot rolling steel is heated above to its recrystallization temperature because material can recrystallize during deformation and equiaxed crystals occurs. Since they have equal axial length, more slip systems are active so the structure becomes highly ductile and strong. During cold rolling, steel becomes strain hardened due to the dislocation movements. Cold rolling products also have homogeneous structure and physical properties which appropriate for white good industry, automotive industry.

Figure 1: Rolling process

Picture 13 : Hot rolled coin

Picture 14 : Cold worked coins (finish products)

References

1. Summer practice notes

2. www.erdemir.com.tr

3. http://www.steeluniversity.org/content/html/eng/default.asp?catid=1&pageid=1016899460

4. http://en.wikipedia.org/wiki/Rolling_(metalworking)

EREGLI IRON AND STEEL WORKS CORPORATION

• Ereğli Iron and Steel Works Corporation was located an area of approximately 4 square kilometers at Karadeniz Eregli / Zonguldak, began production in 1965, the only integrated flat steel producer in Turkey with a total annual crude-steel production capacity of 3,0 million tones, it is producing sheet, hot and cold rolled coils, zinc, tin and chromium plated steel with the international quality standards. Production processes at the plant utilize coke-sinter-blast furnace-BOF-continuous casting-hot rolling-continuous cold rolling technology.

Summer Practice METE 300 Bilge Temiz

Erdemir Prof Dr. Cevdet Kaynak

Week 1 • Orientation program was done in the light of these

topics: -Mission and vision of the company -General rules of the company -Information about work safety - Giving out work clothes and company identity card -Distributing to units in the light of process order. • Process Control Laboratory was oriented and control

tests were learned o Tensile-Compressive and Bending Strength

Tests o Micro and Macro hardness tests o Corrosive Resistant material tests o Abrasive Resistance tests o Environmental Effects Tests o Chemical Analysis and cold room tests

Week 2 • Control tests were applied I learned to apply sample preparation steps which are sampling-sectioning, mounting, grinding, polishing and etching. After preparation sample, I applied all tests myself and received test results. Moreover, our advisor taught doing comparison with respect to standards and determine whether the materials is ‘red’ or ‘ok’.

Week 3 Training of Welding Processes Welding is the process of permanently joining two or more

materials together. In FNSS, mostly the aluminium welding is done and rarely the stainless steel welding is applied.

- Types of Welding TIG Welding

In TIG welding an arc is created between a nonconsumable tungsten electrode and the metal being welded MIG and MAG Welding MIG (Metal Inert Gas) welding means the use of an inert (i.e. non active) gas. MAG (Metal Active Gas) welding requires the use of an active gas (i.e. carbon dioxide and oxygen). CO2 is a more commonly used

shortening of MAG welding gas.

Week 4 Training of Nondestructive Test Techniques Non-destructive Testing is one part of the function of Quality

Control and is complementary to other long established methods. By definition non-destructive testing is the testing of materials, for surface or internal flaws or metallurgical condition, without interfering in any way with the integrity of the material or its suitability for service.

• Radiographic Inspection (X-ray) This technique is suitable for the detection of internal defects in ferrous and nonferrous metals and other materials • Magnetic Particle Inspection (MPI)

This method is suitable for the detection of surface and near surface discontinuities in magnetic material, mainly ferritic steel and iron.

• Penetrant Inspection (PI). This method is frequently used for the detection of surface

breaking flaws in nonferromagnetic materials.

References 1. http://mee-inc.com/tensile-testing.html 2. http://www.fnss.com.tr/ 3. http://www.metengr.com/ 4. http://www.gordonengland.co.uk 5. S. Grynko, "Material Properties Explained" (2012), ISBN 1-4700-7991-7, p. 2. 6. http://lmats.com.au/resource-centre/ 7. http://www.roymech.co.uk/Useful_Tables/Manufacturing/Welding.html

The company was established in 1988 to manufacture 1698 Armored Combat Vehicles (ACV’s)

for Turkish Armed Forces under a direct commercial contract (1st package ACV) with the Undersecretariat

of Defense Industries (SSM). The facilities situated on a total area of 280.000 square meters in Gölbaşı, 6X6X6 PARS

Ankara started the production in August 8X8 PARS Responsible engineer : Hakan BOLVADİN (quality engineer)

Contact e-mail : [email protected]

Summer Practice METE 300 2012/2013 Tuğçe KALELİ

FNSS DEFENSE SYSTEMS INC. Prof. Dr. ALİ KALKANLI

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