WHAT IS DEFECT

A mark or flaw that spoils the appearance of Stainless Steel.

A lack of or abnormality in something necessary surface of stainless steel for
normal functioning; a deficiency or imperfection.

DEFECT COMING IN STAINLESS STEEL

TEXT

COLD ROLLING MECHANICAL

SMS HOT
DEFECTS DEFECTS
DEFECTS ROLLING

Sliver C Sliver B White patches Poor Coiling

Sliver S Digs & Gouges Brush Chatter Inter wrap scratches
TiN segregation Scale Pits Buckling Rolled scratches
Lamination Pitting Dents Telescopicity
Rolled In scale Edge Crack Grinding Mark
Roll Mark Pinching
Scaly Surface ILP Mark
Scratches IMR Mark
Roughness Roll chatter mark
Roll Mark
Burr
Hot Rolling Defect

1. SLIVER-B

DEFINITION:

Thin arrow-shaped slivers or straight line defects varying in length, severity & location.
B type slivers are due to burning at the reheating furnace and are generally present near
the edges up to 300mm from each side of the strip, without repetition. The thicknesses of
these slivers are 200-400 microns with 5-25mm length.

REASONS:

9 Grain boundary oxidation/grain boundaries breakage.

9 High N2/chemistry imbalance &
9 High sulfur in the fuel used in re-heating furnace.

REMEDIES:

9 Avoid overheating (maintain recommended reheating practice).

9 Maintain proper length of flame and do not allow it to touch the slab.
9 Aimed sulfur is as low as possible.
9 Addition of boron helps to make compound with Cr (Cr2B), due to this compound
grain boundaries are more strengthened.
2. SCALE PITS

DEFINITION:

Scales Pits appear as rough pitted surface with sediments of scale in the bottom of pitted
portion.

REASONS:

9 Improper chemical pickling due to less acid concentration.

9 Improper shot blasting pressure.
9 Inadequate pressure of Primary & secondary de -scaling pressure.
9 Improper angle of descaling nozzles.
9 Chocking of Nozzles.
9 Excess exposure to ambient conditions.
9 High retention time in soaking zone.

REMEDIES:

9 Proper chemical pickling with right acid concentration.

9 Adequate pressure of Primary & secondary descaling pressure.
9 Avoid Chocking of Nozzles.
9 Proper arrangement of de-scaling nozzles.
9 Optimum reheating.
 3. ROLLED IN SCALE

DEFINITION:
A surface defect consisting of scale partially rolled into the surface of the sheet.

REASONS:

9 Inadequate high pressure in water descaling in hot strip mill.

9 Excessive reheating time and/ or too high a temperature.
9 Inadequate shot blasting.

REMEDIES:

9 Optimum reheating, descaling and shot blasting.

4. ROLL MARK

DEFINITION:
A repeated mark on the surface of the strip, taking various shapes & sizes with
occurrence at regular intervals along the rolling direction, depending on the roll
diameter and the stage of rolling at which it appears.

REASONS:

9 A damaged roll surface either by adhesion of foreign particles or pits etc in the rolls
do produce these kind of imperfections.

REMEDIES:

9 Ensure defect free roll grinding.

9 Ensure correct rolling procedure & good mill maintenance avoiding breakdowns.
9 Ensure good input material, severe surface defects in the input material like
laminations, edge damage, Edge cut, coil breakage etc. can damage roll surface, that
may lead to roll mark generation.
9 Adequate care should be taken while pushing the work roll inside the mill.
5. SCALY SURFACE

DEFINITION:
Scaly surface is visible as dark surface due to inadequate pickling of the coil annealed in
oxidizing environment. The scale on the strip can also be observed by rubbing with white
paper.

REASONS:

9 Improper chemical pickling due to less acid concentration

9 Improper shot blasting pressure
9 High retention time in soaking zone

REMEDIES:

9 Proper chemical pickling with right acid concentration

9 Proper shot blasting pressure
9 Adequate pressure of Primary, secondary & tertiary descaling pressure
9 Proper arrangement of descaling nozzles
9 Excess exposure to ambient conditions

.
6. SCRATHES

DEFINITION:
Scratches, which occur, may be either longitudinal or transverse. New Scratches show as
bright shining lines on the strip. These scratches are varying in length, width and depth.

REASONS:

9 Inclusion of foreign particles while rolling

9 Slot missing while rolling
9 Defective conveyor
9 Defective roll
9 Plates touching the stationary parts during processing
9 Improper maintenance of processing units

REMEDIES:

9 Prevent the touching of moving strips to the stationary parts in the processing.
9 Proper maintenance of the processing units.
9 To avoid mismatch of speed of the rotating equipments.
7. EDGE DAMAGE /EDGE CRACK

DEFINITION:
Cracking and/ or damages of the edges of the strip.

REASONS:
9 Improper chemistry balance before casting
9 High retention time in soaking zone
9 Improper rolling parameters
9 Improper handling
9 High temperature in the furnace

REMEDIES:
9 Proper chemistry balance before casting
9 Proper retention time in soaking zone
9 Proper rolling tension
9 Proper handling of materials
9 Maintain proper temperature for respective grades
8. PITTING

DEFINITION:
A rough uneven surface, which is produced by either scale pits or, rolled in scale or,
refractory particles, is termed as pitting.

REASONS:

9 Rolled in scale and scale pits due to poor descaling after reheating of the coil
9 at the hot rolling division
9 Refractory particles, rolled at the hot rolling division.
9 Improper descaling
9 Foreign particles embedded while rolling

REMEDIES:

9 Proper descaling of the slab/ coil during hot rolling.

9 Appropriate pressure for the water used for descaling, removal of scale/ refractory
particles completely.
9 Avoid nozzle bending
9 Maintain proper nozzle angle
9 Avoid chocking of nozzles
9. DIGS & GOUGES

DEFINITION:
Surface imperfection, mostly repetitive in nature along the length of the coil or
concentrated in certain localized areas. These defects may appear with some depth or it
may appear with a flake similar to the appearance of sliver. These types of defects can
also be named as mechanical slivers.

REASONS:
9 Damaged rolls/ foreign particle picked up on the rolls at the hot rolling mill.
9 Rubbing during hot rolling.
9 Mechanical scratches during hot rolling.

REMEDIES:
9 Proper maintenance of the hot rolling unit.
9 Defect free rolls at the hot rolling mill.
9 Avoid rubbing & scratches.
9 Avoid loose coiling.
10. DENTS

DEFINITION:
Dents are random or repetitive mechanical indents or depressions on the surface of the
strip.

REASONS:

Dirt or metal pieces picked up on any type of roll, which is in contact with the strip may
lead to this type of mechanical indents. Inclusions while pouring molten metal into the
mold can cause such type of indents.

REMEDIES:
9 Avoid inclusions
9 High standard of maintenance and inspection of processing equipments.
11. STRESS CORROSION CRACKING (PIN HOLES)

DEFINITION:
Stress corrosion cracking (SCC) is the cracking induced from the combined influence of
tensile stress and a corrosive environment.

REASONS:
These defects are most common in the austenitic steel due to presence of slip systems.
Researches show that low nickel austenitic alloys are prone to SCC in various corrosive
environments, especially in chloride environment. High chlorine content of the water
being used at the hot rolling unit (>50 PPM) can be dangerous.

REMEDIES:
9 Higher Nickel content for the austenitic stainless steel.
9 Material should be properly annealed, because the materials with residual stresses
are more susceptible for SCC.
9 Clean steelmaking practice is needed to minimize stress raiser inclusions that may
initiate SCC.
9 Use of water with lesser chloride content (<50PPM).
9 Avoid storage of Full Hard (i.e. as rolled) material in open atmosphere.
12. HR ROUGHNESS

DEFINITION:
Rough uneven grainy surface appearance.

REASONS:
9 Over Pickling.
9 High furnace Temperature.
9 Slow Speed of strip in furnace.

REMEDIES:
9 Optimum concentration in pickling bath and rectifier current in electrolytic pickling
tank should be ensured.
9 Appropriate Speed of strip & temperature of the furnace.
13. POOR COILING

DEFINITION:
Inappropriate coiling, leading to poor build-up.

REASONS:
9 Low Tension value in the tension reel
9 Edge sensor malfunction.
9 Hydraulic Cylinder for movement is not working.
9 Poor shape of the coil.
9 Poor feeding of coil in coiler /tension reel.

REMEDIES:
9 Appropriate tension value.
9 Regular checking of Edge sensor & hydraulic cylinder.
9 Good shape of input coil.
9 Avoid any object between edge sensor & the strip.
9 Rewinding for the poor buildup coils.
9 Appropriate feeding of coil in coiler/ tension reel.
14. TELESCOPICITY

DEFINITION:

Coiling in the shape of Telescope due to transverse slipping of successive layers of a coil
so that the edge of the coil is conical rather than flat.

REASONS:

9 Poor handling of coil.

9 Loose buildup of the coil.
9 High camber or waviness in the coil.
9 Malfunction of the edge guide.

REMEDIES:
9 Take adequate care in coil rewinding.
9 Buildup should not be loose, tension should be appropriate.
9 Check coil-guiding system, for poor buildup.
15. WAVINESS

DEFINITION:
Not flat. Strip deviating from the flat surface along the direction of rolling and exceeding
the standard tolerance for flatness.

REASONS:
Rolling deformation on the edges are more than the center portion of the coil. Uneven
quenching at the Annealing & Pickling line may also generate some waviness.

REMEDIES:
9 Rolling deformation should be same through out the thickness of the strip.
9 Appropriate quenching.
16. CAMBER

DEFINITION:
Edgewise curvature. A lateral departure of a side edge of sheet or strip metal
from a straight line.

REASONS:
Camber is caused by one side being elongated more than the other in the rolling process.
Camber measurement is taken by placing a straight edge on the concave side of a sheet
and measuring the distance between the sheet edge and the straight edge in the center of
the arc.

REMEDIES:

Avoid excessive rolling at one edge of the strip.

17. PINCHING

DEFINITION:

A sharp deviation from flatness in the sheet, appearing as a shadow, which is different
from the original aspect of the strip.

REASONS:

9 Poor shape of the coil.

9 Waviness or heavy buckling in the strip.

REMEDIES:

9 The material should be free from severe waviness or heavy buckling.

9 Coil should have a reasonably good shape.
18. WATER/ ACID STAIN MARK

DEFINITION:

Stains on the plate affecting one or both surfaces , often due to water or acid from the
pickling bath or due to improper drying.

REASONS:
9 Improper drying from Pickling bath
9 Low acid concentration
9 Poor cleanliness and metal content in the pickling bath
9 Poor water quality in the quenching station
9 Poor washing of water surfaces.

REMEDIES:

9 Good water quality

9 Ensure high-pressure water spray.
9 Proper Acid concentration
9 Ensure proper drying
SMS/CCS DEFECT

1. SLIVER-C

DEFINITION:

C type of sliver is a casting defect, caused by the casting powder, reoxidation, surface and
sub-surface cracks, segregation of tramp elements, insufficient inclusion floating in the
mould. These slivers are present at the random locations, without repetition.

REASONS:

9 From casting powder. Mould flux

9 Reoxidation
9 Surface/ sub-surface cracks and entrapped gases.
9 Segregation of tramps
9 Insufficient inclusion floating in the mould

REMEDIES:

9 Avoid entrapment of mould flux & casting powder.

9 Avoid Gas entrapment.
9 Appropriate casting practice in order to minimize thermal stresses.
9 Avoid Micro cracks.
2. SLIVER-S

DEFINITION:
S Type of slivers are slivers due to slag inclusions. These defects are generally revealed
in Cold Rolled Annealed & Pickled or, Bright Annealed stage of material. These slivers
appear as small lines that are randomly distributed on the strip surface. These types of
slivers are thick up to 200 microns with length up to 25mm.

REMEDIES:
9 From slag inclusion
9 Cleanliness of stainless steel
9 Compositional imbalance
9 Excessive tramps

REASONS:

9 Avoid slag inclusion & cleanliness of steel

9 Ensure Compositional balance
9 Avoid trim alloying for minimizing tramps
3. TiN SEGREGATION

DEFINITION:
These are generally appearing as straight lines in the rolling directions of a darker color
than strip surface. The presence of Titanium-Nitride (TiN) as inclusions in the pits is
visible.

REMEDIES:
This type of defects are seen in grade containing Titanium e.g. ASTM A240 409, ASTM A
240 321 etc. These inclusions arise in steelmaking consisting of particles of TiN, which
have become elongated in Hot Rolling.

REASONS:
Appropriate care should be taken during casting so that segregation of TiN is maintained
at a minimum level.
4. WIDTH VARIATION

REASONS:

9 Edger not used properly for controlling the width.

9 Variation in width of the slab.
9 Necking during rolling.

REMEDIES:

9 Edger to be used effectively for controlling the width.

9 Slab width to be uniform (max. 2 to 3 mm variation over entire length of individual
slab).
9 During rolling necking to be avoided (Avoid tension fluctuation).

5. PIPING / LAMINATION

REASONS:

9 Insufficient discard from last piece of heat (PH pc.) cast during casting.
9 High exhaust of center line segregation due to high superheat & inclusion.

REMEDIES:

9 Depth of piping to be checked before cutting the pcs. & fully discard the piping.
9 After cutting material to again check for piping by removing the scale from cut
piece. In case pipe still present discard more.
9 Maintain low super heat during slab casting.
6. LOGITUDINAL CRACK (WIDE SURFACE)

REASONS:

9 Uneven shell thickness in mould, high superheat.

9 Very high/uneven shrinkage in mould.
9 Asymmetrical leaning of strand shell in mould.
9 Sticking/inadequate lubrication in mould.

REMEDIES:

9 Accurate mould geometry, good surface finish free of notch/scratch, proper mould
alignment with foot roller, proper mould cooling.
9 Centering of SEN in mould.
9 Proper quality of casting powder.

7. LOGITUDINAL CRACK (NARROW SURFACE)

REASONS:
9 Insufficient mould taper (narrow face).
9 Insufficient spray cooling on the narrow side.
9 Incorrect setting of the narrow support rolls.
9 Excessive casting speed.

REMEDIES:

9 Correct setting of mould taper as per grade & size.

9 Checking of spray water nozzles.
9 Correct setting of foot rollers
9 Casting speed as per norm.
8. TRANSVERSE CRACK (WIDE SURFACE)

REASONS:
9 High friction with jammed support rolls.
9 Alternate bulging & compression due to improper setting of roll gap.
9 Local super cooling/reheating.

REMEDIES:
9 All rolls should rotate freely with accurate roll alignment.
9 Proper roll gap setting as per design.
9 Correct spray water rate & distribution.

9. TRANSVERSE CRACK (NARROW SURFACE)

REASONS:
9 Hanging or sticking of the strand in the mould corners.
9 Super cooling of the strand corners.

REMEDIES:
9 Checking & maintenance to avoid corner gap.
9 No accumulation/leakage of machine cooling water on strand.
 10. OTHER CASTING DEFECTS
DEFECTS CAUSES
PINHOLES Too low steel temperature /
improper feeding of casting
powder causing mixing with
liquid steel in mould,
moisture in cooling scrap or
casting refractories.
CASTING PITS Localised puncture of
solidified shell in mould
during manual poking to
break slag cast & lump
formation.
MECHANICAL Falling of extraneous
PITS material including slag out
of oozing on the strand in
secondary cooling zone.
SLAG BELTS / Mold level fluctuation
JOINTS/POWDER Speed fluctuations
ENTRAPMENT Jerking in concast machine
Poor quality of casting
powder.
TRANSVERSE Shrinking away of strand
DEPRESSION shell from the mould wall at
meniscus level to excessive
cooling/level flactuation and
subsequent overflow of
liquid steel into the gap.
DEEP / Shrinking away of strand
DISTURBED shell from the mould wall at
OSCILLATION meniscus level to excessive
MARKS cooling/level flactuation and
subsequent overflow of
liquid steel into the gap.
High negative strip time &
slow casting speed.
Unbalanced mould
oscillation.
REMEDIES
Optimum steel temperature,
proper casting powder feeding,
dry scrap, dry casting refractory
& no turbulence in mould.
Careful mould operation during
casting without damaging the
shell and use of dry casting
powder free of any lump.
Proper capping at the end of
casting to avoid oozing, keeping
casting floor and rolls clean.
Mold level fluctuation to be
controlled within the specified
limits time +/- 3 mm.
Speed change should be gradual.
Machine alignment to be
checked too & corrected to avoid
jerking .
Use of dry casting powder free
of any lump.
Reduction of mould cooling &
increase in casting speed.
Control of mould level
fluctuation.
Control of mould level
fluctuation.
Negative strip ratio within
predetermined maximum limit
and casting speed above some
minimum limit.
Check mould level oscillation
with water level.
MECHANICAL Sharp projections in segment Inspection & cleaning of guides
SCRATCHES guides/rolls & conveyor and rolls to be done to avoid
rolls. scratches.
Non-moving rolls. All rolls must be made free from,
Deposit of foreign particles jamming & foreign particles by
on moving/non-moving rolls. regular inspection & cleaning.
CASTING JOINTS/ Severe mold level Proper maintenance of casting
INTERRUPTION fluctuation & temporary machine including electrical &
MARKS. casting speed in between. automation paint.
Bleeding during casting. Casting super heat & speed to be
controlled as per norms to avoid
bleeding during casting.
BLEEDING Insufficient cooling of the Adjustment of mould taper with
narrow faces/mould taper. checking & proper mould
Improper casting flux. cooling with proper
Extreme mould level maintenance.
flactuation. Selection of proper casting
powder and regular checking of
composition.
Control of mould level
fluctuation.
STAR CRACKS Extreme local super cooling Correct spray water flow &
/ reheating. distribution adjustable with
Copper abrasion and casting speed.
weekening of the grain Proper quality casting powder to
boundaries by penetrated give uniform layer of slag in
copper. between mould & strand.
Moulds with protective metal
coating.