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Bisalloy Technical Manual

BISPLATE

Technical Manual

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Bisalloy Technical Manual

Contents

Chapters Page Numbers

Introduction 3

How to Contact us 4

Process Route 5

Range of Grades 6

Available Sizes 23

Manufacturing Tolerances 24

Cutting BISPLATE 27

Welding BISPLATE 35

Bending, Rolling, Shearing and Punching BISPLATE 43

Drilling, Countersinking & Tapping BISPLATE 47

Turning & Milling BISPLATE 53

Design Examples 57

BISPLATE Identification Marking and Colour Coding 69

Testing and Certification 70

Hardness Testing BISPLATE 71

BISPLATE Wear Comparisons 74

Fatigue resistance of BISPLATE 79

Performance of BISPLATE at Elevated Temperatures 87

Galvanising BISPLATE 90

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Introduction
Bisalloy Steels Pty Ltd, located at Unanderra close to BlueScope Steels integrated steel works
at Port Kembla, is Australias only manufacturer of high strength, wear resistant and armour
grade steel plate by the continuos roller quenching and tempering process.

Quenching and tempering, defined as a combination of heating and cooling of a metal or alloy,
changes the microstructure of the steel and improves the strength, hardness and toughness of the
materials being treated.

Utilising the most advanced heat treatment technology; furnace temperatures and quenching
rates are scientifically controlled to obtain the optimum quality grades of steel with low alloy
content. The resulting products of low alloy quenched and tempered steel offer designers the
strength to weight advantages and wear resistant properties not available in conventional steels.

High strength steel has a strength to weight ratio of more than three times that of mild steel.
Principal applications lie in mining equipment, transport, telescopic cranes, materials handling
equipment, high rise construction and forestry. High hardness grades offer improved wear life
making it ideal for applications such as liners for chutes, buckets, dump trucks etc.

BISPLATE Armour grades are suitable for armoured personnel carriers and ballistic
protection of military and civilian fixed plant and transport equipment. BISPLATE grades
can be readily cut, welded, formed and drilled using similar techniques to mild steel.

Bisalloy Steels operates an approved mechanical testing laboratory registered and monitored
by the National Association of Testing Authorities (NATA). The companys quality control and
management system is assessed by Lloyds and accredited to ISO9001:2000.

The capacity, quality and versatility of our heat treatment line enables us to compete in both
domestic and international markets; including North and South America, Asia, New Zealand
and Africa.

Disclaimer

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How To Contact Us
Bisalloy Steels Pty Ltd
18 Resolution Drive
Unanderra
P.O.Box 1246
NSW 2526
Australia

Tel Switch 61 (0)2 4272 0444


Fax 61 (0)2 4272 0456
Web Site www.Bisalloy.com.au

Tasmania, Victoria, Western Australia and South Australia


Greg Check tel 02 4272 0417
Mob. 0418 833030
greg.check@Bisalloy.com.au

New South Wales, Queensland, Northern Territory & New Zealand


Jim Devlin tel 02 4272 0419
Mob. 0418 427766
jim.devlin@Bisalloy.com.au

Export Sales
Willy Pang tel 02 4272 0418
Mob 0419 280765
willy.pang@Bisalloy.com.au

Sales & Marketing Manager


Michael Sampson tel 02 4272 0412
Mob. 0418 603852
michael.sampson@Bisalloy.com.au

Bisalloy Manager
Nick Hardcastle tel 02 4272 0402
Mob. 0418 264370
nick.hardcastle@Bisalloy.com.au

Technical Manager
Russell Barnett tel 02 4272 0470
Mob. 0418 271948
russell.barnett@Bisalloy.com.au

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Schematic Diagram of BISPATE Production Process

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RANGE OF GRADES

INTRODUCTION

Bisalloy Steels grades are world class, our structural grades complying with many of the
international quenched and tempered steel plate standards.

Each of the grades covered by this brochure has specific mechanical and chemical properties
detailed. The process information detailed below is applicable to all BISPLATE product
manufactured by Bisalloy Steels.

BISALLOYS FEED PLATE

The technology used in the manufacture of BISPLATE is not only world class, but the
demands of high strength and high hardness steels dictate the need for one of the most stringent
process routes utilised in the manufacture of steel plate, anywhere in the world.

Hot metal desulphurisation ensures low levels of sulphur and other impurities in steelmaking.
Vacuum degassing is carried out to reduce the Hydrogen content of the steel whilst also
decreasing the amount of undesirable Oxygen and Nitrogen in the steel.
Control of impurities is additionally assisted through the use of hot metal injection and
conditioning of the slag during the Basic Oxygen Steelmaking process.

Close control of chemical composition and final microstructure is maintained through the use of
ladle refining with Calcium injection, Argon bubbling through the heat during steelmaking and
alloying additions made under vacuum.

Following steelmaking, integrity of slab product is ensured by the use of electromagnetic


stirring, continuous casting and controlled cooling of slabs prior to plate rolling.

Finally, plate rolling is carried out in a computer controlled four high rolling mill in which each
draft is modified during rolling for optimisation of final properties.

The net result is steel with improved toughness, structural integrity and fatigue resistance,
providing consistent product performance in service.

BISALLOYS HEAT TREATMENT

Plate is heated in our natural gas fired furnace prior to quenching in the Drever roller quench
unit. Complete PLC control allows tight and consistent control of all furnace and quench
operations including water flow rates and pressures, furnace temperatures and residency times.

Pre and post heat treatment shot blasting removes scale and presents an attractive plate. This
results in improvements in product properties, welding and cutting, as well as simplification
during fabrication.

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The final operation at Bisalloy is plate leveling through the plate leveler in material up to
32mm thickness. This has resulted in significant improvements in flatness of plate to market,
much tighter than the Australian Standard and other international standards.

Our quality assurance system ensures that full traceability exists from initial steelmaking right
through the process to the final plate. Each plate is individually hard stamped with a unique
identification, and this links the overall traceability.

All plates are tested for hardness, whilst all structural grades are tested in Bisalloys NATA
approved mechanical testing laboratory. Plates of all grades are certified. The entire process is
carried out in compliance with ISO-9001 certified by LRQA (Lloyds Register Quality
Assurance).

BISALLOYS TECHNICAL DEVELOPMENT

Each of the grades outlined in this brochure has been developed to optimise chemistry and
mechanical properties in conjunction with Bisalloys heat treatment process.

Our world class steel grades ensure that properties such as ductility, weldability and toughness
are maximised whilst complying with the required hardness and strength requirements.

Ongoing R&D at Bisalloy keeps our product range at the leading edge of available quenched
and tempered steels. Already we are developing steels to meet the emerging requirements for
still stronger structural and higher hardnesses grades, and these will be released to the market as
demand dictates.

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BISPLATE 6 0

BISPLATE 60 is a low carbon, low alloy, high strength structural steel which exhibits
excellent cold formability and low temperature fracture toughness.

APPLICATIONS

The combination of BISPLATE 60 mechanical properties and ease of fabrication offers


economical advantages in many structural applications. Some examples of applications for this
grade include:
Storage tanks (Water/Oil/Gas)
High rise buildings (Columns/Transfer beams)
Lifting equipment (Mobile/Overhead cranes)

FABRICATION

BISPLATE 60 can be welded successfully with minimal levels of preheat and has
excellent low temperature fracture toughness.
BISPLATE 60 has been designed such that a low hardness level is produced in the heat
affected zone (HAZ). As a result this steel has a low susceptibility to HAZ cracking.

For further details on fabrication please refer to Bisalloys technical literature.

MECHANICAL PROPERTIES

PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress 500 MPa (Min) 580 MPa

Tensile Strength 590 730 MPa 640 MPa

Elongation in 50mm G.L. 20% (Min) 30%

Charpy Impact (Longitudinal) -


80J (Min) 200J
20C (10mm X 10mm)

Hardness 210HB

CHEMICAL COMPOSITION
THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)
5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25
16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29
>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30

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BISPLATE 70

BISPLATE 70 is a low carbon, low alloy, high strength structural steel. This grade can be
welded with minimal preheat and has excellent low temperature fracture toughness suitable for
structural applications.

APPLICATIONS

The combination of BISPLATE 70 mechanical properties and ease of fabrication offers


economical advantages in many structural applications. Some examples of applications for this
grade include:
Transport equipment (Trays/Low loaders/Outriggers)
Storage tanks (Water/Oil/Gas)
High rise buildings (Columns/Transfer beams)
Lifting equipment (Mobile/Overhead cranes)
Mining equipment (Dump truck trays/Structural applications)
Longwall mining supports

FABRICATION

BISPLATE 70 exhibits excellent cold formability and low temperature fracture toughness.
BISPLATE 70 has been designed such that a low hardness level is produced in the heat
affected zone (HAZ). As a result, this steel has a low susceptibility to HAZ cracking.
For further details on fabrication please refer to Bisalloy's technical literature.

MECHANICAL PROPERTIES
PROPERTIES SPECIFICATION TYPICAL
0.2% Proof Stress 600 MPa (Min) 670 MPa
Tensile Strength 690 830 MPa 760 MPa
Elongation in 50mm G.L. 20% (Min) 28%
Charpy Impact (Longitudinal) - 75J (Min) 180J
20C (10mm X 10mm)
Hardness 230HB

CHEMICAL COMPOSITION
THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30

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BISPLATE 80
BISPLATE 80 is a high strength, low alloy steel plate with a yield strength three times that of
carbon steel and featuring low carbon, excellent notch toughness, good weldability and
formability.

APPLICATIONS
Utilising the high strength properties of BISPLATE 80 allows reduction in section thickness,
without loss of structural integrity. The following lists some applications where the strength
advantage has been realised:
Transport equipment (Low loaders)
High rise buildings (Columns)
Mining equipment (Dump truck trays/Longwall roof supports)
Lifting equipment (Mobile Cranes/Container handling equipment)
Bridges
Storage tanks Induced draft fans
Excavator buckets

FABRICATION
BISPLATE 80 is a high strength steel manufactured with a controlled carbon equivalent for
optimum weldability. BISPLATE 80 can be successfully welded to itself and a range of
other steels, provided low hydrogen consumables are used and attention is paid to preheat,
interpass temperature, heat input and the degree of joint restraint. Stress Relieving can be
achieved at 540C - 570C. Heating above this temperature should be avoided to minimise any
adverse effects on mechanical properties. Cold forming can be successfully conducted,
provided due account is taken of the increased strength of the steel.
For further details on fabrication please refer to Bisalloy's technical literature.

MECHANICAL PROPERTIES
PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress 690 MPa (Min) 750 MPa

Tensile Strength 790 930 MPa 830 MPa

Elongation in 50mm G.L. 18% (Min) 26%

Charpy Impact (Longitudinal) - 40J (Min) 160J


20C (10mm X 10mm)

Hardness 255HB

CHEMICAL COMPOSITION
THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30

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BISPLATE 8OPV

BISPLATE 80PV is a high strength steel alternative for designers of unfired pressure vessels
which meets the requirements of AS1210 and achieves a light weight structure.

APPLICATIONS
BISPLATE 80PV has been approved by statutory authorities and complies with the
requirements of AS1210 for pressure applications and is supplied ultrasonically tested to
AS1710-Level 1. The high strength offers substantial weight reductions in the following areas:
Transportable road tankers
Storage tanks (Spherical and cylindrical)
Railroad tankers (LPG/Liquid ammonia)
Refinery and Petro chemical equipment (Tube plates/Channel covers)

FABRICATION

BISPLATE 80PV is a high strength, low alloy pressure vessel steel with a controlled carbon
equivalent for optimum weldability.
BISPLATE 80PV can be successfully welded to itself and a range of other steels, provided
low hydrogen consumables are used and attention is paid to preheat, interpass temperature, heat
input and the degree of joint restraint. Stress relieving can be achieved at 540C - 570C.
Heating above this temperature should be avoided to minimise any adverse effects on
mechanical properties. Cold forming can be conducted successfully, provided due account is
taken of the increased strength of the steel.

MECHANICAL PROPERTIES
PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress 690 MPa* (Min) 750 MPa

Tensile Strength 790 930 MPa 830 MPa

Elongation in 50mm G.L. 18% (Min) 26%

Lateral Expansion 0.38mm (Min) 0.70mm


Charpy Impact - 55J

Hardness - 255HB
*Dependant on plate thickness.
CHEMICAL COMPOSITION
THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

6-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25*

16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30
*Low heat input butt welding required to ensure transverse weld tensile properties are achieved. Alternate
chemistry may be specified when necessary.

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BISPLATE 320

BISPLATE 320 is a through hardened, abrasion resistant steel plate, offering long life
expectancy in high impact abrasion applications.

APPLICATIONS

BISPLATE 320 offers the optimum combination of hardness, impact and formability for wear
applications which require extensive forming/drilling or fabrication, in impact abrasive
applications such as:
Deflector plates
Chutes
Storage bins
Dump Truck liners
Earthmoving buckets

FABRICATION

BISPLATE 320 is a high hardness, abrasion resistant steel with a controlled carbon equivalent
for optimum weldability. With appropriate attention to heat input, preheat and consumable
selection, BISPLATE 320 can be readily welded to itself and other steels, using conventional
processes.
Cold forming of BISPLATE 320 plates is possible in all thicknesses, provided the high
strength of this steel is taken into account. Adequate allowance must be made for increased
springback relative to mild steel. Heating above 400C should be avoided, otherwise the
mechanical properties may be affected.

MECHANICAL PROPERTIES
PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress - 970 MPa

Tensile Strength - 1070 MPa

Elongation in 50mm G.L. 18%

Charpy Impact (Longitudinal) - 60J


+20C (10mm X 10mm)

Hardness 320 360HB 340HB

CHEMICAL COMPOSITION
THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30

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BISPLATE 400

BISPLATE 400 is a through hardened, abrasion resistant steel plate, offering long life
expectancy in high impact abrasion applications.

APPLICATIONS

BISPLATE 400 offers excellent wear and abrasion resistance and impact toughness in
applications which include:
Dump truck wear liners
Cyclones
Screw conveyors
Deflector plates
Chutes
Ground engaging tools
Storage bins
Cutting edges
Earthmoving buckets

FABRICATION

BISPLATE 400 is a high hardness, abrasion resistant steel offering very good impact
toughness properties. BISPLATE 400 provides an optimum combination of abrasion
resistance, toughness and weldability
Due to its low alloy content, BISPLATE 400 can be readily welded using conventional
welding processes and low hydrogen consumables.
Cold forming of BISPLATE 400 is achievable on all thicknesses although an allowance for
the higher strength should be taken into account. Bending machine capabilities should also be
taken into consideration prior to any forming operation. Heating above 350C should be
avoided, otherwise mechanical properties may be affected.

MECHANICAL PROPERTIES

PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress - 1070 MPa

Tensile Strength - 1320 MPa

Elongation in 50mm G.L. - 14%

Charpy Impact (Longitudinal) - 55J


+20C (10mm X 10mm)

Hardness 370 430HB 400HB

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CHEMICAL COMPOSITION
THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

5-<16 Typical 0.16 0.010 1.10 0.20 0.003 - 0.20 0.0010 0.40 0.25

16-80 Typical 0.18 0.010 1.40 0.20 0.003 0.20 0.20 0.0010 0.50 0.29

>80-100 Typical 0.16 0.010 1.15 0.20 0.003 0.90 0.20 0.0010 0.58 0.30

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BISPLATE 400XT
BISPLATE 400XT is a through hardened, abrasion resistant steel plate, offering long life
expectancy in high impact abrasion applications.

APPLICATIONS

BISPLATE 400XT offers excellent wear and abrasion resistance and impact toughness in
applications which include:
Dump truck bodies
Armoured Face Conveyors
Mining Bucket Construction
Cutting Edges
Tipper Body Construction

FABRICATION

BISPLATE 400XT is a through hardened, abrasion resistant steel plate, offering long life
expectancy in very high impact abrasion applications. BISPLATE 400XT offers excellent
wear and abrasion resistance, and is supplied with guaranteed impact toughness.
Due to its low alloy content, BISPLATE 400XT can be readily welded using conventional
welding processes and low hydrogen consumables.
Cold forming of BISPLATE 400XT is achievable on all thicknesses although an
allowance for the higher strength should be taken into account. Bending machine
capabilities should also be taken into consideration prior to any forming operation. Heating
above 350C should be avoided, otherwise mechanical properties may be affected.

MECHANICAL PROPERTIES
PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress - 1070 MPa

Tensile Strength - 1320 MPa

Elongation in 50mm G.L. - 16%

Charpy Impact (Longitudinal) - - 45J


40C (10mm X 10mm)
Hardness 370 430HB 400HB

GUARANTEED CHARPY-V IMPACT TOUGHNESS


MIN ENERGY,
THICKNESS (mm) TEST PIECE
LONGITUDINAL -40C
6-8 10 X 5 17J
10 X 7.5 10 X 7.5 21J
12-50 10 X 10 25J

CHEMICAL COMPOSITION *TYPICAL


THICKNESS
C P Mn Si S Ni Cr Mo B CE(IIW) PCM
(mm)

6-20 Maximum 0.165 0.025 1.25 0.25 0.005 0.25 0.25 0.25 0.002 0.39* 0.23*

>20-50 Maximum 0.21 0.025 0.40 0.60 0.005 0.35 1.20 0.30 0.002 0.44* 0.28*

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BISPLATE 425

BISPLATE 425 is a through hardened, abrasion resistant steel plate, offering long life
expectancy in sliding and gouging abrasion applications, with impact loading.

APPLICATIONS

BISPLATE 425 offers exceptionally long life in high abrasion applications with impact
loading. Applications include:
Dump truck wear liners
Chutes
Wear liners
Ground engaging tools
Cutting edges

FABRICATION

BISPLATE 425 is a medium carbon, high hardness, abrasion resistant steel. With
appropriate attention to heat input, preheat and consumable selections, BISPLATE can be
successfully welded to itself and a range of other steels by conventional techniques. Because
of its high hardness, cold forming of BISPLATE 425 requires higher bending and forming
forces, and greater allowances must be made for springback. Heating above 300C should be
avoided, otherwise mechanical properties may be affected.

MECHANICAL PROPERTIES

PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress - 1260 MPa

Tensile Strength - 1480 MPa


Elongation in 50mm G.L. - 11%

Charpy Impact (Longitudinal) - 40J


+20C (10mm X 10mm)

Hardness 400 460HB 440HB

THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

6-100 Typical 0.29 0.015 0.30 0.30 0.003 1.00 0.25 0.0010 0.61 0.40

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BISPLATE 500

BISPLATE 500 is a through hardened, abrasion resistant steel plate, offering long life
expectancy in sliding and gouging abrasion applications.

APPLICATIONS

BISPLATE 500 is the hardest steel produced by Bisalloy Steels and offers exceptionally
long life in sliding abrasion applications such as:
Dump truck wear liners
Chutes
Wear liners
Earthmoving buckets
Cutting edges
Ground engaging tools

FABRICATION

BISPLATE 500 is a medium carbon, high hardness, abrasion resistant steel. With
appropriate attention to heat input, preheat and consumable selections, BISPLATE 500
can be successfully welded to itself and a range of other steels by conventional techniques.
Because of its high hardness, cold forming of BISPLATE 500 is difficult, requiring higher
bending and forming forces, and greater allowances must be made for springback. If heating
is necessary, this should not exceed 200C, otherwise mechanical properties may be
affected.

MECHANICAL PROPERTIES

PROPERTIES SPECIFICATION TYPICAL

0.2% Proof Stress - 1400 MPa

Tensile Strength - 1640 MPa

Elongation in 50mm G.L. - 10%

Charpy Impact (Longitudinal) - 35J


+20C (10mm X 10mm)

Hardness 477 534HB 5000HB

THICKNESS
C P Mn Si S Cr Mo B CE(IIW) PCM
(mm)

6-100 Typical 0.29 0.015 0.30 0.30 0.003 1.00 0.25 0.0010 0.61 0.40

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BISPLATE HIGH HARDNESS ARMOUR PLATE

INTRODUCTION

BISPLATE High Hardness Armour (BISPLATE HHA) is a quenched and tempered


steel armour plate suitable for use in both military and civil applications where light weight
and resistance to ballistic projectiles is required.

METHOD OF MANUFACTURE

BISPLATE HHA is a hot rolled steel product that is subsequently heat treated to promote
its high strength and toughness, high hardness and ballistics properties.

BRINELL HARDNESS
THICKNESS SPECIFICATION TYPICAL
6 25mm 477 534HB 500HB
*Other thicknesses may be available on request

TENSILE PROPERTIES

PROPERTY TYPICAL
0.2% Proof Stress 1400MPa
Tensile Strength 1640 MPa
Elongation in 50mm G.L. 14%

CHARPY IMPACT VALUES


MIN ENERGY MIN ENERGY
THICKNESS TEST PIECE TEST TEMP
(TRANSVERSE) (LONGITUDINAL)
5mm 10 x Thk -20C By Agreement By Agreement
6 -<9.5mm 10 x 5 -20C 8J 10J
9.5 - <12mm 10 x 7.5 -20C 12J 15J
12mm 10 x 10 -20C 16J 20J

MECHANICAL TEST FREQUENCIES


TEST FREQUENCY
Hardness Per Plate
Charpy (L) Per Batch
Charpy (T) Per Batch
Tensile Testing By Agreement
Thickness Testing Per Plate
Ballistic Testing By Agreement

CHEMISTRY

The chemical specification conforms with the requirements of MIL-A-46100, although it is


tighter than the requirements of that specification so as to optimise the materials
performance.
Product chemical analyses are taken on a per heat basis.
Chemical analysis is as follows:

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CHEMICAL COMPOSITION

THICKNESS
C P Mn Si S Ni Cr Mo B CE(IIW) PCM
(mm)

6-25 Max 0.32 0.025 0.40 0.35 0.005 0.35 1.20 0.30 0.002 0.61 0.40
*Note Nickel and Vanadium are intentionally added.

Ballistic Properties

AS 2343 PART 2 1997


BULLET RESISTANT PANELS FOR INTERIOR: OPAQUE PANELS

MEASURED MINIMUM
VELOCITY @ REQUIRED
CLASS CALIBRE AMMUNITION RANGE
DISTANCE FROM HHA
MUZZLE THICKNESS
15.6g LEAD SEMI-
G2 44 MAGNUM WAD CUTTER 488 + 10m/s @ 1.5m 3m 6mm
BULLET
12 GUAGE 70mm
12 GUAGE HIGH VELOCITY
SO 403 + 10m/s @ 1.5m 3m 6mm
(FULL CHOKE) MAGNUM 32g SG
SHOT

12 GUAGE 12 GUAGE 70mm


S1 477 + 10m/s @1.5m 3m 6mm
(FULL CHOKE) 24.8g SINGLE SLUG

M193 5.56mm 3.6g


R1 5.56mm FULL METAL CASE 980 + 15m/s @ 5m 10m 10mm
BULLET
NATO STANDARD
7.62mm 9.3g FULL
R2 7.62mm 853 + 10m/s @ 5m 10m 6mm
METAL CASE
BULLET
CLASS G HAND GUN CLASS S SHOTGUN CLASS R RIFLES

RESIDUAL MAGNETISM
Residual Magnetism will be the maximum 20 gauss.

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GRADE EQUIVALENTS

COUNTRY OF
GRADE STEEL STANDARD COMMENTS
ORIGIN
60 Australia AS3597-1993 Grade 500 Min. yield 500 MPa
60 ISO ISO 4950/3 Grade E500 Min. yield 500 MPa
60 Japan JIS G3106 SM58 Min. yield 430 MPa
60 UK BS4360 Grade 55F Min. yield 430 MPa
60 USA ASTM A572 Grade 60 Min. yield 415 MPa
60 USA ASTM A572 Grade 65 Min. yield 450 MPa
60 USA ASTM A537 CI.2 Min. yield 485 MPa
60 USA ASTM A852 Min. yield 485 MPa
60 Europe EN10137-2 S500Q Min. yield 500 MPa
70 Australia AS3597-1993 Grade 600 Min. yield 600 MPa
70 ISO ISO 4950/3 Grade E620 Min. yield 620 MPa
70 USA ASTM A533 Type A.CI.3 Min. yield 570 MPa
70 Europe EN10137-2 S620Q Min. yield 620 MPa
80 Australia AS3597-1993 Grade 700 Min. yield 690 MPa
80 ISO ISO 4950/3 Grade E690 Min. yield 690 MPa
80 USA ASTM A514 Min. yield 690 MPa
80 Europe EN10137-2 S690Q Min. yield 690 MPa
80 Japan JIS G3128 Min. yield 685 MPa
80PV Australia AS3597-1993 Grade 700PV Min. yield 690 MPa
80PV USA ASTM A517 Min. yield 690 MPa

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SUMMARY TABLES

STRUCTURAL STEEL GRADES


STEEL PLATE CARBON BRINELL MECHANICAL PROPERTIES
GRADE THICKNESS EQUIVALENT HARDNESS TENSILE CHARPY V-NOTCH IMPACT
(mm) (IIW) (HB3000/10) PLATE 0.2% PROOF TENSILE ELONGATION PLATE ENERGY TEST TEST
THICKNES STRESS (MPa) STRENGTH IN 50mm G.L THICKNESS (J) TEMP. DIRECTION
S (MPa) (mm) (C)
(mm)

Bisplate 5 By Agmnt -20 L


60 (AS
3597 5-<16 0.40 6-9.5 45 -20 L
Grade 210 5-100 500 590-730 20
500) 16-80 0.50 9.5-12 60 -20 L
>80-100 0.58 13-100 80 -20 L

Bisplate 5 By Agmnt -20 L


70 (AS
3597 5-<16 0.40 230 6-9.5 40 -20 L
Grade 5-100 600 690-830 20
600) 16-80 0.50 9.5-12 60 -20 L
>80-100 0.58 13-100 75 -20 L

Bisplate 5-<16 0.40 5 650 750-900 18 5 By Agmnt -20 L


80 (AS
3597 16-80 0.50 255 6-65 690 790-930 18 6-9.5 20 -20 L
Grade
700) >80-100 0.58 70-100 620 720-900 16 9.5-12 30 -20 L
13-100 40 -20 L

18 6 100
Bisplate 6-<16 0.40 6-65 690 790-930 Lateral By T
80PV 16 Expansion Agmnt
(AS 16-80 0.50 255 70-100 620 720-900
0.38mm max 0C
3597
Grade >80-100 0.50 min
700PV)

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HIGH HARDNESS STEEL GRADES

MECHANICAL PROPERTIES
PLATE CARBON BRINELL TENSILE CHARPY V-NOTCH IMPACT
STEEL 0.2%
THICKNESS EQUIVALENT HARDNESS TENSILE TEST
GRADE PROOF ELONGATION ENERGY TEST
(mm) (IIW (HB3000/10) STRENGTH TEMP.
STRESS IN 50mm G.L (J) DIRECTION
(MPa) (C)
(MPa)

5-<16 0.40
BISPLATE
320 16-80 0.50 320-360 970 1070 18 60 +20 L
>80-100 0.58
5-<16 0.40
BISPLATE
400 16-80 0.50 370-430 1070 1320 14 55 +20 L
>80-100 0.58
BISPLATE
6-20 0.39
400XT 370-430 1070 1320 16 45 -40 L
>20-50 0.44
BISPLATE
6-100 0.61 400-460 1260 1480 11 40 +20 L
425
BISPLATE
6-100 0.61 477-534 1400 1640 10 35 +20 L
500

LEGEND

L Longitudinal
T Transverse
Guaranteed Values
Typical Values (provided for reference information only)

||W Carbon Equivalent Formula:


C.E. = C + Mn + Cr+Mo+V + Ni+Cu
6 5 15
Please Note:
Every care has been taken to ensure the accuracy of information contained in this manual
which supersedes earlier publications, however Bisalloy Steels shall not be liable for any
loss or damage howsoever caused or arising from the application of such information.
Typical values are provided for reference information only and no guarantee is given that a
specific plate will provide these properties. Information is subject to change without notice.

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BISPLATE SIZE RANGE

SIZE RANGE

STANDARD SIZE SCHEDULE


Table 1:
PLATE MASS IN TONNES
BISPLATE
GRADE BISPLATE 60, 70,80 ,320, 400 BISPLATE 500
450
WIDTH
1525 1525 1900 2485 2485 3100 2485 3100 1525 1900 2485 2485
(mm)
LENGTH
8 6 6 6 8 8 8 8 6 6 5 8
(m)
Thickness
(mm)
5 0.479
6 0.575 0.936 0.431 0.585
8 1.248 1.248 1.248
10 1.561 1.947 1.561 1.947 1.561
12 1.873 2.336 1.873 2.336 1.873
16 2.497 3.115 2.497 3.115 2.497
20 3.121 3.894 3.121 3.894 3.121
25 3.901 4.867 3.901
32 4.994 4.994
40 6.242 6.242
50 7.803 7.803
60 7.023 5.852
70 6.264 6.264
75 6.712 5.387
80 7.159 5.746
90 6.464 6.464
100 7.183 7.183
Plate mass (tonnes) calculation = 7.85 x W x T x L (m)

NON STANDARD SIZES

Available subject to sales enquiry.


Minimum order quantities may apply.

EDGE CONDITION

All plate 1525mm wide and 5 & 6mm thick


is supplied with untrimmed edge.
All other plate is supplied with trimmed edge.

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MANUFACTURING TOLERANCES

THICKNESS TOLERANCE
Table 2:
Thickness (+ / - mm)
WIDTH >6 >8 >10 >13 >18 >22 >30 >42
6 >63
8 10 13 18 22 30 42 63
<1600 0.53 0.60 0.60 0.68 0.83 0.90 1.05 1.28 1.73 2.55
1600 <2100 0.60 0.68 0.68 0.75 0.90 0.98 1.13 1.35 1.80 2.63
2100 <2700 0.75 0.75 0.83 0.90 0.98 1.05 1.28 1.50 1.95 -
2700 - 0.98 1.05 1.13 1.20 1.35 1.43 - - -

Notes: 1. Measurement can be conducted anywhere on plate.


2. All dimensions are in millimetres.

WIDTH TOLERANCE

TRIMMED EDGE PLATE

Table 3:
THICKNESS <16 16 <50 50

Width Plus Minus Plus Minus Plus Minus

<1520 16 0 20 0 25 0

1520 20 0 25 0 30 0

Note: All dimensions are in millimetres

UNTRIMMED EDGE PLATE


Table 4:
ALL THICKNESS PLUS MINUS

Width

1800 40 0

>1800 50 0

Note: All dimensions are in millimetres.

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LENGTH TOLERANCE

Table 5:
THICKNESS <25 25

Length Plus Minus Plus MINUS

<6000 25 0 30 0

6000 <12000 30 0 45 0

1200 50 0 65 0

Note: All dimensions are in millimetres.

CAMBER

EDGE CAMBER TOLERANCE


Table 6:
SPECIFIED UNTRIMMED
TRIMMED EDGE
WIDTH EDGE

ALL 4 6

Note: All dimensions are in millimetres

Edge Camber shall be limited so that it shall be


possible to inscribe the dimensions of the ordered plate
within the delivered size.

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FLATNESS Measurement of flatness tolerance should be made when the product,


resting under its own mass, is placed on a flat horizontal surface. A
straight edge shall be placed on the plate and the maximum vertical
distance from the plate shall be measured (H).

Table 7:
SPECIFIED DISTANCE SPECIFIED WIDTH OF PLATE (mm)
THICKNESS BETWEEN
PLATE POINTS OF 1500 1800 2400
(mm) CONTACT <1500 3000
<1800 <2400 <3000
(mm)

8 1000 8 8 8 10 15
2000 15 15 15 25 30

>8 12 1000 6 6 8 10 15
2000 10 10 15 20 25

>12 25 1000 6 6 6 10 10
2000 8 10 12 16 16

>25 1000 6 6 6 6 6
2000 8 8 10 10 10

Notes: 1. The tolerances apply when measured at least 20mm from the longitudinal edges and
100mm from the transverse edges.

2. Where the distance between the points of contact is between 500mm and 1000mmm,
the permissible deviation is obtained as follows.

DISTANCE BETWEEN POINTS OF CONTACT x H


1000

Where H = allowable deviation for 1000mm


Note: This table is an extract of the AS1365 - 1986 (table 3.4).
However Bisalloy Steels Pty Ltd internal manufacturing tolerances are considerably
more restrictive.

3. All dimensions are in millimetres.

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Bisalloy Technical Manual

FLAME CUTTING, PLASMA CUTTING, LASER CUTTING,


WATERJET CUTTING AND SAWING RECOMMENDATIONS
All grades of BISPLATE quenched and tempered
steel can be cut by either thermal cutting, laser cutting,
waterjet cutting or power saw operations. The cutting
operations can be carried out either in the workshop or,
in the case of flame cutting, in field conditions. Both
the high strength structural grades and the wear and
abrasion resistant grades can be cut using the same type
of equipment employed in cutting plain carbon steels.

CUTTING OPERATIONS

Dependant on the grade and thickness being cut, the following operations
can be used on BISPLATE grades.

Flame Cutting (Oxy-LPG and Oxy-acetylene)


Plasma Cutting
Laser Cutting
Waterjet Cutting
Power Sawing

FLAME CUTTING

Both Oxy-LPG and Oxy-acetylene processes are acceptable for sectioning


all thicknesses of BISPLATE. With these processes, the following
techniques are recommended:

Gas pressure to be the same as for cutting the equivalent thickness in plain carbon steel.

Reduce travel speeds by 30% when compared to the equivalent thickness plain carbon steels
when using a standard cutting nozzle.

Nozzle size to be the same as for equivalent thickness plain carbon steel.

Correct selection of nozzle size for the plate thickness being cut is important to ensure
efficient cutting and to minimise the width of the heat affected zone (HAZ).

As with all plate steels, the smoothness of the cut is affected by surface scale. If this is
present, it is advisable to remove it prior to cutting. (BISPLATE is normally supplied in
the shotblasted condition)

Under normal Oxy cutting conditions, the total heat affected zone adjacent to the flame cut
edge will extend into the plate approximately 2-3mm, as shown left in figure 2a for
BISPLATE 80. It should be noted that the heat affected zone produces a hard layer
adjacent to the flame cut edge, with a soft layer inside this. The original plate hardness

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returns after the 2-3mm distance from the cut edge. For BISPLATE 500 the HAZ may
extend as much as 4-5mm into the plate as shown in figure 2b.

Preheating BISPLATE steel prior to flame cutting will minimise the hardness of the flame
cut edge and also reduce the risk of delayed cracking from this cut edge. This is particularly
important in cold environments where plate temperature is less than 20C and for the high
hardenability grades of BISPLATE 425 and 500.

Table 1 below, gives guidance on the preheat requirements. It is recommended that the zone
to be preheated should extend at least 75mm either side of the line of cut, with the
temperature being measured on the opposite surface and at a distance of 75mm, as shown in
figure 3.

Recommended Minimum Preheat Temperatures for Flame Cutting of BISPLATE Grades

Table 1:
BISPLATE GRADE PLATE THICKNESS MINIMUM PRE-HEAT
(mm) TEMPERATURE
60, 70 8 32 20C
80, 80PV 5 31 20C
32 100 50C
320, 400, 450 5 31 20C
32 - 100 50C
500 6 20 50C
21 100 100C

If the flame cut surface is to be the face of a welded joint,


the heat affected zone from the flame cutting need not be
removed. However, all slag and loose scale should be
removed by light grinding, and prior to welding, the cut
surface should be dry and free from organic matter such as
oil, grease, etc (as directed by good workshop practice).

Recommended preheat zone and location


of Preheat measurement

When stripping plates, the use of multiple cutting heads will help to minimise distortion
of the cut pieces. Correct nozzle size, gas pressure and travel speed will also minimise
distortion during cutting. Softening on edges can also occur when flame cutting small
strips, eg. 50mm wide x 50mm thick plate.

Quench cutting of BISPLATE grades to minimise distortion is not recommended,


while cooling in still air is preferred. The technique of stacking plates during profile
cutting should also be avoided.

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SUMMARY OF FLAME CUTTING RECOMMENDATIONS

For Oxy processes use gas pressures and nozzle sizes as for an equivalent thickness of
plain carbon steel.

For oxy processes use cutting speeds two thirds of that recommended for an equivalent
thickness of plain carbon steel.

Flame cutting produces a heat affected zone on all grades.

The risk of delayed cracking is reduced by using preheat especially for thick plate and for
BISPLATE 500 grade.

Use multiple cutting heads when stripping plates.

Still air cooling after cutting.

Do not stack cut.

Do not quench cut plates.

Use thermal crayons or surface thermometers to measure preheat temperatures.

REFERENCES/FURTHER READING

WTIA Technical Note 5 Flame Cutting of Steels.

PLASMA CUTTING

Plasma cutting is an acceptable method of sectioning all grades of BISPLATE. The


process offers particular advantages of productivity over flame cutting in thicknesses up
to 20mm using currently available equipment. For instance, the cutting speed of 6mm
BISPLATE 400 may be up to 9 times that recommended for conventional flame cutting
techniques.

The cut quality may be inferior, however, due to rounding of the top edges and difficulty
in obtaining a square cut face of both edges. Guidance on the optimum settings for
nozzle size, gas pressure, gas composition and cutting speeds will be provided by the
equipment manufacturer. BISPLATE with low alloy contents should be treated
similarly to conventional structural steels.

The heat affected zone from a plasma cut is narrower than that produced from flame
cutting but peak hardnesses are generally higher. General recommendations for the
removal of this hardened zone are outlined below.

Hardness Profile Characteristics for Plasma Cutting

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Table 2:
PLATE RECOMMENDED PEAK HARDNESS
THICKNESS DEPTH (HB)
(mm) OF REMOVAL (mm)
BISPLATE BISPLATE BISPLATE
60, 70, 80 450 500
320
400
58 0.4 0.5 430 480 540
>8 12 0.6 0.8 450 480 540
>12 - 20 1.0 1.2 450 480 540

The plasma cut HAZ typically extends 0.5 1.0mm into the plate under normal conditions.
As is the case for flame cutting, complete removal by grinding is recommended if cold
forming of the cut plate is contemplated.

All other comments for flame cutting regarding preheating, removal of the HAZ, stripping
and stack cutting of plates would apply to plasma cutting.

LASER CUTTING
Laser cutting is a productive method for sectioning all grades
of BISPLATE up to 12mm thickness, particularly where
high levels of accuracy and minimal distortion is required.
Currently, with thicknesses above 12mm, productivity levels
drop when compared with other processes.

The laser cutting process is unlike other thermal cutting in so


far as the material is essentially vapourised from the kerf
rather than melting and removal by kinetic energy.

The laser concentrates its energy into a focused beam resulting in low levels of excess heat.
This results in very small HAZ areas (0.05 0.15mm) and small kerfs (0.3mm).

Comparison of Flame, Plasma and Laser Cutting on 6mm BISPLATE 400

Table 3:
PROCESS KERF WIDTH (mm) HAZ WIDTH (mm)
Flame cutting 0.9 1.5
Plasma cutting 3.2 0.5
Laser cutting 0.3 0.2

Cutting speeds are typically 5000mm/min and the edge is generally square, burr free and
minimal dross.

Peak hardness levels are lower than those obtained from alternate cutting methods
previously described. Removal of the HAZ is generally not considered necessary for most
applications, however, for forming operations it is advised that Bisalloy Steels are
contacted for guidance.

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POWER SAWING

All BISPLATE grades can be cut with power saws, provided lower blade speeds and blade
pressures up to 50% higher than those used for cutting plain carbon steel are used. Best
results have been achieved using power saw blades normally recommended for cutting
stainless steel (generally, blades having 4-6 teeth per 25mm). Sawing directly onto a flame
cut surface should be avoided where possible.

Correct practice of sawing BISPLATE grades Incorrect practice of sawing BISPLATE grades

WATERJET CUTTING
Waterjet cutting can be performed on all grades of
BISPLATE, although its widespread use is limited due to the
current machines available in Australia and their low cutting
speeds.

A key advantage of water jet cutting is that it leaves the surface


free of HAZ. Cutting without heat protects against
metallurgical changes in the plate, ensuring original plate
mechanical properties are maintained.

Recent tests performed by the CSIRO Division of Manufacturing Technology on waterjet


cutting 8mm BISPLATE 500 at 40mm/min resulting in near perfect cut edges. Speeds to
75mm/min are possible but with reduced smoothness of the cut edge.

The micrographs show the parent material adjacent to the cut edge for waterjet cutting in
comparison to laser cutting. The waterjet cut shows no change in material structure at the
edge of the cut. The laser cut edge shows a distinct change in structure to a depth of 0.2mm.

Both laser cutting and waterjet cutting are industrial processes which should be considered
by structural designers and fabricators as alternate means to avoiding problems associated
with fit up, cut edge squareness, shape precision, dross and gross HAZs which can occur
with conventional thermal cutting processes.
Bisalloy steels wish to thank the Australian Welding journal, CSIRO-DMT,
Ian Henderson,CRC for Materials Welding and joining and Rory Thompson, CSIRO Industry Liasion Manager for information pertaining
to laser and waterjet cuting contained in this publication .

Please Note:
Every care has been taken to ensure the accuracy of information contained in this manual which supersedes earlier publications, however
Bisalloy Steels shall not be liable for any loss or damage howsoever caused arising from the application of such information. Typical
values are provided for reference information only and no guarantee is given that a specific plate will provide these properties. Information
is subject to change without notice.

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WELDING OF BISPLATE QUENCHED AND TEMPERED STEELS

GENERAL INFORMATION

All grades of BISPLATE can be readily welded using any of the conventional low
hydrogen welding processes. Their low carbon content and carefully balanced, but relatively
small additions of alloying elements (Mn, Cr, Mo, Ni, B) ensures good weldability, in
addition to the advantages of high strength, impact toughness and high hardness.

HYDROGEN CONTROL

To ensure adequate welding of BISPLATE, it is necessary to be more mindful of the levels


of hydrogen, preheat temperatures and arc energy inputs in order to minimise the hardening
and maintain the properties of the weld Heat Affected Zone (HAZ).

Particular attention must be paid to the control of hydrogen content to minimise the risk of
weld and HAZ cracking. Weld hydrogen content is minimised by careful attention to the
cleanliness and dryness of the joint preparations and the use of hydrogen controlled welding
consumables. Recommendations on the correct storage and handling of consumables may be
obtained from welding consumable manufacturers, for instance the use of Hot Boxes for
storage and reconditioning are required when using manual metal arc welding electrodes.
Refer WTIA Tech Note 3 for further guidance.

HEAT AFFECTED ZONE PROPERTY CONTROL

The HAZ, a region directly adjacent to the weld, experiences a thermal cycle ranging from
unaffected parent plate to near melting at the fusion boundary. The properties of this zone
are determined by the steel composition as well as the cooling rate.

STEEL COMPOSITION

BISPLATE grades and chemical compositions may be divided into categories based on
Carbon Equivalent and Pcm, as follows:
Table 1:
CARBON Pcm%
BISPLATE PLATE
EQUIVALENT (JWES) CET
GRADE THICKNESS (mm)
(IIW) TYPICAL TYPICAL
60, 70, 80 5-12 0.40 0.25 0.29
320, 400
60, 70, 80 13 - 80 0.50 0.29 0.35
320, 400
60, 70, 80 81 - 100 0.58 0.30 0.34
320, 400
450 6-20 0.45 0.29 0.29
500 5 - 100 0.62 0.39 0.42

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Notes:
1. C.E. (IIW) = C + Mn + Cr+Mo+V + Cu+Ni
6 5 15
2. Pcm% (JWES) = C + Si + Mn+Cu+Cr + Ni + Mo + V + 5B
30 20 60 15 10

3. CET = C + Mn +Mo + Cr + Cu + Ni
10 20 40

These categories give an indication of the degree of care required in the proper selection of
welding preheat/heat inputs.

COOLING RATE

Limitations on both preheat and heat input are necessary to ensure that the HAZ cools at an
appropriate rate and that the correct hardness and microstructure are achieved. Too slow a
cooling rate can result in a soft HAZ and thus a loss of tensile and fracture toughness
properties. Too rapid a cooling rate produces a hard HAZ which may cause loss of ductility.
Cooling is controlled by a balance between preheat and heat input for a particular plate
thickness and joint configuration.

PREHEAT/HEAT INPUT

The preheat/heat input recommendations outlined in tables 2 and 3 will ensure that the
cooling rate of the HAZ is satisfactory.

Recommended Preheat/Interpass Temperatures (C) for BISPLATE


Table 2:
MAXIMUM THICKNESS IN JOINT (mm)
BISPLATE GRADE
<13 >13<25 >25<50 >50
Minimum Preheat TempC
High Strength Structural
Grades

60 (AS 3597 Grade 500) Nil* 50 75 140


70 (AS 3597 Grade 600) Nil* 50 75 140
80 (AS 3597 Grade 700) Nil* 50 75 140
Abrasion Resistant Grades
320 50 75 125 150
400 50 75 125 150
450 Nil***
500 100 150 150 **
Maximum Interpass
TemperatureC
All Grades 150 175 200 220
*Chill must be removed from plates prior to welding.
**Refer to Bisalloy Steels for availability, preheat/interpass requirements.
***Nil preheat up to a max thickness in the joint of 20mm. Note that under rigid weld joint restraint conditions
preheating temperature should be increased by 25C.

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Above details on recommended minimum preheat and maximum interpass temperatures are
based on low restraint butt weld joint configurations. Increase in preheats is necessary for
more complex joint configurations. Guidance is provided in WTIA Tech. Note 15 i.e.
calculation of Joint Combined Thickness and determination of minimum preheat and
interpass temperature conditions.

Permissible Heat Input (kJ /mm) for BISPLATE

Table 3:
WELDING MAXIMUM PLATE THICKNESS IN JOINT (mm)
PROCESS 3 12*** >12 25 >25 32 >32 - 100
MMAW 1.25 2.5 1.25 3.5 1.25 4.5 1.5 5.0
GMAW 1.0 2.5 1.0 3.5 1.25 4.5 1.5 5.0
FCAW 0.8 2.5 0.8 3.5 1.5 4.5 1.5 5.0
SAW 1.0 2.5 1.0 3.5 1.5 4.5 1.5 5.0

Heat input (kJ/mm) = Volts x Amps x0.06


Travel Speed (mm/minute)

***For these thicknesses in structural grades, the maximum arc energy input may need to be limited to
1.5kJ/mm maximum in specific applications. Refer to Bisalloy Steels for further guidance if required.

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WELDING CONSUMABLES

Welding Consumable Selection Guide for BISPLATE (AS Classifications)

Table 4a:
BISPLATE 60 BISPLATE BISPLATE BISPLATE 320,
70 80 400, 450, 500
MMAW Consumables1
Warning: Only use
Hydrogen Controlled
consumables
Strength Level Matching E55XX/E62XX+ E69XX* E76XX N.R.
Lower E48XX E55XX E55XX/E62XX E55XX
Lower E48XX E48XX E48XX E48XX
Hardness Matching N.R. N.R. N.R. 1430-AX, 1855-AX**
GMAW Consumables 2
Strength Level Matching W55XX/W62XX+ W69XX* W76XX N.R.
Lower W50XX W55XX W62XX/W69XX W55XX
Lower W50XX W50XX W55XX.X W50XX
Hardness Matching N.R. N.R. N.R. 1855-BX**
3
FCAW Consumables
Strength Level Matching W55XX.X/ W69XX.X* W76XX.X N.R.
Lower W62XX.X+ W62XX.X W62XX.X W55XX.X
Lower W50XX.X W55XX.X W55XX.X W50XX.X
Hardness Matching W50XX.X N.R. N.R. 1430-BX, 1855-BX, 1860BX**
N.R.
4
SAW Consumables
Strength Level Matching W55XX/W62XX+ W69XX* W76XX N.R.
Lower W50XX W50XX W50XX W50XX
Lower W40XX W40XX W40XX W40XX
Hardness Matching N.R. N.R. N.R 1855-BX**
Table 4a courtesy of WTIA (Tech Note 15)
Notes:
1 MMAW - AS/NZS 1553.1 - 1995 and AS1553.2 - 1987 consumable classification.
2 GMAW - AS271 7.1 - 1984 consumable classification.
3 FCAW - AS2203 - 1990 consumable classification.
4 SAW - AS1858. 1 - 1996 and AS1858.2 - 1989 consumable classification.
X = A Variable - any value allowed by the relevant standard may be acceptable provided that the consumable is hydrogen controlled (ie
low hydrogen).
+ E62XX and W62XX type consumables overmatch the strength requirements but may be used.
*
These Consumables may be difficult to obtain. In some cases E62XX or W62XX type consumables may be substituted, otherwise use
E76XX or W76XX types.
**
AS2576 and WTIA TN 4 Classifications.
N.R. Not Recommended.

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Welding Consumable Selection Guide for BISPLATE (AWS Classifications)


Table 4b:
BISPLATE 60 BISPLATE BISPLATE 80 BISPLATE 320,
70 400, 450, 500
MMAW Consumables1
Warning: Only use
Hydrogen Controlled
consumables
Strength Level Matching E80XX/E90XX+ E100XX* E110XX N.R.
Lower E70XX E80XX E80XX/E90XX E80XX
Lower E70XX E70XX E70XX E70XX
Hardness Matching N.R. N.R. N.R. 1430-AX, 1855-AX**
2
GMAW Consumables
Strength Level Matching ER80S-X/ER90S-X+ ER100S-X* ER110S-X N.R.
Lower ER70S-X ER80S-X ER90S-X/ER100S-X W55XX
Lower ER70S-X ER70S-X ER80S-X W50XX
Hardness Matching N.R. N.R. N.R. 1855-BX**
FCAW Consumables3
Strength Level Matching E8XTX-X/E9XTX-X+ E10XTX-X8 E11XTX-X N.R.
Lower E7XTX-X E9XTX-X E9XTX-X E8XTX-X
Lower E7XTX-X E8XTX-X E8XTX-X E7XTX-X
Hardness Matching N.R. N.R. N.R. 1430-BX, 1855-BX, 1860BX**
4
SAW Consumables
Strength Level Matching F8XX/F9XX+ F10XX* F11XX N.R.
Lower F7XX F7XX F7XX F7XX
Lower F6XX F6XX F6XX F6XX
Hardness Matching N.R. N.R. N.R. 1855-BX**

Table 4B courtesy of WTIA (Tech Note 15)


Notes:
1 MMAW AWS A5. 1-91 and AWS A5.5-81 consumable classification.
2 GMAW AWS A5. 18-93 and AWS A5.28-79 consumable classification.
3 FCAW AWS A5.20-79 and AWS A5.29-80 consumable classification.
4 SAW - AWS A5.17-89 and AWS A5.23-90 consumable classification.

X = A Variable - any value allowed by the relevant standard may be acceptable provided that the consumable is hydrogen controlled (ie
low hydrogen).
+ E90XX, ER90S, E9XTX and F9XX type consumables overmatch the strength requirements but may be used.
*
These Consumables may be difficult to obtain. In some cases E90XX, ER90S, E9XTX or F9XX type consumables may be substituted,
otherwise use E110XX, ER110S, E11XTX or F11XX types.
**
AS2576-1982 WTIA TN 4 Classifications.
N.R. Not Recommended.

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MANUFACTURERS WELDING CONSUMABLES

Welding Consumables suitable for matching strength, lower strength and matching hardness
are readily available from a range of consumable manufacturers as per following tables 5 to
8.

Welding Consumables for Manual Metal Arc Welding (MMAW)


Table 5:

BISPLATE 320
BRANDS BISPLATE 60 BISPLATE 70 BISPLATE 80
400, 450, 500
CIGWELD M.S. Alloycraft 90 Alloycraft 110*, (Alloycraft90) Alloycraft 110 N.R.
L.S. Ferrocraft 61 Ferrocraft 61 Ferrocraft 61 Ferrocraft 61
Multicraft 7016 Multicraft 7016 Multicraft 7016 Multicraft 7016
M.H. N.R. N.R. N.R. Cobalarc 350, 650
Lincoln Electric M.S. Jetweld LH90-MR (Jetweld LH90-MR) Jetweld LH110M-MR NR
L.S. Jetweld LH70, LH75-MR Jetweld LH70, LH75-MR Jetweld LH70, LH75-MR Jetweld LH70, LH75-MR
M.H. N.R. N.R. N.R. Wearshield ABR
LiquidArc M.S. N.A. N.A. N.A. N.R.
L.S Easyarc 16GP, Easyarc 16GP, Easyarc 16GP, Easyarc 16GP,
Easyarc 18MR Easyarc 18MR Easyarc 18MR Easyarc 18MR
M.H. N.R. N.R. N.R. Liquidarc HF 600
W.I.A M.S. Austalloy 6218-M Austarc 761 8-M, (621 8-M), Austalloy 7818-M, N.R.
(Austarc 18TT) Weldwell PH118 Weldwell PH118
L.S. Austarc 18TT, 16TC, Austarc 18TT, 16TC, Austarc 18TT, 16TC, Austarc 18TT, 16TC,
Weldwell PH77, PH56S Weldwell PH77, PH56S Weldwell PH77, PH56S Weldwell PH77, PH56S
M.H. N.R. N.R. N.R. AbrasoCord 350, 700,
Weldwell PH400, PH600
Eutectic M.S. N.A. N.A. N.A. N.R.
Castolin L.S. Eutectrode 66*66 Eutectrode 66*66 Eutectrode 66*66 Eutectrode 66*66
M.H. N.R. N.R. N.R. N.R.
SWP/Metrode M.S. E9018-D1 E1001 8-D2 E11018-M N.R.
Products L.S. MP51 MP51 MP51 MP51
M.H. N.R. N.R. N.R. Methard 350,
Methard 650
ESAB M.S. OK 48.08 OK 74.78 OK 75.75 N.R.
L.S. OK 48.04 OK 48.04, OK 48.08 OK 48.04, OK 48.08 OK 48.04, OK 48.08
M.H. N.R. N.R. N.R. OK 83.28, OK 83.50

M.S. Matching Strength


L.S. Lower Strength
M.H. Matching hardness
N.R. Not Recommended
N.A. Not available
N.B. Consumables in brackets will match mechanical property requirements in the majority of instances as per
manufacturers recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should
be carried out to establish actual Weld metal properties.

*Consumable recommendations overmatch mechanical property requirements.

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Welding Consumables for Gas Metal Arc Welding (GMAW)


Table 6:
M.S. Matching Strength
L.S. Lower Strength
M.H. Matching hardness
N.R. Not Recommended
BISPLATE 320
BRANDS BISPLATE 60 BISPLATE 70 BISPLATE 80
400, 450, 500
CIGWELD M.S. Autocraft Mn Mo/ Autocraft Ni Cr Mo*/ Autocraft Ni Cr Mo/ N.R.
Argoshield 51 or 52 Argoshield 60 or 52, Argoshield 60 or 52
(Autocraft Mn Mo/
Argoshield 51 or 52)
L.S. Autocraft LW1/ Autocraft LW1/ Autocraft LW1 Autocraft LW1/
Argoshield 51 or 52, Argoshield 51 or 52 Argoshield 51 or 52 Argoshield 51 or 52
Autocraft LW1-6/ Autocraft LW1-6/ Autocraft LW1-6/ Autocraft LW1-6/
Argoshield 51 or CO2 Argoshield 51 or CO2 Argoshield 51 or CO2 Argoshield 51 or CO2
M.H. N.R. N.R. N.R. Cobalarc 350-FC,
Cobalarc 650-FC
Lincoln Electric M.S. LA-90/C02 or Ar+CO2 LA-100/AR+2%O2 N.A. N.R.
L.S. L54, L54 Ultra/ L54, L54 Ultra/ L54, L54 Ultra/ L54, L54 Ultra/
CO2 or Mixed Gas, CO2 or Mixed Gas, CO2 or Mixed Gas, CO2 or Mixed Gas,
L56 Ultra/CO2 L56 Ultra/C02 L56 Ultra/CO2 L56 Ultra/CO2
LiquidArc M.S. LA6047*/CO2 or Mixed Gas LA6047*/CO2 or Mixed Gas LA6047*/CO2 or Gas N.R.
L.S Steelmig Super 4/ Steelmig Super 4/ Steelmig Super 4/ Steelmig Super 4/
CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas
M.H. Steelmig Super 6/CO2 Steelmig Super 6/CO2 Steelmig Super 6/CO2 Steelmig Super 6/CO2
W.I.A M.S. Austmig ESD2/CO2 PZ6047/CO2 PZ6047/CO2 N.R.
or Mixed Gas Or mixed Gas Or mixed Gas
L.S. Austmig ES6/ Austmig ES6/ Austmig ES6/ Austmig ES6/
CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas
M.H. PZ6000/ PZ6000/ PZ6000/ PZ6000/
CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas
N.A. N.A. N.A. TD600/CO2
or Mixed Gas
Eutectic M.S. AN45252/ AN45252/ AN45252/ N.R.
Castolin CO2 or Mixed Gas CO2 or Mixed Gas CO2 or Mixed Gas
L.S. DO*65/CO2 DO*65/CO2 DO*65/CO2 DO*65/CO2
Or Mixed Gas Or Mixed Gas Or Mixed Gas Or Mixed Gas
N.A. Not available
N.B. Consumables in brackets will match mechanical property requirements in the majority of instances as per
manufacturers recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should
be carried out to establish actual Weld metal properties.

*Consumable recommendations overmatch mechanical property requirements.

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Welding Consumables for Flux Cored Arc Welding (FCAW)

Table 7:
BRANDS BISPLATE 60 BISPLATE 70 BISPLATE 80 BISPLATE 320, 400,
450, 500
CIGWELD M.S. Verti-Cor 91-K2/ Tensi-Cor 110TXP*/ Tensi-Cor 110TXP*/ N.R.
Argoshield 52 CO2 CO2
(Verti-cor 91-K2/
Argoshield 52)
L.S. SupreCor 5 or SupreCor 5 or SupreCor 5 or SupreCor 5 or
Verti-Cor 80 Ni 1/ Verti-Cor 80 Ni 1/ Verti-Cor 80 Ni 1/ Verti-Cor 80 Ni 1/
Argoshield 52 Argoshield 52 Argoshield 52 Argoshield 52
M.H. N.R. N.R. N.R. Cobalarc 350 FC,
Cobalarc 650 FC
Lincoln Electric M.S. O/Shield 91K2-H/Ar O/Shield MC100/Ar+5% CO2 O/Shield MC 120-55Ar N.R.
+25% CO2 or 2% CO2 +2% O2
L.S. O/Shield 70, 71, 71M/ O/Shield 70, 71, 71M/ O/Shield 70, 71, 71M/ O/Shield 70, 71, 71M/
CO2 or Ar+25% CO2 CO2 or Ar+25% CO2 CO2 or Ar+25% CO2 CO2 or Ar+25% CO2
O/Shield 71C-H, 75H/ O/Shield 71C-H, 75H/ O/Shield 71C-H, 75H/ O/Shield 71C-H, 75H/
Ar+25% CO2 Ar+25% CO2 Ar+25% CO2 Ar+25% CO2
IShield NS3M, NR232 IShield NS3M, NR232 IShield NS3M, NR232 IShield NS3M, NR232
NR203M NR203M NR203M NR203M
M.H N.R. N.R. N.R. Lincore 55
LiquidArc M.S. N.A. N.A. N.A. N.R.
L.S. Easy-Core 70T-1/ Easy-Core 70T-1/ Easy-Core 70T-1/ Easy-Core 70T-1/
CO2 or mixed gas, CO2 or mixed gas, CO2 or mixed gas, CO2 or mixed gas,
Easy Core 71M/CO2 Easy Core 71M/CO2 Easy Core 71M/CO2 Easy Core 71M/CO2
Or mixed gas Or mixed gas Or mixed gas Or mixed gas
Easy-Core 71C-H, 75-H/ Easy-Core 71C-H, 75-H/ Easy-Core 71C-H, 75-H/ Easy-Core 71C-H, 75-H/
Ar+25% CO2 Ar+25% CO2 Ar+25% CO2 Ar+25% CO2
M.H N.R. N.R. N.R. N.A.
W.I.A M.S. Fluxofil 41/CO2 or Fluxofil 42/CO2 or Fluxofil 42/CO2 or N.R
Mixed gas Mixed gas Mixed gas
L.S. Fluxofil 20, 31, 36/ Fluxofil 20, 31, 36/ Fluxofil 20, 31, 36/ Fluxofil 20,31,36/
CO2 or Mixed gas CO2 or Mixed gas CO2 or Mixed gas CO2 or Mixed gas
M.H N.R. N.R. N.R. Fluxodur 1430, 1855/
CO2 or Mixed gas
Eutectic M.S. N.A. N.A. N.A. N.A.
Castolin L.S. Teromatec OA2020 Teromatec OA2020 Teromatec OA2020 Teromatec OA2020
M.H. N.R. N.R. N.R. N.R.
SWP/Welding M.S. X91X-T5-K2/ X110-T5-K4*/ X110-T5-K4/ N.R.
Alloys Ltd CO2 or Ar+20% CO2 CO2 or Ar+20% CO2 CO2 or Ar+20% CO2
L.S. X71-T1/CO2 X71-T1/CO2 X71-T1/CO2 X71-T1/CO2
or Ar+20% CO2 or Ar+20% CO2 or Ar+20% CO2 Or Ar+20% CO2
X71-T5/CO2 X71-T5/CO2 X71-T5/CO2 X71-T5/CO2
or Ar+20% CO2 or Ar+20% CO2 or Ar+20% CO2 Or Ar+20% CO2
M.H N.R. N.R. N.R. Hardface T-O/S/G,
L-O/S/G
ESAB/Alloy Rods M.S. Dualshield II-70/Ar + Dualshield II-100/CO2 Dualshield II-110/CO2 N.R.
25% CO2
Dualshield II-71/CO2
L.S. Dualshield T-5/mixed gas Dualshield T-5/mixed gas Dualshield T-5/mixed gas Dualshield T-5/mixed gas
Dualshield 7000/mixed gas Dualshield 7000/mixed gas
M.H. N.R. N.R. N.R. N.R.

M.S. Matching Strength


L.S. Lower Strength
M.H. Matching Hardness
N.R. Not Recommended
N.A. Not available
N.B. Consumables in brackets will match mechanical property requirements in the majority of instances as per
manufacturers recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should
be carried out to establish actual Weld metal properties.

*Consumable recommendations overmatch mechanical property requirements.

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Welding Consumables for Submerged Arc Welding (SAW)

Table 8:
BRANDS BISPLATE 60 BISPLATE 70 BISPLATE 80 BISPLATE 320, 400,
450, 500
CIGWELD M.S. N.A. N.A. N.A. N.A.
L.S. Autocraft SA1, SA2/ Autocraft SA1, SA2/ Autocraft SA1, SA2/ Autocraft SA1, SA2/
Satinarc 4 Satinarc 4 Satinarc 4 Satinarc 4
M.H. N.R. N.R. N.R. Cobalarc 107-SA/
Satinarc 4
Lincoln Electric M.S. LA 100/880M* LA 100/Mil 800H LACM2/880M or 880 N.R.
L.S. L60,L61/761,780 or 860 L60, 61/761,780 or 860 L60, 61/761,780 or 860 L60, 61/761,780 or 860
N.R. N.R. N.R. Lincore 55/802
M.H.
WIA M.S. N.A Fluxocord 42/OP121TT* Fluxocord 42/OP121TT N.R.
L.S. Austmatic Austmatic SD3/OP121TT* Austmatic Austmatic
SD3/OP121TT N.R. SD3/OP121TT* SD3/OP121TT
M.H. N.R. N.R. N.A.

M.S. Matching Strength


L.S. Lower Strength
M.H. Matching Hardness
N.R. Not Recommended
N.A. Not available
N.B. Consumables in brackets will match mechanical property requirements in the majority of instances as per
manufacturers recommendations and where the appropriate weld procedure is applied. Weld Qualification procedures should
be carried out to establish actual Weld metal properties.

*Consumable recommendations overmatch mechanical property requirements.

WELDING PROCEDURES

The specific effects of welding on weld joint properties in any practical situation will depend
on many factors including the choice of consumables, total weld heat input, level of
restraint, weld geometry and proximity of adjacent welds.

Guidance on weld procedures for specific applications may be sought from Bisalloy
Technical staff or consumable suppliers.

ARC STRIKES

Arc strikes outside the welded zone can result in cracks, particularly on dynamically loaded
structures. All strikes should be made within the joint preparation.

TACK WELDING

Tack welds require special care due to the abnormal stresses and high cooling rates
experienced by the adjacent material. The same preheat, heat input requirements should be
employed and lower strength welding consumables considered.

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FILLET WELDING

Good fillet welding techniques are important in welding Q and T steels because often very
high stresses are applied in service. It is essential that welds have good root penetration, be
smooth, correctly contoured and well flared into the legs of the joined pieces. Lower
strength consumables are suggested when design permits.
WTIA Tech. Note 15 provides guidance on correct procedures for fillet welding.

REPAIR WORK

It is good practice to weld repair with lower strength consumables (low hydrogen type),
since plate materials which have been highly stressed in service may tend to warp or distort
slightly during welding and improved ductility may be required. In some situations, such as
joints under restraint, joints subjected to impact/fatigue stresses, etc, special welding
consumables may be necessary.

WELDING STRESSES

It should be emphasised that the recommended values of preheat and heat input are based on
low to moderate levels of restraint. For conditions of high restraint it is important to
minimise the degree to which free contraction is hampered and it may be necessary to use
higher preheats. Proper welding sequence and small joint configurations would be
considered important in high restraint situations and it is advisable to establish welding
parameters with simulated full scale weld tests.

Care should also be exercised at the assembly stage to avoid offset and angular distortion at
the plate edge, undercutting and bad appearance.

STRESS RELIEF

Stress relief may be conducted on BISPLATE 60, 70, 80 and 80PV grades but is advisable
only if absolutely necessary (eg. to comply with AS1210 in the case of road tankers). Stress
relief is recommended within a 540 - 5700C temperature range for one hour per 25mm of
thickness. Thermal cycling is generally performed in accordance with AS 1210-1989 Code
requirements for Q and T steels. The toes of weld beads should be dressed by grinding prior
to any stress relief treatment in order to prevent stress relief cracking.

When stress relieving BISPLATE 12mm (typically 0.40 CEIIW) and matching strength
across the weld is a requirement, it is recommended to weld with minimum permissible
preheat/ interpass temperatures (Table 2) and heat input (Table 3) conditions to minimise the
degree of softening or any loss of strength which may occur in the HAZ.

Consult Bisalloy Steels for further information if required.

POST-WELD HEATING

Post-weld heating at 200-250 may be conducted as an effective hydrogen dissolution


treatment particularly when consumables other than H5 or H10 are used.

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HELPFUL HINTS

General rules for good quality welding of BISPLATE:


Use a low hydrogen process, eg GMAW (MIG), FCAW (gas shielded).
Adhere to the correct rules for storage and handling of low hydrogen consumables
per the manufacturers recommendations, or WTIA Tech. Note 3.
Clean joint area of all contaminants prior to welding.
Remove 1 - 2mm from flame cut or gouged surfaces by grinding.
Select the recommended preheat, interpass and heat input parameters.
Position for downhand welding where possible. Always use stringer beads, never
wide weaves.
Use lower strength consumables on root runs and fillet welds (when the design
permits).
Use temper beads when necessary.
Arc strikes to be made in the joint preparation.
Particular attention should be given to tack welds re preheat, heat input and joint
cleanliness requirements.
Grinding toes of fillet welds is particularly important in fatigue applications.

REFERENCES/FURTHER READING

AS1554 Part 4 - 1989 Welding of Q & T Steels.


AS1554 Part 5 - 1995 Welding of Steel Structures Subject to High Levels of Fatigue
Loading.
WTIA Technical Note 15, 1996.
WTIA Technical Note 3, 1994.

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BENDING AND ROLLING.

FORMING, SHEARING AND PUNCHING


RECOMMENDATIONS
FORMING

COLD FORMING

All of the BISPLATE quenched and tempered steel


grades can be cold formed, using brake press bending or
plate rolling techniques.

However, with an increase in both hardness and yield stress


compared to plain carbon steel grades, suitable
consideration of sufficient machine power, plate bending
direction and former radii must be made.

In addition, springback allowances should be greater than


for plain carbon steel and will depend on the type of
forming. Plate edges should be ground smooth, and for
thick plates and high hardness grades, the plate edges
should be rounded prior to forming.

It is recommended for the high hardness grades that where


possible the bend axis be at right angles to the plate rolling
direction (transverse bending). For plate 16mm and above
in BISPLATE 500 grade, it is suggested bending be done
in the transverse direction only (refer to figure 1a).

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MINIMUM FORMER RADII (R)


IN MM FOR COLD FORMING

Table 1 following gives the minimum former radii for cold forming of the BISPLATE
grades (where possible a larger former radii should be used).

Table 1:
BISPLATE 60 70 80 320,400 450 500
GRADE
Bend Direction T L T L T L T L T L T L
Plate Thickness (t)
(mm)
5
6 12 12 12 12 12 12 15 20 - -
8 12 15 12 15 15 15 20 25 32 40 25 50
10 12 16 12 16 20 20 25 35 40 50 40 70
12 15 20 15 20 25 25 30 45 48 60 50 90
16 18 24 18 24 30 30 35 55 64 80 60 110
20 24 32 24 32 45 45 50 75 80 100 85 -
25 40 50 40 50 65 65 70 100 100 -
32 50 62 50 62 75 75 80 125 150 -
40 64 80 80 95 100 110 110 175 250 -
50 100 120 110 130 125 140 170 250 - -
140 190 150 200 150 200 300 - - -

T: Transverse Bending Direction (refer to fig 1a).


L: Longitudinal Bending Direction (refer to fig 1b).

Notes re Table 1
1. Above values were determined for plate at a temperature of 30C. If minimum
former radii values are to be used, plate temperature should be at least 30C,
maximum 100C.

If forming at a temperature less than 30C, an increase in former radii of


minimum 50% must be made.

2. When pressing is being done in a single pass operation, an


increase in former radii of minimum 50% must be made.

3. When forming using these minimum former radii, flame cut


hardened edge (heat affected zone of 1-2mm) should be
removed.

4. The use of smaller former radii than in the table is not


recommended.

5. For best cold forming results, ensure adequate lubrication


between the plate, die and former.

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CAPACITY OF PRESS

All BISPLATE grades have yield and tensile strengths higher than for plain carbon steel.

It is important that the capacity of the machine is suitable, bending press manufacturers
provide information on bending loads in relation to V-block opening, plate thickness and
steel strength.

Table 2 gives an indication of the approximate bending force required when forming
BISPLATE grades, compared to plain carbon steel (e.g. AS3678-Grade 250).

Approximate Bending Force (P) Required for BISPLATE Grades, Compared to


Plain Carbon Steel, for a Given Forming Geometry
(refer fig 2)

Table 2:
STEEL GRADE BENDING
FORCE (P)
AS3678 Grade 250 P
BISPLATE
60 2.0P
70 2.4P
80 2.8P
320 4.0P
400 5.0P
450 5.0P
500 6.4P

Approximate Die Openings


(refer fig 2)
Table 3:
BISPLATE W/t W/t
GRADE TRANSVERSE LONGITUDINAL
BENDING BENDING
60 6.0 7.5
70 6.0 7.5
80 7.0 8.5
320 8.5 10.0
400 8.5 10.0
450 8.5 10.0
500 10.0 12.0

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HOT FORMING

The operation of hot forming is not recommended for the BISPLATE grades, as hot
forming is generally done at a high temperature (900-1000C) which exceeds the tempering
temperature.

As a result, the mechanical properties of quenched and tempered steels will be reduced
considerably.

However, if hot forming is unavoidable, it is essential that the component be requenched


and tempered to restore original mechanical properties.

SHEARING AND PUNCHING

Shearing and punching of the lower hardness BISPLATE grades can be done successfully,
provided a machine of sufficient power and stability is used.

BISPLATE 60, 70 and 80 grades can normally be cold sheared up to 25mm thickness.
However, the necessary shearing force is in the order of 2-3 times that required for plain
carbon steel grades. The grades of BISPLATE 400, 450 and 500 should not be considered
for shearing.

The guillotine blades should be very sharp and set with a clearance of 0.25 to 0.40mm. note,
the maximum limiting thickness for cold punching are approximately half the cold shearing
values.

Maximum Thickness for Cold Shearing and Punching

Table 4:
BISPLATE GRADE COLD SHEARING COLD PUNCHING
60 25mm 12mm
70 25mm 12mm
80 25mm 12mm
320 10mm 6mm
400 Not recommended Not recommended
450 Not recommended Not recommended
500 Not recommended Not recommended

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DRILLING, COUNTERSINKING & TAPPING BISPLATE

DRILLING, COUNTERSINKING AND TAPPING RECOMMENDATIONS

GENERAL INFORMATION

All grades of BISPLATE are able to be drilled, countersunk and tapped although, as with
most fabrication aspects, care should be taken with these grades of steel.

In all cases, suitable high powered and rigid drilling equipment should be used.

DRILLING OF HIGH STRENGTH STRUCTURAL GRADES

When drilling the BISPLATE grades 60, 70 and 80 the use of cobalt type high speed steel
drills is recommended. Drills equipped with replaceable carbide inserts can also be used.

DRILLING OF WEAR/ABRASION RESISTANT GRADES

BISPLATE 320, 400 and 450 grades may be drilled with either cobalt type high speed
steel drills or drills equipped with replaceable carbide inserts.

With regards to the drilling of BISPLATE 500 grade, we recommend only the use of drills
equipped with replaceable carbide inserts.

RECOMMENDATIONS FOR IMPROVED RESULTS

The supporting bars under the plate should be placed as close to the hole as
possible.
If possible, use a plain carbon steel backing plate under the BISPLATE.
The drilling head should be placed as close as possible to the main support.
Short length drills are preferred.
The last part of the hole to be drilled should be done with manual feed.
Usage of adequate coolant (water and oil emulsion mixture).

Delta C Drills. The grades of Bisplate 60, 70, 80,


320, 400 and 450 can be drilled using these types
of drills. (Drills courtesy of Sandvik Coromant)

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Approximate Feeds and Speeds Using Cobalt Type High Speed Steel Drills

Table 1:
STEEL GRADE PERIPHERAL R.P.M (UPPER FIGURES) AND FEED PER HARDNESS
SPEED REVOLUTION (mm) FOR GIVEN DRILL SIZE BRINELL
(m/min) 3mm 6mm 12mm 20mm 25mm
AS3678-Grade 250 23 2300 1150 575 385 285 ~120
0.050 0.100 0.200 0.300 0.400
BISPLATE 60 16 1450 720 380 250 200 ~220
0.040 0.060 0.130 0.190 0.254
BISPLATE 70 15 1400 700 360 240 180 ~240
0.040 0.060 0.130 0.190 0.254
BISPLATE 80 14 1370 685 340 230 170 ~260
0.040 0.060 0.130 0.190 0.254
BISPLATE 320 9 920 460 230 150 115 320
0.025 0.050 0.100 0.150 0.200 (min)
BISPLATE 400 7 460 230 115 110 90 360
0.025 0.050 0.100 0.150 0.200 (min)
BISPLATE 450 7 440 220 115 110 90 425
(min)

Note: This table applies when cobalt type high speed drills are used
with a cutting fluid, if no fluid is used the speeds shown above must be
reduced.

Drill Tip Configuration Using Cobalt Type High Speed Steel Drills

Table 2:
BISPLATE GRADE POINT ANGLE LIP/CLEARANCE ANGLE
60 118 deg. 10 deg.
70 118 deg. 10 deg.
80 118 deg. 10 deg.
320 125 deg. 7.5 deg.
400, 450 150 deg. 5 deg.

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Approximate Feeds and Speeds Using Drills With Replaceable Carbide Inserts

Table 3:
BISPLATE INSERT GRADE SURFACE SPEED FEED RATE HARDNESS
GRADE (m/min) (mm/rev) BRINELL
60 1020 125 210 0.06 0.18 ~220
70 1020 125 210 0.06 0.18 ~240
80 1020 125 210 0.06 0.18 ~260
320 1020 125 210 0.06 0.18 320 360
400 H13A 125 210 0.06 0.18 370 430
450 H13A 70 - 90 0.06 0.14 425 - 475
500 H13A 70 - 90 0.06 0.12 500 (avg)
Note: Above drilling recommendations are based on u sing a
Sandvik Coromant U drill and is based on hole sizes of 12.7 - 60mm diameter. Through the tool coolant must be used. It
may be necessary to use different insert grades and geometrics to suit the application.

Further information can be obtained from your local Sandvik Coromant office.

COUNTERSINKING AND COUNTERBORING

Countersinking and counterboring of holes is possible in all BISPLATE grades with best
performance obtained using tools with a revolving pilot. The pilot increases the stability and
allows tools with replaceable carbide inserts to be used.

Cobalt type high speed steel drills with a pilot can be used for the BISPLATE grades 60,
70, 80, 320, 400 and 450. The cutting data will vary from machine to machine. A coolant
should be used. Replaceable carbide insert tools should be used on BISPLATE 500 grade.
Cutting Speeds and Feeds When Using High Speed Steel Cobalt Type Tools

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Table 4:
BISPLATE CUTTING 16 20 25 32 40 60
GRADE SPEED Rpm FEED Rpm FEED Rpm FEED Rpm FEED Rpm FEED Rpm FEED
(m/min) (mm/r) (mm/r) (mm/r) (mm/r) (mm/r) (mm/r)
60 10-12 250 0.05 - 200 0.05 - 160 0.07 - 110 0.07 - 90 0.07 - 70 0.07 -
0.2 0.2 0.3 0.3 0.3 0.3
70 9-11 210 0.05 - 170 0.05 - 130 0.07 - 90 0.07 - 60 0.07 - 60 0.07 -
0.2 0.2 0.3 0.3 0.3 0.3
80 7-9 170 0.05 - 130 0.05 - 100 0.07 - 70 0.07 - 60 0.07 - 40 0.07 -
0.2 0.2 0.3 0.3 0.3 0.3
320 6-8 150 0.05 - 120 0.05 - 90 0.07 - 60 0.07 - 50 0.07 - 40 0.07 -
0.2 0.2 0.3 0.3 0.3 0.3
400 4-6 130 0.05 - 105 0.05 - 75 0.07 - 50 0.07 - 40 0.07 - 30 0.07 -
450 0.2 0.2 0.3 0.3 0.3 0.3

Fig 4: Fig 5:

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Cutting Speeds and Feeds When using Replaceable Insert Tools

Table 5:
BISPLATE CUTTING 20 25 32 40 60
GRADE SPEED Rpm FEED Rpm FEED Rpm FEED Rpm FEED Rpm FEED
(m/min) (mm/r) (mm/r) (mm/r) (mm/r) (mm/r)
60 90 - 110 1675 0.15- 1320 0.15- 935 0.10- 760 0.10- 560 0.10-
0.20 0.20 0.15 0.17 0.15
70 80 100 1500 0.15- 1195 0.15- 840 0.10- 680 0.10- 500 0.10-
0.20 0.20 0.15 0.17 0.15
80 70 90 1340 0.15- 1060 0.15- 750 0.10- 605 0.10- 445 0.10-
0.20 0.20 0.15 0.17 0.15
320 40 60 840 0.15- 660 0.15- 470 0.10- 380 0.10- 280 0.10-
0.20 0.20 0.15 0.17 0.15
400 28 35 550 0.15- 420 0.15- 300 0.10- 250 0.10- 175 0.10-
0.20 0.20 0.15 0.17 0.15
450 25 - 30 450 0.15- 360 0.15- 250 0.10- 205 0.10- 150 0.10-
0.20 0.20 0.15 0.17 0.15
500 17 20 300 0.15- 240 0.15- 170 0.10- 136 0.10- 100 0.10-
0.20 0.20 0.15 0.17 0.15

TAPPING

With the correct tools and cutting speeds, tapping can be performed in all the BISPLATE
grades of steel. For the high hardness BISPLATE 400, 450 and 500 grades, higher alloyed
taps must be used.

Difficulties that commonly arise when thread cutting higher tensile strength steels include
tap sticking, torn threads and the short life of taps. The Prototyp brand tools have been
specifically developed for tapping in the BISPLATE grades of steel.

With all tapping it is recommended that the cutting speed is accurately controlled.

For best results, cutting oil or grease should be used. For through-holes of up to 2 times
diameter in thread depth, in metric sizes, the following tapping tools are recommended.

Note: The introduction of stress concentrations (as a result of tapping) is an important consideration in fatigue
applications.

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Tapping Speeds and Types Recommended for BISPLATE Grades

Table 6:
BISPLATE TAP TYPE TAPPING SPEED SIZE RANGE LUBRICATION
GRADE (prototype) (m/min)
60 Paradur 20360 15 M3 M56 Cutting Oil
70 Paradur 20360 15 M3 M56 Cutting Oil
80 Prototex Inox 6 15* M1.6 M36 Cutting Oil
202135
320 Prototex Inox 6 15* M1.6 M36 Cutting Oil
202135
400 Prototex Inox 6 15* M1.6 M36 Cutting Oil
202135
450 Prototex Ni 202602 3 M1.6 M24 Cutting Oil
500 Paradur H/C 80311 1.6 M3 M12** Cutting Oil
* 6m/min using steam tempered taps and 15m/min using tin
coated tips.
** For larger size threads, thread milling is recommended.

Straight fluted gun-nose tap for through-hole. Spiral sluted tap foe blind holes. (Taps coutesy of Ti-Tek)
Bisalloy Steels wish to thanks Sandvik Coromant and Ti-Tek
for the information pertaining to drilling, tapping and
countersinking contained in this publication.

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TURNING
MILLING

MILLING AND TURNING RECOMMENDATIONS

MILLING

Milling operations can be performed satisfactorily on all BISPLATE grades; utilisation of


cemented carbide tooling is recommended.

In many situations, the milling operation entails the dressing of a flame cut edge, and then
subsequent bulk milling of material to the desired surface finish and dimensional tolerance.

Care must be taken to make a first cut sufficiently deep to remove the heat affected zone of
the flame cut edge. Cutters must be sufficiently robust to take this heavy loading. In such
circumstances it is desirable that, due to the high hardness adjacent to the flame cut surfaces,
cutter speeds and feed rates for initial milling should be reduced to 40-59% of the speed
normally used when milling plain carbon steel. The importance of adequate preheating prior
to flame cutting and slow cooling after cutting to minimise edge hardening is again
emphasised. Speed and feed rates may be increased somewhat for subsequent bulk milling to
50-75% of the settings used for plain carbon steel.

Milling Recommendations

Table 1:
BISPLATE CEMENTED SURFACE SPEED FEED/TOOTH
GRADE CARBIDE
TOOLING
GRADE
60 GC4030 295m/min 0.25mm
70 GC4030 275m/min 0.25mm
80 GC4030 257m/min 0.25mm
320 GC4030 131m/mon 0.25mm
400 GC4030 110m/min 0.25mm
450 GC4030 100m/min 0.25mm
500 GC4030 87m/min 0.25mm
Note: These recommendations are given as a guide only, and are based on stable working conditions. It is
suggested a 45 deg. Approach angle or a round insert facesmill be used. In certain conditions it may be
necessary to use negative geometry milling tools. Feed rates are dependant on geometry selected.
Eg. PM medium machining (0.1 0.28) fz mm/tooth
PH heavy machining (0.1 0.42) fz mm/tooth.

AVOID VIBRATIONS

Indexable inserts are sensitive to vibrations. These can be avoided or reduced by observing
the following.

When turning or milling gas cut edges the cutting depth should be at least 2mm to cope with
the hardness and unevenness of the edge.

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OTHER MILLING REQUIREMENTS

Firm clamping of the workpiece.


Use cutters with the smallest possible gap between the teeth.
Machine stability permitting, unidirectional milling is preferable, see figure 1.
If a large cutter is used for the milling of small areas, place the milling cutter
eccentrically to get as many teeth as possible operating, see figure 2.
Avoid, if possible, the use of a universal cutterhead which generally causes
weakening of the power transmission and the tool holder.

TURNING

All BISPLATE grades, including those with hardness in excess of 360 Brinell can be
satisfactorily with carbide tooling, provided spindle speeds and feed rates are reduced from
those normally employed when carrying out similar machining operations on plain carbon
steel. Reductions of 50-70% in spindle speed and up to 50% in feed rate may be necessary,
depending on the hardness of the component being machined, High speed tools are not
recommended.

As an example, the following settings have been found to give satisfactory results when
turning cylindrical workpieces of 25mm diameter from the various BISPLATE grades.
With increases in stock diameter, spindle speeds will obviously need to be decreased.

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Turning Recommendations

Table 2:

BISPLATE CARBIDE TOOLING SURFACE SPEED


GRADE GRADE
60 GC4025 295m/min
70 GC4025 275m/min
80 GC4025 257m/min
320 GC4025 131m/min
400 GC4025 110m/min
425 GC4025 100m/min
500 GC4025 87m/min

For operations under favourable conditions where higher productivity can be obtained GC
4015 could be used.

For operations with high toughness requirements and where increased security is needed GC
4035 could be used.

Note: These recommendations are given as a guide only. And are based on stable working conditions. The geometry of the
inserts used will be dependant on the operation.

Eg. PF for finishing.


PM for medium machining
PR for roughing.

OTHER TURNING REQUIREMENTS

Firm clamping of the workpiece


Avoid long overhangs for both workpiece and tool holder.
Use correct tip radius: too large a tip radius, combined with insufficient clamping,
causes vibrations.
Small setting angles also can cause vibrations.

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Fig 4

FORMULA FOR THE CALCULATION OF SPEEDS AND FEEDS FOR GENERAL


MILLING AND TURNING OPERATIONS.

Formula for calculation of cutting speed:

v= Dn m/min
1000

Formula for calculation of turning speed:


n= v 1000 m/min
D

Formula for calculation of table feed:


u = n z sz m/min

v = cutting speed m/min


D = Diameter in mm of milling cutter or workpiece
Z = Number of cutters
Sz = Feed per cutter, mm
n = Turning speed, rpm
u = Table feed, mm/min

Bisalloy Steels wish to thank Sandvik Coromant for information pertaining to milling and turning
contained in this publication.

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DESIGN EXAMPLES

The following five structural design examples demonstrate the significant savings which can
be achieved in the areas of weight and cost by using Grade 690 MPa Bisplate 80 steel
instead of the more commonly used lower grade structural steels. These examples primarily
compare Bisplate 80 to Grade 300 Plus Steel which is currently the most commonly used
structural steel in Australia. Comparison with other steels are noted where appropriate.

The design examples are as follows:

Heavily Loaded Column


Heavily Loaded Beam - I section
Heavily Loaded Beam - Box section
Heavily Loaded Truss
70 MI Water tank

Where appropriate, these examples have been simplified as much as possible in order to
facilitate ease of comparison between the different steels. Each example contains a brief
explanation of the structural element and the loading applied. Also provided are some typical
examples of applications in which the structural element may be utilised.

DESIGN CODES RELATING TO THE USE OF HIGH STRENGTH QUENCHED AND TEMPERED PLATE
MEMBERS IN STRUCTURAL ENGINEERING APPLICATIONS.

There is currently no Australian Standard covering the design of structural elements utilising
high strength quenched and tempered steels. The SAA Steel Structures Code, AS 4100-1990,
may be used for the design of structures in steel grades up to 450 MPa, beyond which the
general provisions of the code are not applicable.

AS4100 does not exclude the use of structural steels in excess of 450 MPa yield stress.
However, in order to adequately design and demonstrate the validity of a design in such
steels, it is necessary to engage an appropriate international standard which has been
specifically developed to cater for the use of high strength steels.

One such code, and the most commonly used in Australia for design in high strength steels is
the American Institute of Steel Constructions (AISC) Specification For Structural Steel
Buildings - Allowable Stress Design and Plastic Design, June 1, 1989. This code has been
proven to provide relatively simple and efficient methods of structural design for all types of
structural elements, and has been used in the development of each of the design examples
contained within this publication.

A limit state version of the AISC specification is also available, and should be equally
effective in the design of High Strength Steel structures. It should also be noted that Bisplate
80 steel, at 690 MPa yield stress, is right on the upper limit of 100 ksi yield stress steel
covered by the AISC specification. Above this yield stress the AISC specification is not
applicable.

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EXAMPLE 1
HEAVILY LOADED COLUMN

Consider a braced column, 10m high, loaded


axially with an 11,000 KN factored live load
(Fig. 1).

Some examples of practical applications where


such a column may be required are as follows:

In multi-storey construction
Heavy industrial structures
Storage silos/Hopper supports

Structural column design was carried out


for Grade 300 MPa steel using AS4100-1990. C
Corresponding design was carried out for
Grade 690 MPa Bisplate 80 Steel using the
AISC specification.

The results of each design are summarised in Table 1. Representative calculations are
provided on following pages.

STEEL GRADE MPa SECTION WEIGHT Kg/m


300 500WC383 383
tf = 20 d1 = 400
690 207
tw = 16 bf = 500

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COLUM DESIGN USING GRADE 300 STEEL COLUMN DESIGN USING GRADE 690 MPA YIELD
Design in accordance with AS4100 1900. STRENGTH BISPLATE 80

Design in accordance with American Institute of Steel


Fig 3 Construction Specification for Structural Steel Buildings - 1989.
Ag = 48,800 mm2
Ix = 1,890 x 106mm4
Iy = 751 x 106mm4 Ag = 26,400 mm2 = An = Ae
rx = 197mm Iy = 416.8 x 106mm4
ry = 124mm Ry = Iy
fy = 280 MPa A = 125.7mm

fy = 690 MPa
= 100 Ksi
AS4100 500WC383
Reference
AISC Spec. Design Load = 11,000 = 7,333 KN
Section Capacity Reference 1.5
6.2.1 NS = KfAnfy
An=Ag=Ae
fa = 7,333 = 277.78 MPa
Kf = 1.0 Ag
Ns = 13664 KN
Ns = 12,298 KN > N* OK Fa = 40.29 ksi

Member Capacity B5 Check Local Buckling


6.3.3 Nc = c Ns N
Table B5.1 Flanges : 95 = 95 = 9.5 < b = 12.1
2
c = {[1-[1-(90/) ]} = 0.8945 Fy 100 t
Kc 1.0
Nc = 12,222 KN
Nc = 11,000 KN N* OK
Slender Element
Nominal Mass of Column = 383 kg/m
Table B5.1 Web: 253 = 253 = 25.3 > b = 25.0
Fy 100 t

Non-Compact Element

Slender elements involved

Design by Appendix B

App. B Stress Reduction Factor for Flange,

B5a Qs = 1.293 0.00309 b Fy = 0.907


t Kc

Stress Reduction Factor for Web,


Qa = 1.0
Member stress reduction factor,
Q = QsQa = 0.907

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COLUMN DESIGN USING GRADE 690 MPA YIELD


STRENGTH BISPLATE 80 (CONTINUED)

AISC Spec.
Reference

B5c Allowable Stress, Fa

C1c = 79.44 > kl


r

kl 2
r
Q 1- Fy
2Cc,2
Fa =
3
Eq A-B5-11 kl kl
3
r r
5
3+ 8Cc 8Cc3

Fa = 43.13 ksi > fa OK

Nominal mass of Column = 208 kg/m

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EXAMPLE 2
HEAVILY LOADED BEAM (I SECTION)

Consider a beam with full lateral restraint spanning 10m, loaded continuously with a live load of
470 KN/m (factored) as shown in Fig.5.
Practical applications where such a beam may
required are:

In multi-storey construction
Heavy industrial structures
Roof support in underground mining

Structural beam design was carried out for Grade 300 MPa steel using AS4100-1990.
Corresponding design was carried out for Grade 690 MPa Bisplate 80 steel using the AISC
specification.

The results of each design are summarised in Table 2. Representative calculations are provided on
the following pages.

STEEL GRADE
SECTION WEIGHT Kg/m
MPa
300 1200WB392 392
tf = 25 d1 = 850
690 256
tw = 12 bf = 450

Note that a significant reduction in the depth of the beam was achieved through the use of Bisplate 80, in addition to
the weight waving, while still satisfying the permissible deflection requirements. This is of great importance in
underground mining and multi-storey construction applications, where head room is at a premium.

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BEAM DESIGN USING BEAM DESIGN USING GRADE 690 MPA


GRADE 300 STEEL YIELD STRENGTH BISPLATE 80
Design in accordance with AS4100 1990.

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EXAMPLE 3
HEAVILY LOADED BEAM (BOX SECTION)

Consider a beam with full lateral restraint spanning 10m, loaded continuously with a live load of
470 KN/m (factored) as shown in Fig 9.

Practical applications are :


Heavy industrial structures
Roof support in mining
A box section is effective in long spans where additional lateral restraint is required within
the beam section to compensate for a lack of external restraints.
A common application of a box section fabricated from high strength Q & T steel
in which the load configuration varies significantly from that described above, is
in the lifting booms of mobile cranes.

Structural beam design was carried out for both Grade 250 MPa steel and Grade 690 MPa
Bisplate 80 steel using the AISC specification.

The results of each design are summarised in Table 3. Representative calculations are
provided on the following pages.

Table 3:
STEEL GRADE
SECTION WEIGHT Kg/m
MPa
tf = 40 d1 = 1120
250 490
tw = 10 bf = 500
tf = 25 d1 = 850
690 284
tw = 8 bf = 450

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BOX SECTION BEAM DESIGN USING BOX SECTION BEAM DESIGN USING
GRADE 250 MPA ASTM A36 GRADE 690 MPA BISPLATE 80
In accordance with AISC Spec. In accordance with AISC Spec.

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EXAMPLE 4
HEAVILY LOADED TRUSS

Consider a heavily loaded truss spanning 40m.

Some examples of practical applications where such a truss may be required include :

Underground construction supporting a trafficable roof


(e.g. a hydro-electric power station).
Multi-storey construction supporting several floors.

In this example the following loading parameters have been considered.


Truss spacing 10m
Live Load 3 KPa
Dead Load 1 KPa
Occasional Load 20 KN mid span

The resulting load configuration is illustrated in Fig.13.

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Structural member design was carried out for Grade 300 and 350 MPa steels using
AS4100 1990. Corresponding design was carried out for Grade 690 Bisplate 80 steel
using the American Institute of Steel Construction Specification for Structural Steel
Buildings. Results are summarised in Tables 4 and 5.

TRUSS DESIGN SUMMARY

Grade 300 & 350 MPa AS4100 1990

Table 4:
MEMBER SECTION kg/m TOTAL LENGTH TOTAL WEIGHT
m TONNES
Top Cord 310 UC 137 137 40 5.480
Bottom Cord 310 UC 96.8 96.8 40 3.872
Webs 250 UC89.5 89.5 87.3 7.814

* (250 x 250 x 6 SHS) (45) (87.3) (3.929)


Total Weight = 17.166
(13.281)

*Figures in brackets correspond to the use of Grade 350


square Hollow Sections as web members.
All other members are Grade 300.

Grade 690 Bisplate 80 AISC Spec.

Table 5:
MEMBER SECTION kg/m TOTAL LENGTH TOTAL WEIGHT
m TONNES
Top Cord tf = 10 d1 = 212 55 40 2.200
tw = 8 bf = 256
Bottom Cord tf = 10 d1 = 212 58 40 2.320
tw = 10 bf = 260
Webs tf = 8 d1 = 225 43 87.3 3.754
tw = 6 bf = 256
Total Weight = 8.274

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EXAMPLE 5
REVISED DESIGN FOR A LARGE WATER STORAGE TANK

A water storage tank was originally designed in AS3678-1990 Grade 250 and 350 steel
plate to the following parameters:

Height = 14.25m
Diameter = 83.8m
Capacity = 70 MI

The stress calculations for the original design are as shown in Table 6.

Table 6::
DEPTH (m) PRESSURE HOOP PLATE YIELD PLATE STRESS
(KPa) TENSION STRENGTH THICKNESS (MPa)
(KN/m) (MPa) (mm)
2.85 28.5 1194 250 10 119
5.70 57.0 2388 250 20 119
8.55 85.5 3582 250 25 143
11.40 114.0 4777 350 28 171
14.25 142.5 5971 350 36 166

A revised design incorporating 690 MPa yield strength Q & T steel plates in the lower
two sections produced the following set of values, shown in Table 7.

Table 7:

DEPTH (m) PRESSURE HOOP PLATE YIELD PLATE STRESS


(KPa) TENSION STRENGTH THICKNESS (MPa)
(KN/m) (MPa) (mm)
2.85 28.5 1194 250 10 119
5.70 57.0 2388 250 20 119
8.55 85.5 3582 250 20 179
11.40 114.0 4777 690 20 239
14.25 142.5 5971 690 20 298

As shown in Fig. 15, this revised design resulting in a saving of 25% in the mass of
steelwork in the walls of the tank.

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Please Note:
Every care has been taken to ensure the accuracy of the design examples, however, the information is
provided as a guide only. A structural engineer should be consulted with respect to use for specific projects.
Bisalloy does not warrant the suitability of the design examples for a particular purpose. The purchaser
relies on its own skill and judgement as to the suitability of Bisalloy 80 (Bisplate 80) for its purpose.
Bisalloy Steels shall not be liable for any loss or damage howsoever caused arising from the application of
such information.

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BISPLATE Identification Marking and Colour Coding


Bisalloy Steels has a series of identification markings and colour codes to clearly
identify the plate specifications and differentiate the grades from each other and other
grades of steel. It is crucial that when plates are profiled that this identification is
transferred to all off-cuts to prevent grade and size mixes.

Grade identification stencils - there are two grade id stencils on each plate located at
opposite ends so that if plates are halved then each end remains identified. These stencils
are colour matched to the grade colour coding.

Plate identification stencils there are two plate id stencils on each plate located at
opposite ends so that if plates are halved then each end remains identified.

For domestic orders


Customer Name
Dimensions Plate Weight
Grade
Australian Standard (if applic.)

Plates delivered via central stock will not have a customer name

For Export Orders


Customer Name
Customer O/No.
Plate Dimensions Plate Weight
Grade
Plate Number

Plate Corners two diagonal corners of the plate are coloured with the relevant grade
colour code. The other two plate corners are hard stamped with the plate number, which
is then over sprayed with the plate number.

R.D.

Plate number Colour Code


Grade Colour Code
BISPLATE 60 - White BISPLATE 320 - Blue
BISPLATE 70 - Lime Green BISPLATE 400 - Orange
BISPLATE 80 - Pink BISPLATE 450 - Yellow
BISPLATE 80PV - Pink/Red BISPLATE 500 - Black

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Testing and Certification

Mechanical testing

Brinell Hardness Test Brinell hardness test is performed in accordance with the
requirements of AS 1816 1990. All plates are individually hardness tested.

Tensile Tests Structural steel grades only are tensile tested in accordance with the
requirements of AS1391 1991 and these tensile tests are done on a batch basis, one test
per heat per 20 tonne (max.) per thickness production run.

Charpy V-Notch Impact Tests Structural steel grades only are impact tested. Charpy V-
Notch tests are done on a batch basis, one test per heat per 20 tonne production run.

Standard test direction is longitudinal and standard test temperature is 20 deg C.

Tests conducted in accordance with AS 1544.2 1989 requirements

Certification

A separate NATA certified test certificate will be issued for each full plate supplied.
Tests are conducted in our NATA certified laboratory and will detail chemical analysis,
hardness and relevant mechanical test information dependent on the grade ordered.

Bisalloy Customer

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HARDNESS TESTING BISPLATE

WHAT IS HARDNESS?

Hardness is the resistance of material to plastic deformation usually by indentation or


penetration. It also defines the ability of material to resist scratching, abrasion or cutting.

WHY TEST FOR IT?

Hardness testing is undertaken to:

1. Specify and certify a range of wear resistance products.


2. Double check the tensile strength of structural grade materials.
3. Assist in failure analyses and material identification.
Table 1:
Method Standard Basis Measurement Accuracy Max
Approx % Temp
Brinell (4) AS1816 10mm Tungsten Surface area for known 2 50C
Carbide ball (1) load
impressed under
3,000kg load
Vickers AS1817 136 Diamond Surface area for known 2 50C
(HV) pyramid impressed load
under load
Rockwell AS1815 120 Conical Depth of impression under 2 50C
(HR) A, B, C ISO6517-1 Diamond Steel ball known load (15 150kg)
used for soft metals
Equotip (2) NIL Rebound Method Height of rebound Poor -
Poldi (3) NIL 10mm Ball Comparative impression Very Poor -
impressed with ( 20)
hammered test bar

WHERE TO TEST?

Testing can be carried out in the laboratory, workshop or on site.

However, site testing with portable equipment can often have difficulties of access,
surface preparation and vibration, which may reduce the accuracy of testing.

TESTING PROCEDURES AND EQUIPMENT

The table above sets out the methods of identifying common indentation hardness, and
other types of hardness tests.

It is absolutely vital to understand the specific uses, strengths and any weaknesses of
and correct requirements and procedures demanded by each of these methods in order
to ensure consistent, comparable results in testing.

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Interpreting Table 1 Some Important Considerations


1. Where the maximum hardness of the work exceed 450 HB, but doesnt exceed
650 HB, the standard says a tungsten carbide ball must be used.
2. Equotip is a rebound method of hardness testing, which does NOT measure
hardness (indentation or plastic deformation) but gives a result convertible
within a restricted range into an indentation hardness figure.
This method is not standardized and gives only indicative results. It is
extremely dependent on the operator, test material and surface condition. It is
NOT recommended on quenched and tempered steel, or surfaces that arent
bright and smoothly ground.
3. The Poldi test is sometimes employed in the field. Even though it is an
impression method, it displays very poor accuracy. It is not recommended for
quenched and tempered steel.
4. The Brinell test is strongly recommended for all BISPLATE grades as it is
widely accepted as the industry standard. (Brinell gives a more definite
reading, by leaving a more definite impression on the plate). It is the standard
employed at Bisalloy and by other manufacturers, both on the production
line and in the laboratory.
The hardness rating on a certificate issued by Bisalloy is measured in Brinell
hardness. Converted values from other methods such as Rockwell or Vickers
(more often used in laboratory testing small samples of steel, or in small-parts
engineering, and not ideal for use in the production environment) can cause
small discrepancies from the Brinell rating on the certificate.

Proper Preparation of the test surface

Since BISPLATE is a quenched and tempered steel, some decarburisation will occur on
the plate surface during the heat treatment process. The thickness of the decarburised
layer (the very thin surface layer which has lost carbon during austenitising) will vary
depending on the plate thickness. This decarburized layer will get thicker as the plate
thickness increases.

To ensure testing accuracy, surface scale and the decarburized layer must always be
removed by either grinding or machining from the areas where hardness measurements
are taken. The minimum grinding or machining depths are listed in the Table 2.

Table 2:
Plate Thickness Min Grinding or
Machining Depths
(mm)
6 0.2
>6 10 0.3
>10 20 0.5
> 20 50 0.7
> 50 80 1.0
> 80 1.5

Without removing the entire decarburized layer by grinding or machining, the results of
the hardness test will be invalid.

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It should also be noted that the area tested should be a min. of 75mm from any thermally
cut surface to avoid any hear-affected zone.

The tested area must represent the whole material, must be clean, free from unwanted
scale, and must be flat, sufficiently thick and smooth. The test piece must be well
supported and not subject to movement or vibration.

CALIBRATION
To further ensure accuracy and consistency, all testing equipment must be calibrated
(usually 3 yearly) and checked daily against calibration blocks.

PERSONNEL COMPETENCY
For all tests, the operator requires training in the correct methods and assessment
acceptable to the employer. Preference is given to NATA registered laboratories for high-
risk applications.

REPORTING
Reporting should include plate identification, location, method, result, date, surface
condition, operators name and signature. Refer to AS1816-2002.
Table 3
Grade Specified Typical Hardness
Hardness (HB) (HB)
BIS80 255
BIS320 320 360 340
BIS400 360 430 400
BIS425 400 460 440
BIS450 425 - 475 450
BIS500 477 - 534 500

Currently already unique among other manufactures Bisalloy goes to the extent of
physically testing every plate produced that is, each one goes through the full process of
grinding, test and measure.

The size of the indentation is measured using the latest video imaging technology, which
is interfaced with a dedicated computer to generate a BHN number to within one point.

This testing procedure is now fully automated including automated grinding and
indentation, guaranteeing an even greater and more consistent level of accuracy and
repeatability.

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BISPLATE WEAR COMPARISONS

THEORY OF ABRASIVE WEAR

Abrasive wear is wear by displacement of material caused by hard particles or


protuberances. Abrasive wear occurs when particles slide or roll under pressure across a
surface of the material and may be classified generally as a) gouging abrasion, b) high
stress grinding abrasion and c) low stress scratching abrasion or erosion. A similar action
is involved in all three types of abrasive wear; i.e. a hard particle is dragged across a
softer surface and material removal takes place by the formation of chips, leaving a
scratch in the surface as shown in Fig. 1.

Fig 1 Material removal takes place by formation of chips

Abrasive wear is determined by:


Properties of wear material.
Properties of abrasive material.
Nature and severity of the interaction between abrasive and wear materials.

They are related to the hardness of the material, hardness of the particles and the pressure
between the particle and the material surface. According to the simplified abrasion wear
theory, volume loss (Q) is proportional to the applied load (N) and inversely proportional
to the hardness (H) of the abraded surface for a certain abrasive material applied

Q = N/H

It can be seen that, in a specific working environment, the wear loss of a material is
dependent on hardness of the material. In general, as the hardness of the material
increases, the wear rate decreases.

To assess the wear properties of BISPLATE, three grades of BISPLATE (BIS80,


360/400 and 500) have been tested against mild steel, overseas Q&T steels and clad
plates under sliding abrasive wear environment complying ASTM standard G65-86.

DRY SAND RUBBER WHEEL WEAR TEST (DSRW) ASTM G65-86

DSRW is a standardised low stress sliding abrasion wear test designed to simulate the
wear experienced in applications such as chutes or bin and dump truck liners for post
crushed ore.

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Sand flow
Sand Nozzle

Rotation

Mounted Rubber
Ring
Steel Disk
Weights
Specimen
Holder
Specimen

Fig. 2 Schematic diagram of test apparatus (Dry Sand / Rubber Wheel abrasion wear)

Parameters set up for wear testing (ASTM Standard G65-86)


Specimen Abrasive Rubber Wheel
Dimension Surface Sand Sand Diameter Rubber Revolution Time Load
(mm) Condition Grade Flow & Width Hardness (r.p.m)
(g/min)
25x10x76 Ground 60 360-380 228 & A-60 200 30min 130N
12.7mm

RESULTS

1. Relationship between Wear Resistance and Hardness of the Materials

In general, as the hardness of a wear resistant material increases, the wear resistance ratio
increases (Abrasion Resistance Ratio = mass loss of mild steel / mass loss of tested steel).
That is, steel with a hardness of 250 Brinell, i.e. BIS80, has relatively higher wear
resistance than mild steel, which has a hardness of 120 Brinell. BIS500 has a hardness
twice high as that of BIS80. Therefore it is expected that BIS500 has a resistance one
time higher than BIS80 (see Fig. 3a and b).

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Mild Steel BIS 80 BIS 400 BIS500

Fig. 3 Wear resistance comparison between


BISPLATE and mild steel

2. Wear Rate Comparison between BISPLATE and Other Q&T Products

BIS 80 Structural Type

BIS 80 wear was slightly better than one


Japanese brand and slightly worse than
another. All grades were however
very similar in wear resistance. BIS 80
wear resistance was 60% better than
mild steel.

Fig.4 Comparison of wear resistance between BIS80


and Japanese products

BIS 400 Wear Grade

BIS 400 performed best from all the


400 grades tested. European grades,
which were water quenched with leaner
chemistry, were slightly worse than
BIS 400. Oil quenched 400 type was
about 5% worse than BIS 400 in the
wear resistance rate.

Fig. 5 Comparison of wear resistance between BIS


400 and other products

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BIS 500 Wear Type

BISPLATE 500 performed very well


compared to most Japanese 500
grade plates, 10% better than European
water quenched and 30% better than
European oil quenched plate.

Fig. 6 Wear resistance comparison between BIS


500 and other products

PADDLE IMPACT ABRASION TEST

The Paddle Wear Testing was conducted at the Advanced Manufacturing Technologies
Centre (AMTC), a Division of Central TAFE, Subiaco WA. The testing offers a medium
stress impact & sliding abrasion wear normally experienced by such components as chute
liners, grizzly bars, and other impact plate liners in mining industries.

The testing is performed by placing two specimens (test material and reference material)
to be compared against each other at either end of the Paddle Arm located in a Drum.
Both the arm and the drum rotate in the same direction with their speeds being 270 rpm
and 45 rpm respectively as shown in Figure 1. Blue metal ore sized between 5.5 and 14.0
mm was used as the abrasion medium. Each test lasts 15 minutes. Three materials were
chosen as reference specimens, BIS80, BIS400 and BIS500. The testing materials are
listed in Table 1 below, including three Japanese products, four European plates and tow
clad (overlaid) products.
Test specimen (held by the
arm rotating at 270rpm)
Drum (rotating at 45 rpm)

Reference sample

Gravel (5.5 14 mm in size)

Fig. 1 Schematic set-up of Paddle Wear Tester

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Table 1
Test and reference materials
Test Material Mild steel Jap400-1 Jap400-2 Euro400 EurO4*
Reference BIS80 BIS400 BIS400 BIS400 BIS400

Test Material Jap500 Euro500 EurO8* DClad D60


Reference BIS500 BIS500 BIS500 BIS500 BIS500
* European oil quenched 400 and 500 grade products

RESULTS
Two samples from each material were tested against two same reference samples. The
relative wear rate (RWR) of the test material was recorded as:

RWR = (MLt x t) / (MLr x r),

Where: MLt and MLr mass loss (g) of test specimen and reference specimen
respectively, and t, r are specific densities (g/cm3) of test and reference materials
respectively.

Table 5
Lists average relative wear rates for the Paddle tested specimens.
Test Material (HB) Reference Material (HB) Relative Wear Rate
Mild Steel (121) BIS80 (255) 1.518
Jap400-1 (425) BIS400 (424) 1.115
Euro400 (401) BIS400 (424) 1.015
EurO4 (391) BIS400 (424) 1.064
Jap400-2 (398) BIS400 (424) 1.044
Euro500 (495) BIS500 (503) 0.984
Jap500 (514) BIS500 (503) 1.036
EurO8 (465) BIS500 (503) 1.223
D60 (664) BIS500 (503) 1.462
Dclad (573) BIS500 (503) 1.164

It can be seen that BIS80 performed 50% better than mild steel under impact abrasion
condition. 400 and 500 grade Q&T plates did not show major differences between
manufacturers although BISPLATEs did perform slightly better than most overseas
products. Clad plates performed poorly under impact abrasion wear conditions compared
to Q&T steel, especially high hardness D60 which experienced almost 50% more wear
compared to Q&T plate. Higher mass loss from clad materials compared to quenched
plates are caused by chipping off due to impact. Clad layer contains high volume of CrC
and this layer is hard but can be very brittle. Under impact, brittle material tends to be
fractured and chipped off easily compared to quenched plate.

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FATIGUE

WHAT IS FATIGUE
A metal component subjected to repeated or cyclic stresses may eventually fail even
when the maximum applied stress is less than the yield stress of the parent steel. This
phenomenon is known as fatigue.

It is known that in machines and other kinds of structures that are subjected to fatigue
loads, that 80-90% of all fractures that occur are fatigue fractures.

However, it is relatively easy to appreciate why this occurs, since structures are usually
designed against plastic deformation (i.e. yielding) and not against fatigue!

FATIGUE FAILURES

CHARACTERISTICS OF FATIGUE FAILURES

The surface of a fatigue fracture is distinctive and from a knowledge of various


characteristics of the fracture surface considerable information can be obtained about the
cause(s) of crack nucleation and the nature of the fatigue loading.

The material adjacent to a fatigue fracture displays no evidence of plastic deformation.


The fracture surface is relatively smooth and generally contains concoidal markings
which appear to radiate from a particular point on the outer surface, see figure 6.5.

Figure 6.5 Fatigue fracture


surface of a failed gear showing
the concoidal beach markings
radiating from the oil hole,
marked (A). Also shown are the
beach markings associated
with fatigue crack growth (B),
and the area where ductile
overload occurred (C).

Fatigue cracks generally nucleate at the surface, and because crack growth requires a
tensile stress, the direction of the fatigue crack is always perpendicular to maximum
tensile stress.

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Because the load is applied in a pulsating manner, the crack grows in small steps.
Pulsating loads are invariably not uniform (as say a sine wave would be), so that crack
growth rate variations occur and these reflected in the form of ridges on the fracture
surface as can be seen in figure 6.5. These are given the name beach markings, and are
the single most distinctive feature of fatigue crack failure.

As the crack grows, the section supporting the load is progressively reduced. As such the
stress of each cycle is progressively increased and the crack growth rate become faster,
and the beach markings become larger and more distinct.

Ultimately, the cross sectional area supporting the load is reduced to such an extent that it
is too small to support the applied load, and final failure occurs by ductile overload; the
area marked C in figure 6.5.

WHY IS KNOWLEDGE OF FATIGUE IMPORTANT WHEN DESIGNING WITH HIGH STRENGTH


STEELS?

There are two main reasons:

Firstly, fatigue cracks propogate at approximately the same rate in all steels, and
since the life of welded joints is dependent upon crack propogation, welded
sections of high strength steels exhibit the same strength at around 2 x 106 load
cycles as welded plain carbon steels.
Secondly, a principal reason for using high strength steels is to reduce plate
thickness (i.e. weight reduction). When this is done, the stresses in the steel both
static and fatigue stresses will naturally increase for a given load case.
As a result, design against fatigue is more important when high strength steel is
used in welded structures, since fatigue strength does not increase at the same rate
as static strength.

In addition, high strength steels are often used is applications that are naturally
subjected to high fatigue loads, e.g. mining and transport equipment.

FATIGUE STRENGTH OF STEELS

FATIGUE DATA

Fatigue data generated under laboratory conditions is generally in the form of the
number of cycles to cause failure at a particular stress amplitude.

This may be in the form of simple bending, so that a point on the surface of the specimen
may be in tension when bending occurs in one direction, followed by compression when
bending occurs in the opposite direction. Alternatively, the specimen may be subjected to
a pulsating axial load causing alternate tension and compression. This simple situation
can be presented as a sine wave as shown in figure 6.6.

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Figure 6.6 Diagram showing the sinusoidal type of pulsating load generally applied in
laboratory type work (carried out to determine fatigue data).

The fatigue diagrams produced from cycles to failure tests can be presented as either
stress amplitude (Sa) or stress range (Sr) and for most steels takes a form similar to that
shown in figure 6.7, the cycles to failure generally being represented on a logarithmic
scale.

Fig. 6.7 Diagram showing the form in which data is presented, relating number of cycles
to failure for a particular stress.

It can be seen in figure 6.7 that after about 2 x 106 cycles the curve tends to flatten out,
indicating an almost infinite fatigue life at stress loadings below a critical value. The
critical value is generally referred to as the fatigue limit and for most steels is referred to
at 2 x 106.

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Figure 6.6 and 6.7 represent a situation where the tensile stress and compressive stress are
equal in magnitude so that SMAX = -SMIN. There are however, other cyclic stress
situations.

For example, after the application of a tensile load the specimen may simply return to
zero stress before re-application of the tensile load. Alternatively, an applied static tensile
load may be present and an alternating cyclic load may be superimposed. To differentiate
between such loading conditions a convenient means to define the loading conditions is
achieved by the use of the stress ratio, R which is defined as:

R= SMIN
SMAX

For the simple bending situation of equal tension and compression stress (shown
diagrammatically in fig. 6.6) where SMAX = -SMIN, R= -1.

If only a tensile pulsating load is applied and SMIN = 0, then R = 0.

When a pre-existing tensile static load is present and pulsating loads are applied R
becomes positive; the limiting case of R = 1 when the static load equals the tensile
strength of the steel.

Obviously there can exist a variety of loading conditions between R=-1 and R = 1. These
are represented in the form of a Goodman Diagram as shown in figure 6.8. It can be
seen that Smin is represented on the abscissa (negative and positive) and Smax is
represented on the ordinate. In such diagrams, the line ABCDE represents the stress ratio,
R, at failure from -1 to +1 for a specified number of cycles to failure, i.e. 2 x 106.

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Fig. 6.8 Goodman Diagram depicting the various stress configurations required to
determine the points on the diagram.

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From laboratory controlled fatigue tests the Goodman Diagrams for two steels having
tensile strengths of 400MPa (AS3678-Grade 250), and 800MPa (BISPLATE 80 grade)
are shown in figure 6.9. Here it can be seen that over the entire fatigue stress range there
is a distinct advantage in using the higher strength BISPLATE 80 grade steel.

However, most structures involve welded connections, so that when examining a simple
butt weld joint (with the weld bead left in place) a different Goodman Diagram emerges.

It can be seen in figure 6.10 that for butt welds when R = -1 (equal tension and
compression) the fatigue strength of BISPLATE 80 is reduced by more than half its
base material value (fig 6.9) and to substantially the same values of AS3678-Grade 250.
This indicates that there is very little advantage in using high strength steels under such
loading condition. On the other hand, for conditions where R is positive, i.e. high static
loads with a superimposed pulsating load, there is a distinct advantage in the use of high
strength steels.

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WHERE CAN HIGH STRENGTH STEELS BE USED TO ADVANTAGE?

There are a number of key areas in which high strength steels can be used to advantage,
in structures subjected to fatigue loading, as follows:

PARENT PLATE MATERIAL UNAFFECTED BY WELD

Welding can influence the fatigue behaviour of steels due to:

(a) the existence of geometrical stress concentrations in the vicinity of welds due
to weld deposit profiles.
(b) The presence of welding deposits such as porosity, lack of fusion, slag
inclusions, etc, which facilitate the initiation of fatigue cracks, and
(c) The generation of residual stresses in the welded component.

Obviously, in structures in which welds are absent are absent or where welds can be
suitably located in areas of low stress, high strength steels can be used to advantage (as
fatigue strength is higher than for plain carbon steels).

HIGH STRESS LEVELS

In many structures, the load consists of a high static load with a superimposed smaller
fatigue load. In this instance, it is relatively easy to exceed the permissible static stress or
the yield of plain carbon steels.

As we have seen previously, we can permit the same stress range at high stress levels as
at low low stress levels. In these cases, R is in the range R = 0 to R = +1.

LOW LOAD CYCLE NUMBERS

The region for the permissible stress range is limited by the S-N curve and by the yield
stress (or permissible static stress) of the steel.

In other words, high strength steels are advantageous when the number of load cycles is
less than 105, there is a full load spectrum (constant amplitude) and R = 0.

SUITABLE LOAD SPECTRA

In many situations, there are multiple fatigue loading conditions (different amplitudes)
and hence it is incorrect to design with constant amplitude data if the load is of variable
amplitude.

WHEN IT IS POSSIBLE AND DESIRABLE TO INCREASE THE FATIGUE STRENGTH OF THE WELDS.

There are a number of techniques available to improve the fatigue strength of welded
joints, including: redesign of the joint itself, removal of butt weld reinforcement,
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reduction of the stress concentrating effects by grinding or TIG dressing the toes of fillet
welds, and reduction of the residual stress pattern around welds by thermal stress
relieving treatments or shot peening.

With each of these techniques, substantial improvement in the fatigue strength of the as-
welded joint is possible, although the resultant fatigue strength will always be less than
that of the parent plate material.

References/further reading
Fatigue of Welded Structures, T.R. Gurney, Cambridge University Press UK 1979
Australian Standard AS1554 Part 5- 1989. SAA Structural steel welding code welding of steel
structures subject to high levels of fatigue loading.
American Institute of Steel Construction, Specification for the design, fabrication and erection of
structural steel for buildings, 1978.

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PERFORMANCE AT ELEVATED TEMPERATURE

BISPLATE processed grades perform favorably against other types of structural steels
at elevated temperature. This can be seen below in Table 1, where the performance of
BISPLATE 80 is superior when compared with other well-known structural grades at
an elevated temperature of 600C.

GRADE 0.2% Proof Stress @ 600C


BISPLATE 80 300 MPa
AS3678-250 127 MPa
AS3678-350 140 MPa

Table 1: 0.2% Proof Stress at elevated temperature of 600C.

However, the use of BISPLATE at elevated temperatures should be approached with


caution. Prolonged exposure to excessive heat will lead to loss of mechanical properties
including strength and hardness. This is primarily due to a microstructural change of the
plate due to over-tempering.

Any proposal for the use of BISPLATE at temperatures above 150C should be referred
to the manufacturer. The following graphs show the results of high temperature tests
performed on BISPLATE 80 and BISPLATE 400. Please note that these graphs
depict instantaneous tensile measurements only and are not indictative of results when
BISPLATE is exposed to excessive heat for a prolonged period of time.

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BISPLATE 80 (12mm)
900
800
700
Stress (MPa)

600
500
400
300
200
100
0
0 100 200 300 400 500 600
Temperature (deg.C)
0.2% Proof Stress Tensile Strength

BISPLATE 400 (12mm)


1600
1400
1200
Stress (MPa)

1000
800
600
400
200
0
0 100 200 300 400 500 600
Temperature (deg.C)
0.2% Proof Stress Tensile Strength

The results of this project indicate the Bisalloy processed grades perform comparably
or favourably with other types of structural steel in terms of the temperature at which the
strength of the material is half that of its room temperature strength. This temperature was
identified as being between 500C and 600C for processed grades. This temperature for
greenfeed grades was seen to be beyond 600C. There was no significant difference in
0.2% Proof Stress at 600C between the processed and greenfeed samples, all values
being in the vicinity of 300MPa. This compares with 127MPa and 140MPa for AS3678-
250 grade and AS3678-350 grade respectively at 600C The results confirm the
suitability of Bisalloy products for use in structural and elevated temperature
applications.

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Table 1. Results summary for all samples

Sample number/grade. Temp. (deg. C) Reduction in area 0.2%P.S. (MPa) U.T.S. (MPa) Elongation (%) Yield/tensile
PX441/ BIS53, 20mm 20 45% 504 706 16% 0.71
200 64% 475 637 15% 0.75
300 58% 530 697 5% 0.76
400 71% 486 650 19% 0.75
500 83% 434 520 23% 0.83
600 89% 327 393 19% 0.83
PX461/ BIS52, 12mm 20 62% 496 659 20% 0.75%
100 67% 483 620 16% 0.78%
200 57% 476 618 16% 0.77%
300 58% 679 705 21% 0.96%
400 85% 515 596 25% 0.86%
500 79% 401 481 20% 0.83%
600 90% 297 349 22% 0.85%
71815/ BIS400, 12mm 20 56% 971 1338 4% 0.73
100 44% 976 1318 9% 0.74
200 48% 1017 1374 4% 0.74
300 70% 922 1234 12% 0.75
400 84% 789 962 4% 0.82
500 82% 580 679 15% 0.85
600 89% 297 431 20% 0.69
71831/ BIS400, 20mm 20 52% 1020 1416 11% 0.72
100 5% 1024 1328 10% 0.77
200 42% 989 1462 11% 0.68
300 68% 955 1340 14% 0.71
400 77% 757 986 14% 0.77
500 79% 582 674 14% 0.86
600 91% 293 438 26% 0.67
RF464A1, BIS1, 100mm 20 65% 560 752 17% 0.74
100 71% 572 663 16% 0.86
200 62% 561 709 12% 0.79
300 64% 550 737 15% 0.75
400 71% 501 717 16% 0.70
500 79% 464 593 16% 0.78
600 87% 336 421 7% 0.80
77873, BIS80, 100mm 20 72% 713 773 16% 0.92
100 70% 638 704 15% 0.91
200 70% 527 617 16% 0.85
300 68% 512 673 7% 0.76
400 78% 490 559 19% 0.82
500 86% 460 522 17% 0.88
600 84% 327 407 17% 0.80
71974/BIS80, 12mm 20 815 862 13% 0.95
100 62% 795 843 13% 0.94
200 61% 759 829 11% 0.91
300 55% 720 837 11% 0.86
400 80% 664 748 17% 0.89
500 79% 538 600 15% 0.90
600 90% 272 382 28% 0.71
72005/BIS80, 20mm 20 63% 816 876 17% 0.93
100 58% 800 859 13% 0.93
200 58% 746 833 11% 0.90
300 61% 741 846 15% 0.88
400 75% 635 736 15% 0.86
500 82% 553 633 15% 0.87
600 91% 290 413 24% 0.70

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GALVANISING

BISPLATE structural grades can be readily galvanised. BISPLATE wear grades are
not suitable for galvanising.

BISPLATE achieves sound and continuous galvanised coatings because they contain
0.20% Silicon, which is an optimal level for galvanising.

Galvanising does not affect the mechanical properties of BISPLATE structural grades.
However, there are some precautions & recommendations that should be taken into
account when galvanising BISPLATE.

DO NOT ACID DESCALE to prepare the surface. Acid descaling can lead to
hydrogen being absorbed into the steel, increasing the likelihood of hydrogen
embrittlement.

To prepare the surface it is recommended to use grit/shot blasting. This


method not only ensures there is no hydrogen contamination it assists the
galvanizing process by increasing the surface reactiveness to molten zinc.

Care should be taken when galvanizing BISPLATE structures that contain


severe internal stresses, such as those caused by large weldments, as liquid metal
embrittlement may occur. In these cases, it may be appropriate to prototype test or
attain the use of painted or sprayed coatings in place of galvanizing.

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