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~~~~SCHEMEIo;OF TESTING AND INSPECTION "

FOR CERTIFICATION OF.. ~ I!o ...

~ SI"EELS FOR HAIlDEN?ING~ANDTEMP&RINGACCORDING TO ~S :551I-1993

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1. e;,Uiboratory- A "'lab6ratory sl'rall E be ~aintai'1~d whichshall be sui~ta~biyequipped and staffed, where the tests~sha~ll becarr i ed out in", accordance wi.th the methods given i n ~the '"spec i f i cat i on. " '"

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1.1, A11 the tes"ti n~ apparatus.shall be per i od i c~l lyand records of sueh~er~ks sha11 .be maihta i ned~ ~ ~

checked

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2. Test Records - A11 records of~tests and anal ys iskept in suitable forms approved by the Bureau.

shall s be

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NOTE: The existing forms etc., as being maintaqped by themanufacturers may.be rexain~d. These forms, however,sha11 ~contai n "a11 the i nformat ion requ i red foroperating this Scheme o~Testing~and Inspection.

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2.1 'Copies of any~records,;

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3.2 MARKING -All bars of 50 mm diameter orcross-section and above shall be st~mpedor suitablyone end with the following:

equivalentmarked at

a) Nameor trade-mark of the manufacturer, andb) The cast number or any other identification mark by whichthe steel can be traced to the cast and heat-treatment batchfrom which it was made.

3.2.1 Bars below 50mmdia. or of equivalent cross sectionalarea shall be tied in suitable bundles which will carry metaltags. The metal tag attached to each bundle shall be markedasgiven in 3.2 above.

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3.2.2 The bars, billets, etc., shall be suitably colour codedat the ends to mark the grade of the material. The colour schemefollowed can be in- ~ccordance with 15:2049-1978 or as perpurchaser's requirement.

4. METHOD OF MANUFACTURE

4.1 Unless otherwise agreed to in the order, the processesused in making the steel and product 'are left to thediscretion of the manufacturer, but the steel shall be fullykilled. When so desired, the purchaser shall be informed of thesteel making process.However, for continuously cast steels andfor steels in specially treated condition, like elctro fluxrefined, vacuumdegassed, secondary refined, etc, the steelmaking process should be agreed to at the time of enquiry andorder. .

4.1.1 For continuously cast bar/billets, a minimumreductionratio of 6:1 between the cast product and the final product isrecommended. However, other reduction ratios may be mutually

. agreed upon between the manufacturer and the purchaser at thetime of enquiry and order.4.1.2 The steels maybe madeby agreementwith the additionof micro alloying elements like Titanium, Niobium, Vanadium,Boron, etc, either individually or in combination.

5. Levels of Control - Inspection and testing at variouslevels of control (Table 1) shall 'be carried out on allQuantities of ste~l intended to be covered under BISCertification Marks Scheme and appropriate records maintainedin accordance with para 2 above.All the croduction which conformsto th~ Indian Standard and covered by this licence shall bemarked with BI5 Certification Mark.

5.1 On the basis of tests and inspection results, decisionregarding conformity or otherwise of lots of steels forhardening' and tempering to the requirements of thespecification shall be taken as indicated below: Vr,..

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5.1.1 CHEMICAL COMPOSITION- The ladle analysis of steelshall be as given in Table 2 of the specification.The checkanalysis shall be Qarried out at the rate of one sample for eachcast on the finished product.The permissible variation in case ofsuch check analysis from the limits specified in Table 2 shall beas given in Toable 3 of the specification.

5.1.2 FREEDOMFROMDEFECTS - The material shall be ~ree fromsuch internal and surface defects which may impair the end use.Sufficient reduction &' discard shall be made from each ingot toensure freedom from pipe, harmful segregation & other'defects.

5.1.3 HEAT TR4EATMENTworking and heat treatmentsmachinability, shearability,guidance only.

Recommended temperature for hotaimed at controlling the hardness,etc, are given in Table 4 for

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5.1.4 HARDNESS- One sample product shall be taken from eachannaled batch, subject to the minimumof at least one samplefrom each cast for the determination of hardness. The hardnessfor products delivered in the as rolled, annealed or improvedmachinability condition when determined in accordance withIS:1500-1983 shall be as given in Table 6 of the specification.

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5.1.5 MECHANICAL PROPERTIES - If required, the mechanicalproperties of the reference test bars after hardening andtempering in accordance with Table 6 shall conform to therequiremants given in Table 5 of the specification. Theproperties given in Table 5 are applicable to test pieces takenon rounds in the direction of rolling fibre, the axis of whichcorresponds to Fig. 1 of the specification. For rectangularsections the ranges for equivalent sections shall be as given inFig. 2 of the specification.

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5.1.5.1 Methods for determining the mechanical propertiesspecified in Table 5 of the specification shall be in accordancewith 18:1598-1977 and IS:1608-1972.

5.1.6 GRAIN SIZE - Unless otherwise agreed, the steel whentested in accordance with IS 4748:1988 shall show grain size inthe range of 5' to. 8 for inherently fine grained steel.Steel with

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grain size outside th..e range of 5 to 8 (for microalloyedsteel)may however, be supplied with mutual agreement.

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5.1.7 CLEANLINESS OF THE STEEL - Inclusion rating of thesteel shall be determined in accordance with 18 4163:1982.Theinclusion rating for th~ specimen shall not exceed the limitsspecified in clause 11.1 of the specification.

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5.1.7.1 When required and ordered, cleanliness of the steel canalso be assessed by step down test, blue f~acture test andmagnetic particle test methodsas per IS 10138 (part 1 to 3) oragre~d to at the time of enquiry and order.

5.1.8 .HARDENABILITY- For steels ordered on the basisof end quenchedhardenability, the requirements shall be asgiven in Table 7 of the specifcationor as mutually agreed tobetween the purchaser and the manufacturer. The methodof testlng hardenability of steels shall be in accordancewith IS:3848-1981.

5.1.9 DIMENSIONALTOLERANCES- The dimensional tolerances forhot rolled steel products shall be in accordance withIS:3739-1987.Any additional stipulation on dimensions may bemutually agreed at the time of enquiry and order, if the forgingprocess or product' "so ca 11s for. . For' forged bars,billets,blooms etc,' the tolerances shall be in accordance withIS:3469 (Part 1 to 3)-1974.Tolerance on straightness shall be asgiven in clause 13.3 of the specification unless otherwise agreedto between the purchaser and the manufacturer.

5.2 RETESTS

5.2.1 Retest for Product Analysis - If the results of theproduct analysis do nqt meet the composition requirements givenin Tables 2 and 3 of the specification, unless otherwiseagreed to between the purchaser and the manufacturer, two newsamples shall be taken on different pieces from the samecast. Should the two analysis satisfy the requirements, the lotrepresented shall be accepted. Should either of the tests fail,the material shall be taken as not complying with this standard.

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5.2.2 Retest for Hardness Test in the Normalized orAnnealed Condition - If the samples selected under 14.2fails to meet the requirements under 8 of the specification twofurther samples shall be selected from the same heat-treatmentbatch. The consignment shall be considered to conform to therequirements if both the additional tests are satisfactory.Should either of the samples fail, the manufacturer have th@.right, if ~heso desjres, to re-heat-treat the product in anysuitable manner befor~ two fresh samples are taken for testing.Should the two tests satisfy the requirements of this standardthe lot represented shall be accepted. Should either of thesamples fails, the material shall be taken as not complying withthis standard.

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5.3.3 Retest for MechanicalTests on Test pieces - If thesample selected under 14.3 fails to meet the requirementsunder 9 of the specification two further samples shall beselected from the samesize grouping for making fresh test barsand tested. The consignment shall be considered to conformto the requirements if both the additional tests aresatisfactory. Should either of the samples fail, themanufacturer have the right, if he so desires, to re-heat-treatthe product in any suitable mannerbefore two fresh samples aretaken for testing. Should the two tests satisfy the'requirements of this standard the lot represented shall beaccepted. Should either of the samples fails, the material shallbe taken as not complying with this standard.6. Additional Tests - If agreed to betweenthe purchaser andthe manurfacturer at the time of enquiry and order, any or acombination of the following tests may be carried out to"',ensure that the steels meet the purchaser's requirements:

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a) Macro-etch test in accordance with IS 11371 : 1985,I!

b) Ultrasonic test in accordance with IS 3664 : 1981," '

c) Hardenability test in accordance with IS 3848 : 1981 andvalues as per Table 7 of IS 5517 : 1993,

d) Blank hardening test for core strength guaranteerecommendations of Table 5 of IS 5517 : 1993,

as per

e) Cleanliness test as per IS,10138 (Part 1 to 3),i,"

f) Microstructure for machinability, including bending, and

g) Hot upset for forgibility.

The acceptance level for each or any of these tests shall bemutually agreed to at the time of enquiry and order.

7. SUPPLY OF MATERIAL - Steel covered by this standard shall beordered rand delivered in anyone of the basis given in Table 1 ofthe specification.

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8. REJECTION - Recdrds shall be maintained for a reasonabletime from which information relating to the rejection ofmaterial on the basis of test, which do not conform toIS:5517-1993 shall be available. Such rejected material shallnot be mixed up with that which conforms to the specification.

9. Samples-Thesamples requiredBureau of Indianshall pay for the

licensee shall supply, free of charge, thein accordance with Regulations of the

Standards from hls factory or godown. BISsamples taken by it from the open market.

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10. Replacement - Whenever a complaint is received soon afterthe goods with Certification Mark have been purchased and used,and if there is adequate evidence that the goods have notbeen misused, defective goods shall be replaced free of cost bythe licensee in case the complaint is proved to be genuine andthe warranty period (where applicable) has not expired. Thefinal auth~rity to judge conformity of the product to theStandard shall be with BIS.

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11. STOPMARKING- The marking of the product shall besuspended under intimation to BIS, if, at any time, there issome difficulty in maintaining the conformity of theproduct to the specification, or the testing equipment goesout of order, or if directed to do so by BIS for ~ny reason.The marking may be resumed as soon as the defects are removed orwhen BIS gives the permission to do so. The information regardingresumption of marking 'sha) 1 also be sent to BIS.

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12. PRODUCTIONDATA - The licensee shall sendto BIS as perthe enclosed proforma, a statement of the quantity produced,marked and exported by him and the trade value the~eofduring the half-year ending 30 June and 31 December. ThisStatement is required to be forwarded to BIS on or before the31st day of July and January for the preceding half-year.

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~ . . j .IS:5517-1993

SPECIFICATION FOR STEELS FOR HARDENINGAND TEMPERING

TABLE 1 LEVELS OF CONTROL

(Para5 of theSchemeof TestingandInspection)

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TestDetai1s : Levelsof Control :I I

~ I ,REMARKS

TestMethod: No.of : LotSize: Frequency:: :Samp1es: : ::C1a~se:Reference: :

1 1 1 1 1 11 1 1 ' 1 1 1_____------------------------

Clause:Requirement

8 15:1500-1983OneHardness

9. Mechanicalpropertiesinhardened& temperedcondition

11:1598-1977OneIS:1608-1972

10. Grainsize IS:4748-1988One

12. Hardenabi1ity IS:3848-1981:

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ANNEXUREI

(Para3.1of theSchemeof TestingandInspection)XYZ IRON AND STEEL COMPANY STANDARD

MARK

(RegisteredOffice Addressandworksaddress)

TEST CERTIFICATE FOR STEELS FOR HARDFNING&TEMPERING

TEST CERTIFICATE No. DATE -------------

TO M!s --------------------------------

It is certifiedthatthematerialdescribedbelowfully conformsto IS: 5517-1993.

ChemicalcompositionandMechanicalpropertiesof theProduct,astestedin AccordancewiththeSchemeof TestingandInspectioncontainedin theBISCertificationMarksLicenceNo.CM/L areas indicatedbelowagainsteachorderNo.etc.

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(P~EASE REFER TO IS:5517-1993FOR DETAILS OF SPECIFICATION REQUIREMENTS)

TEST RESULTS

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Order:Steel: Cast: : LADLE ANALYSIS : MECHANICALPROPERTIES :RNo. & : designa-:No.: Size: : : EDate:tion&: : 111m:C: Mn:Si:Ni:Cr:Mo:V:Al: S: P : Hard-:Tens-:.2S :Elon-:Izod:Harde-:Other:M

: Delivery: : ::::::::::: Ness:ile :proof:gati-:impact:nabi-:Test:A:condition: : ::::::::::: :St. :Stress:on:Joules:lity: : RI I I I.. I .. 1 .. I .. 1 .. I .. 1 .. I .. 1 .. 1 .. I

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M Pa I.. 1 I I I KI lit" I " 1 " I " I " 1 " 1 " I " 1 " I " 1 I 1 I" 1 I. I 11 1 1 1 I I 1 1 I 1 1 1 1 1 1 I 1 lit 1 S1 1__1 ~-- 1__1---1_- 1__1---1__- 1__1__1---1---1__1 1__1 1 1 1 1- -

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Note: Thematerialsuppliedconformstothespecifieddimensionaltolerances

REMARKS

SHIPPINGADVICE NO.

WAGONNOS. ,S SIGNATURE;

DESIGNATION:

FOR XYZ IRON AND STEEL COMPANY

(It is suggestedthatsize A-4paper(210x 297111m)beusedforthisTestCertificate)

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