Title of Invention	A PROCESS OF MANUFACTURING A METAL BAR
Abstract	The invention relates to a process of manufacturing a metal bar having cross ribs on both the surfaces of the bar front and back intersected by straight ribs passing through the appex of the individual cross on both of its surface front and back comprising charging suitable metal composition in a furnace to produce an ingots; treating the ingots in a rolling mill to give a specific configuration suitable for civil construction providing a surface treatment of Ethylene oxide. So as to obtained corrosion resistant with high stencil straight metal bar suitable for civil construction.

Title of Invention

A PROCESS OF MANUFACTURING A METAL BAR

Abstract

The invention relates to a process of manufacturing a metal bar having cross ribs on both the surfaces of the bar front and back intersected by straight ribs passing through the appex of the individual cross on both of its surface front and back comprising charging suitable metal composition in a furnace to produce an ingots; treating the ingots in a rolling mill to give a specific configuration suitable for civil construction providing a surface treatment of Ethylene oxide. So as to obtained corrosion resistant with high stencil straight metal bar suitable for civil construction.

Full Text	FORM 2 THE PATENT ACT 1970 (39 of 1970) & The Patents Rules, 2003 COMPLETE SPECIFICATION See Section 10, and rule 13) 1. TITLE OF INVENTION AN IMPROVED METAL BARS WITH SURFACE TREATMENT 2. APPLICANT(S) a) Name : ALLIED FERROMELT PVT. LTD. b) Nationality : INDIAN Company c) Address : PLOT NO 376, 381-385 VILLAGE SANGHVI, TALUKA KHANDALA, DIST. SATARA, MAHARASHTRA 3. PREAMBLE TO THE DESCRIPTION The following specification particularly describes the invention and the manner in which it is to be performed :- AN IMPROVED THERMOMECHANICALLY TREATED METAL BARS WITH SURFACE TRETEMENT The invention relate to a metal composition for high corrosion resistance, tensile strength better elongation and better pull out properties The existing procedure of twisting reinforcement concrete steel bars after rolling, have less tensile strength. 0.2% proof stress and elongation as well as less corrosion property because of lack in specific treatment provided on the surface of the bars. The newly composed metal composition having ingredients with percentage ranges are as under Carbon 0.25% max Sulphur 0.045% max Phosphorous 0.045% max S&P 0.090% max Mn 0.55% min These percentage give us following mechanical properties GRADE YIELD ULTIMATE TENSILE %Age STRENGTH STRENGTH Elongation In N / MM2 InN/MM2 Min Fe415 460 520 18% Fe 500 540 585 16% Fe550 580 620 14% The prior art composition differ very much from the invention claimed therefore, use of the specific use of this bars in the civil construction not only economical but also 2 substantive advantage on the technical properties such as yield stress, ultimate tensile strength, elongation, and pullout strength. Main factors is T M T process, which involves temperature at entry of T M T tube, temperature at the exit of T M T tube and water pressure at T M T tube which also play an important role in having specific grade as per IS 1786-1985. The object of this invention is therefore, to provide a metal composition suitable for making iron bars with surface treatment so as to achieve above said properties for civil constructions. It is interesting to note that replacement of conventional C T D Bars by T M T Bars and further to change design to transverse rib of T M T bars to Cross Rib Bars design transverse rib bars. The percentage saving will depend upon the type of structural member and grade of steel. The types convolutions provided on the surface which very vary much with each other depending on the end use of rods for the construction purpose. Different diameter of rods is required for different element of construction but the composition of melt and process of manufacturing composition and the article manufacture by the process is of prime importance. Iron & Steel Scrap and Sponge Iron use to manufacture ingots / billets is also play an important role to have better quality of T M T Bars with the local scrap one has to mix iron ore in the form of D R I & H B I and the ratio with which to mix secondly. Alloys addition is more important and the time when to add alloy so that they should not evaporate as a gasses but should mix homogeneously with liquid metal All these play to have good quality of ingots / billets which is also very important to good quality of T M T Bars. 3 Cross rib Bars which gives more surface rib area that adds to bond strength as shown in fig.no.1 Cross rib ALLIED T M T steel bar is a new generation high strength thermo-Mechanically Treated REINFORCEMENT STEEL BARS WHICH gives better mechanical properties as compare ordinary reinforcement steel bars Allied Cross rib steel gives the unique combination of properties possessed by T M T Bars. It gives better ULTIMATE TENSILE STRENGTH It gives 0.2% PROOF STRESS It gives better ELOGATION, which is very good sismic zone area. It gives better BOND strength due to more rib area. By putting alloys it gives resistance to CORROSION These are the main beneficial property of CROSS RIB ALLIED T M T BARS Armed with these outstanding features Allied T M T gives greater advantage over conventional reinforcement steel bars. Allied Ferromelt names which give symbolized quality under took a major commissioning of T M T process to meet stringent global quality requirement for 21st century product is subjected to quality checks in the quality control laboratory, chemically and physically to ensure the best product of the day. An improved metal bar with cross ribs which is useful for civil construction has been found encouraging due to its strength as well as resistant to corrosion. The prior art bars having convolution on its surface which has uni directional therefore whenever 4 there is a load in the same direction there is a possibility of giving up of the metal bars from the mortar and therefore it was felt necessary to overcome this problem by providing both ways convolutions clockwise and anticlockwise on the surface of the metal bars so as to take care the load from any direction the said metal rods are again provided with surface treatment or a coating subsequent to the metal quenching process. So as to have a metal rod with cross ribs on both the surface of the rod intersected by straight ribs passing through the apex of the individual cross on both of its surfaces front and back. Manufacturing process of ALLIED T M T CROSS RIB BARs as follows Re-heating of Ingots : The Ingots are heated to 1200 °C in the pusher type suspended roof (German design), double raw re-heating furnace. The re-heating Furnace is equipped with low air pressure SCHIELDROP burners, Air blower, recuperator, Chimney, Oil preheating and pumping units etc. Pt-PtRh thermocouple and Electronic Digital temperature indicator indicate the furnace temperature. The ingots are discharged from the furnace with the help of mechanical ejector. The ingot carried by a Roller Conveyor (RC) to the main Roller Table (RT) and then automatically fed into the first pass of Roughing Mill Stand. Roughing or Cogging in Roughing Mill : 410 mm (16") Roughing Mill, having four stands, driven with the help of 800 HP Electric Motor, Flywheel and Gear Boxes. Several passes are cut into the Rolls to reduce the material in different size and shapes, and to achieve intermediate size for finishing in the intermediate and finishing mill. The cutting of passes in the rolls is very important, cutting of passes varies with size, shape and quality of the material to be rolled. Pass design in a Rolling Mill is very important aspect for which experienced foreman or engineers are appointed. 5 The material (ingot) is fed into the bottom passes with help of Main Roller Table (RT) and Turning Walls and in the top passes are fed with the help of Free Roll. The material after leaving the first stand travels via repeater to the IIND stand and then via repeater to IIIrd stand and again via same repeater back to II nd stand. Again via repeater from III rd stand to IVth stand. After that it travels through channel with the help of Pinch Roll (PR1) and (PR2) to the first stand of Intermediate Mill. While travelling from Roughing Mill to Finishing Mill, the front and back end (split end) is cut with the help of fix type Rotary Shears (RSI) and (RS2) Finishing in Intermediate and Finishing Mill : When the material reaches the intermediate Mill the cross section is reduced and the length is increased. The intermediate Mill is equipped with 258 mm (10") four nos. stands driven by 500 HP electric Motor and Reduction cum Pinion Gear Box. The material is fed into the first stand automatically with the help of Repeater and it further travels via Repeater to 2nd 3rd and 4th stands to achieve the final shape and size of 12 mm. The material becomes quite lengthy and the it is fed into Finishing Mill via Repeaters. Finishing Mill comprises of 500 HP Drive motor, reduction-cum-pinion two stands of 258 mm (10") and Reduction-cum-pinion and gain two stands of 258 mm (10"). From intermediate Mill the material is fed into first stand of Finishing Mill and then via oval repeater it goes to second stand. Then via Square Repeater it comes to the third stand the then finished from the fourth stand. Then the same is conveyed through nozzles and pinch roll (PR3) to the specially designed water cooling tubes. The biggest advantage of automatic Mill is when the material reaches tube the temperature remains 800°C to 900°C. Since the temperature drop is only 300° C to 400° C, the thermomech treatment of the material is better in comparison with manual Mill. 6 Cooling in Cooling Bed : The material after passing through tube reaches 'W¢ channel of cooling bed & is shifted to cooling bed platform. The second stage of 'tempering' begins as the bar leaves the water cooling section. In this stage, the heat flows from the core to the surface layer, transforming it into a structure called 'Tempered 'Martensite': while the core continues to stay 'Austenite'. The third and final stage takes place on the cooling bed. Here the Austenitic core is transformed to a ductile 'Ferrite-Pearlite' core. The finished bar has a grain structure comprising a tough outer layer of 'Tempered Martensite' and a ductile core of 'Ferrite Pearlite' Coating and Surface Treatment Process: The coating composition may comprised from the following ingredients in percentage which are applied subsequent to quenching process. Recent years have seen a sharp rise in the keen interest amoung engineers and concrete specialist around India and worldwide regarding the long-term durability of concrete structure. Ways and means are constantly being sought to increase the durability and simultaneously also decrease the Iifecycle costs associated with the structure. Amougest the long-term measure, one of the methods for protection of concrete reinforcement bars against corrosion is epoxy coating on these bars by electrostatic spraying of fusion-bonded epoxy powder. Keeping in view the country's need for appropriate corrosion-resistant reinforcing bars of accepted quality, is this kind of an application by non-technical personnel feasible on remote sites ? Corrosion during metal manufacturing process is a phenomenon resulting out of primary corrosion is inevitable and is not always visible to the naked eye. Primary corrosion can be controlled / reduced / arrested at the time of manufacturing the metal 7 by coating process. This process reduces primary corrosion percentage substantially, and prevents its multiple, progressive growth. These treatment is a polymeric, non-ionic, water repellant, antistatic, high penetration ability and the materiel used for the same is Ethylene oxide, Fatty Acids, Fatty Alcohol's, Alkyl Phenols, etc. The process of making metal bars with surface treatment having cross ribs on both the surface of the rod intersected by straight ribs passing through the apex of the individual cross on both of its surfaces front and back comprising the following steps. Accordingly there is provided a process that metal bar with having cross ribs on both the surfaces of the bar front and back intersected by straight ribs passing through the appex of the individual cross on both of its surface front and back comprising charging suitable metal composition in a furnace to produce an ingots; treating the ingots in a rolling mill to give a specific configuration suitable for civil construction providing a surface treatment of Ethylene oxide. So as to obtained corrosion resistant with high stencil straight metal bar suitable for civil construction. This is an embodiment of the invention several modification are possible which may be considered within the ambit and spirit of this invention. WE CLAIM: 1. A process of manufacturing a metal bar having cross ribs on both the surfaces of the bar front and back intersected by straight ribs passing through the appex of the individual cross on both of its surface front and back comprising charging metal composition as herein described charged in a furnace to produce an ingots; treating the ingots in a rolling mill to give a specific configuration for civil construction providing a surface treatment of Ethylene oxide, so as to obtained corrosion resistant with high tensile strength metal bar suitable for civil construction. 2. A process of manufacturing a metal bars with surface treatment as claimed in claim 1, wherein the ingots are heated at a temperature ranging 800-1000°C and passed through the rolling mill whereby the ribs are formed having cross ribs on both surfaces front and back intersected by straight ribs. 3. A process of manufacturing a metal bars with surface treatment as claimed in claim 1, wherein the surface coating composition applied after quenching stage with forced water jet applied from opposite direction. 4. A process of manufacturing a metal bars with surface treatment as claimed in claim 1, wherein the quenching is performed by the first stage of quenching begins as the hot rolled ribbed bar emerges from the finishing stand of the Bar Mill, it is rapidly cooled; said quenching process carried out by water spraying to obtain hardened structure called "Martensite" on the surface and core remains "Austenite".

Full Text

FORM 2
THE PATENT ACT 1970 (39 of 1970)
&
The Patents Rules, 2003 COMPLETE SPECIFICATION See Section 10, and rule 13)
1. TITLE OF INVENTION
AN IMPROVED METAL BARS WITH SURFACE TREATMENT
2. APPLICANT(S)
a) Name : ALLIED FERROMELT PVT. LTD.
b) Nationality : INDIAN Company
c) Address : PLOT NO 376, 381-385
VILLAGE SANGHVI, TALUKA KHANDALA, DIST. SATARA, MAHARASHTRA
3. PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed :-

AN IMPROVED THERMOMECHANICALLY TREATED METAL BARS WITH
SURFACE TRETEMENT
The invention relate to a metal composition for high corrosion resistance, tensile strength better elongation and better pull out properties
The existing procedure of twisting reinforcement concrete steel bars after rolling, have less tensile strength. 0.2% proof stress and elongation as well as less corrosion property because of lack in specific treatment provided on the surface of the bars.
The newly composed metal composition having ingredients with percentage ranges are as under

Carbon 0.25% max
Sulphur 0.045% max
Phosphorous 0.045% max
S&P 0.090% max
Mn 0.55% min
These percentage give us following mechanical properties

GRADE YIELD ULTIMATE TENSILE %Age
STRENGTH STRENGTH Elongation
In N / MM2 InN/MM2 Min
Fe415 460 520 18%
Fe 500 540 585 16%
Fe550 580 620 14%
The prior art composition differ very much from the invention claimed therefore, use of the specific use of this bars in the civil construction not only economical but also
2

substantive advantage on the technical properties such as yield stress, ultimate tensile strength, elongation, and pullout strength.
Main factors is T M T process, which involves temperature at entry of T M T tube, temperature at the exit of T M T tube and water pressure at T M T tube which also play an important role in having specific grade as per IS 1786-1985.
The object of this invention is therefore, to provide a metal composition suitable for making iron bars with surface treatment so as to achieve above said properties for civil constructions.
It is interesting to note that replacement of conventional C T D Bars by T M T Bars and further to change design to transverse rib of T M T bars to Cross Rib Bars design transverse rib bars. The percentage saving will depend upon the type of structural member and grade of steel.
The types convolutions provided on the surface which very vary much with each other depending on the end use of rods for the construction purpose.
Different diameter of rods is required for different element of construction but the composition of melt and process of manufacturing composition and the article manufacture by the process is of prime importance.
Iron & Steel Scrap and Sponge Iron use to manufacture ingots / billets is also play an important role to have better quality of T M T Bars with the local scrap one has to mix iron ore in the form of D R I & H B I and the ratio with which to mix secondly. Alloys addition is more important and the time when to add alloy so that they should not evaporate as a gasses but should mix homogeneously with liquid metal All these play to have good quality of ingots / billets which is also very important to good quality of T M T Bars.
3

Cross rib Bars which gives more surface rib area that adds to bond strength as shown in fig.no.1
Cross rib ALLIED T M T steel bar is a new generation high strength thermo-Mechanically Treated REINFORCEMENT STEEL BARS WHICH gives better mechanical properties as compare ordinary reinforcement steel bars Allied Cross rib steel gives the unique combination of properties possessed by T M T Bars.
It gives better ULTIMATE TENSILE STRENGTH
It gives 0.2% PROOF STRESS
It gives better ELOGATION, which is very good sismic zone area.
It gives better BOND strength due to more rib area.
By putting alloys it gives resistance to CORROSION
These are the main beneficial property of CROSS RIB ALLIED T M T BARS
Armed with these outstanding features Allied T M T gives greater advantage over conventional reinforcement steel bars.
Allied Ferromelt names which give symbolized quality under took a major commissioning of T M T process to meet stringent global quality requirement for 21st century product is subjected to quality checks in the quality control laboratory, chemically and physically to ensure the best product of the day.
An improved metal bar with cross ribs which is useful for civil construction has been found encouraging due to its strength as well as resistant to corrosion. The prior art bars having convolution on its surface which has uni directional therefore whenever
4

there is a load in the same direction there is a possibility of giving up of the metal bars from the mortar and therefore it was felt necessary to overcome this problem by providing both ways convolutions clockwise and anticlockwise on the surface of the metal bars so as to take care the load from any direction the said metal rods are again provided with surface treatment or a coating subsequent to the metal quenching process. So as to have a metal rod with cross ribs on both the surface of the rod intersected by straight ribs passing through the apex of the individual cross on both of its surfaces front and back. Manufacturing process of ALLIED T M T CROSS RIB BARs as follows
Re-heating of Ingots :
The Ingots are heated to 1200 °C in the pusher type suspended roof (German design), double raw re-heating furnace. The re-heating Furnace is equipped with low air pressure SCHIELDROP burners, Air blower, recuperator, Chimney, Oil preheating and pumping units etc.
Pt-PtRh thermocouple and Electronic Digital temperature indicator indicate the furnace temperature. The ingots are discharged from the furnace with the help of mechanical ejector. The ingot carried by a Roller Conveyor (RC) to the main Roller Table (RT) and then automatically fed into the first pass of Roughing Mill Stand.
Roughing or Cogging in Roughing Mill :
410 mm (16") Roughing Mill, having four stands, driven with the help of 800 HP Electric Motor, Flywheel and Gear Boxes. Several passes are cut into the Rolls to reduce the material in different size and shapes, and to achieve intermediate size for finishing in the intermediate and finishing mill. The cutting of passes in the rolls is very important, cutting of passes varies with size, shape and quality of the material to be rolled. Pass design in a Rolling Mill is very important aspect for which experienced foreman or engineers are appointed.
5

The material (ingot) is fed into the bottom passes with help of Main Roller Table (RT) and Turning Walls and in the top passes are fed with the help of Free Roll. The material after leaving the first stand travels via repeater to the IIND stand and then via repeater to IIIrd stand and again via same repeater back to II nd stand. Again via repeater from III rd stand to IVth stand. After that it travels through channel with the help of Pinch Roll (PR1) and (PR2) to the first stand of Intermediate Mill. While travelling from Roughing Mill to Finishing Mill, the front and back end (split end) is cut with the help of fix type Rotary Shears (RSI) and (RS2)
Finishing in Intermediate and Finishing Mill :
When the material reaches the intermediate Mill the cross section is reduced and the length is increased. The intermediate Mill is equipped with 258 mm (10") four nos. stands driven by 500 HP electric Motor and Reduction cum Pinion Gear Box. The material is fed into the first stand automatically with the help of Repeater and it further travels via Repeater to 2nd 3rd and 4th stands to achieve the final shape and size of 12 mm. The material becomes quite lengthy and the it is fed into Finishing Mill via Repeaters. Finishing Mill comprises of 500 HP Drive motor, reduction-cum-pinion two stands of 258 mm (10") and Reduction-cum-pinion and gain two stands of 258 mm (10"). From intermediate Mill the material is fed into first stand of Finishing Mill and then via oval repeater it goes to second stand. Then via Square Repeater it comes to the third stand the then finished from the fourth stand.
Then the same is conveyed through nozzles and pinch roll (PR3) to the specially designed water cooling tubes. The biggest advantage of automatic Mill is when the material reaches tube the temperature remains 800°C to 900°C. Since the temperature drop is only 300° C to 400° C, the thermomech treatment of the material is better in comparison with manual Mill.
6

Cooling in Cooling Bed :
The material after passing through tube reaches 'W¢ channel of cooling bed & is shifted to cooling bed platform.
The second stage of 'tempering' begins as the bar leaves the water cooling section. In this stage, the heat flows from the core to the surface layer, transforming it into a structure called 'Tempered 'Martensite': while the core continues to stay 'Austenite'. The third and final stage takes place on the cooling bed. Here the Austenitic core is transformed to a ductile 'Ferrite-Pearlite' core. The finished bar has a grain structure comprising a tough outer layer of 'Tempered Martensite' and a ductile core of 'Ferrite Pearlite'
Coating and Surface Treatment Process:
The coating composition may comprised from the following ingredients in percentage which are applied subsequent to quenching process.
Recent years have seen a sharp rise in the keen interest amoung engineers and concrete specialist around India and worldwide regarding the long-term durability of concrete structure. Ways and means are constantly being sought to increase the durability and simultaneously also decrease the Iifecycle costs associated with the structure. Amougest the long-term measure, one of the methods for protection of concrete reinforcement bars against corrosion is epoxy coating on these bars by electrostatic spraying of fusion-bonded epoxy powder. Keeping in view the country's need for appropriate corrosion-resistant reinforcing bars of accepted quality, is this kind of an application by non-technical personnel feasible on remote sites ?
Corrosion during metal manufacturing process is a phenomenon resulting out of primary corrosion is inevitable and is not always visible to the naked eye. Primary corrosion can be controlled / reduced / arrested at the time of manufacturing the metal
7

by coating process. This process reduces primary corrosion percentage substantially, and prevents its multiple, progressive growth.
These treatment is a polymeric, non-ionic, water repellant, antistatic, high penetration ability and the materiel used for the same is Ethylene oxide, Fatty Acids, Fatty Alcohol's, Alkyl Phenols, etc.
The process of making metal bars with surface treatment having cross ribs on both the surface of the rod intersected by straight ribs passing through the apex of the individual cross on both of its surfaces front and back comprising the following steps.
Accordingly there is provided a process that metal bar with having cross ribs on both the surfaces of the bar front and back intersected by straight ribs passing through the appex of the individual cross on both of its surface front and back comprising charging suitable metal composition in a furnace to produce an ingots; treating the ingots in a rolling mill to give a specific configuration suitable for civil construction providing a surface treatment of Ethylene oxide. So as to obtained corrosion resistant with high stencil straight metal bar suitable for civil construction.
This is an embodiment of the invention several modification are possible which may be considered within the ambit and spirit of this invention.

WE CLAIM:
1. A process of manufacturing a metal bar having cross ribs on both the surfaces of the bar front and back intersected by straight ribs passing through the appex of the individual cross on both of its surface front and back comprising charging metal composition as herein described charged in a furnace to produce an ingots; treating the ingots in a rolling mill to give a specific configuration for civil construction providing a surface treatment of Ethylene oxide, so as to obtained corrosion resistant with high tensile strength metal bar suitable for civil construction.
2. A process of manufacturing a metal bars with surface treatment as claimed in claim 1, wherein the ingots are heated at a temperature ranging 800-1000°C and passed through the rolling mill whereby the ribs are formed having cross ribs on both surfaces front and back intersected by straight ribs.
3. A process of manufacturing a metal bars with surface treatment as claimed in claim 1, wherein the surface coating composition applied after quenching stage with forced water jet applied from opposite direction.
4. A process of manufacturing a metal bars with surface treatment as claimed in claim 1, wherein the quenching is performed by the first stage of quenching begins as the hot rolled ribbed bar emerges from the finishing stand of the Bar Mill, it is rapidly cooled; said quenching process carried out by water spraying to obtain hardened structure called "Martensite" on the surface and core remains "Austenite".

A PROCESS OF MANUFACTURING A METAL BAR

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