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Contents
Mobile: 07710 066804 BSSA Editorial contact: Laura Willcox 0114 267 1260 Annual Subscription 2009: Europe inc UK: 175.00 (230) Rest of World: 180.00 (240) Airmail: 20.00 (40) extra Copyright 2008 Modern Metals Publications Ltd
4 Alans AngleA look at Martensitics 7 Pharmaceutical Engineering demands the highest quality in stainless steel by Mark Lock, Midas Technology 9 Production of neutral micro pellets for the pharmaceutical industry by Centro Inox, Italy 10 Laser Tube Ireland providing strategic solutions to some of todays market problems 11 Putting stainless steel in the front line of the war against infection by Dave Crowley of Anopol Ltd 12 Electropolishing of stainless steel surfaces
by Herr Siegfried Piesslinger-Schweiger CEO Poligrat GmbH
Industry News:
17 Ticaret invests in new warehouse 17 North American Stainless starts annealing line 17 Sandvik cuts lag seamless surcharge time 17 AK cost cutting measures 17 Growth in third quarter output 18 Midas builds giant fingerprint 18 Electropolishing with a difference 18 Outokumpu cutbacks 19 Product and Services Guide
Front Cover: Courtesy of Anopol Ltd
Stainless Steel Industry is published six times a year by Modern Metals Publications Ltd, PO Box 1187, Gerrards Cross, SL9 7YP, UK; E-mail: [email protected]. Web site: www.stainless-steel-ind.com It is read by purchasing officers, design engineers, metallurgists, architects and other executives in a wide variety of companies in the stainless steel producing and consuming industries worldwide. It is the official magazine of the British Stainless Steel Association. PRINTED BY: GPEX LTD, TATLING END, GERRARDS CROSS, SL9 7BJ.
EN number
Generic Name
Cr
Mo
Ni
HT Condition
0.2% (MPa)
PS UTS (MPa)
El (%) Min
Impact (J)
EN 10088-3 Standard Martensitic Grades 1.4005 1.4006 416 410 0.06/0.15 12.0/14.0 0.08/0.15 11.5/13.5 160 160 +QT650 +QT650 450 450 650/ 850 15 25 25 20 15 12 12
1.4021
420
0.16/0.25 12.0/14.0
0.26/0.35 12.0/14.0 0.36/0.42 12.5/14.5 0.43/0.50 12.5/14.5 0.36/ 13.0/ 0.60/ 0.42 14.5 1.00 0.45/0.55 14.0/15.0 0.50/0.80 0.48/0.60 13.0/15.0 0.50/0.80
650/ 12 850 160 +QT700 500 700/ 13 850 160 +QT800 600 800/ 12 950 160 +QT850 650 850/ 10 1000 160 +QT800 650 800/ 10 1000 160 +QT800 650 850/ 10 1000 No properties defined in Quenched and Tempered condition 0.10/ 0.20 < 0.15 No properties defined in Quenched and Tempered condition No properties defined in Quenched and Tempered condition 60 12 +QT650 160 60 500 650/ 850 10
1.4104
1.4122
160 60 160
+QT750
550
20 12 14 14 25 20 20 15 70 50 70 50 50 40 90 70 80 60
+QT800
600
12 12
1.4057
431
0.12/0.22 15.0/17.0
1.50/ 2.50
60 160 160 250 160 +QT700 520 700/ 800 +QT900 700 900/ 1050
10 15 12 15
1.4313
F6NM
3.5/ 4.5
+QT780 +QT900
620 800
12 12 10 16
+QT760 +QT900
550 700
14 16 14
1.4418
0.06 max
160 250
EN 10088-3 Special Martensitic Grades 1.4029 1.4035 1.4109 1.4123 1.4125 1.4112 440C 440B 0.25/0.32 12.0/13.5 0.43/0.50 12.5/14.0 0.60/0.75 14.0/16.0 0.40/0.80 0.35/0.50 14.0/16.0 1.00/2.50 0.95/1.20 16.0/18.0 0.40/0.80 0.85/0.95 17.0/19.0 0.90/1.30 0.07/ 0.12 4.5/ 6.5 0.10/ 0.50 1.5 max 850/ 9 1000 No properties defined in Quenched and Tempered condition No properties defined in Quenched and Tempered condition No properties defined in Quenched and Tempered condition No properties defined in Quenched and Tempered condition No properties defined in Quenched and Tempered condition +QT750 1.4415 0.03 max 11.5/13.5 1.50/2.50 160 +QT850 650 750 750/ 900 850/ 18 15 100 80 160 +QT850 650
has to think of kitchen knives to realise that martensitic stainless steels are corrosion resistant in moderate conditions. The higher Cr grades such as 1.4057 (431), 1.4122 and 1.4418 offer corrosion resistance just below or comparable to that of 1.4301 (304) in many environments. No martensitic stainless steel can compare with 316 or higher grades for corrosion resistance. Applications of Martensitic Stainless Steels The combination of high strength, good toughness and moderate corrosion resistance allow martensitics to be used in a wide variety of applications including:
Courtesy of AZOM
We can now clearly see what sort of strength and hardness levels this material is capable of. 6.It is also true that standards tend to be conservative in the mechanical properties that can be achieved. Take for example, 431. The table below again from AZOM shows that much higher levels of strength can be obtained than would be implied by the EN standard alone. Of course, section size is important and these properties would only be achievable on small diameter bar.
Mechanical properties of Grade 431 Stainless Steels
Razor strip Blades and cutting tools Surgical instruments Gears Valves Pumps Shafts Offshore oil and gas components Bearings Mixers and stirrers Turbine parts Aerospace Many of these applications are hidden to most of us which probably explains why martensitic stainless steels do not have a prominent public profile. It is good to remind ourselves that much of our modern world rests on martensitic stainless steels quietly doing their job behind the scenes. Summary Martensitic stainless steels have a long history stretching right back to Harry Brearleys invention in 1913. Their combination of strength, toughness and moderate corrosion resistance makes them ideal for a wide range of applications. Although not used in large quantities compared to austenitic and ferritic grades, they are a vital part of the stainless steel armoury.
Courtesy of AZOM
Of course, martensitic grades can also be obtained as flat products mainly for blades of various kinds. Most of the grades listed in EN 10088-3 are also found in EN 100882. Details of these can be found at http:// www.bssa.org.uk/topics.php?article=65 The class of martensitic creep-resisting steels of the 1.49xx type are found in EN 10302. These are generally of the 9-12% CrMoV type often with additions of other elements such as niobium and tungsten. A summary of these steels can be found at http://www.bssa.org.uk/topics.php?article=155 Compositions http://www.bssa.org.uk/topics.php?article=405 Properties These steels are used in the power generation industry. Corrosion Resistance of Martensitic Grades The corrosion resistance of martensitic stainless steels is generally lower than for the other types of stainless steel. However, with at least 11.5% chromium, they are genuine stainless steels giving a significantly improved corrosion resistance compared to low alloy steels. One only
6 STAINLESS STEEL INDUSTRY February 2009
Most of today's major pharmaceutical companies were founded in the late 19th and early 20th centuries. Key discoveries of the 1920s and 1930s, such as insulin and penicillin, became mass-manufactured and distributed. Switzerland, Germany and Italy had particularly strong industries, with the UK, US, Belgium and the Netherlands following suit. The industry remained relatively small scale until the 1970s when it began to expand at a greater rate. Legislation allowing for strong patents, to cover both the process of manufacture and the specific products, came in to force in most countries, together with The US FDA regulations such regulations being due to the Thalidomide crisis in the 1960s. The pharmaceutical industry entered the 1980s pressured by economics and a host of new regulations, both safety and environmental, but also transformed by new DNA chemistries and new technologies for analysis and computation. Drugs for heart disease and for AIDS were a feature of the 1980s, involving challenges to regulatory bodies and a faster approval process. There are now more than 200 major pharmaceutical companies, jointly said to be more profitable than almost any other industry, and employing more political lobbyists than any other industry. Advances in biotechnology and the human genome project promise ever more sophisticated, and possibly more individualized, medications. The cost for discovering, developing and launching (which factors in marketing and other business expenses) a new drug (along with the prospective drugs that fail) rose over a five year period to nearly $1.7 billion in 2003. With the rapid growth and sophistication the engineering sector has had to try and keep pace without the high profit margins that the Pharmaceutical companies generate themselves. More sophisticated materials have been developed (visit www.bssa.org.uk for dates and analysis) together with better finishing processes such as automated polishing, electropolishing (visit www.polgrat.co.uk for more information). For the first time ever, in 2006, global spending on prescription drugs topped $643 billion, even as growth slowed somewhat in Europe and North America. The United States accounts for almost
The Table below and the one on the following page show the 20 largest pharmaceutical and biotech companies ranked by healthcare revenue. Some companies (eg, Bayer, Johnson and Johnson and Procter & Gamble) have additional revenue not included here. The phrase Big Pharma is often used to refer to companies with revenue in excess of $3 billion, and/or R&D expenditure in excess of $500 million. Market leaders in terms of sales The top ten pharmaceutical companies by 2006 sales are:
Rank Sales ($m) MarGrow ket th Shar e (%) (%) 7.3 5.9 5.7 Based/ Headquartered in US UK France Switzerland Switzerland UK/Sweden US US US US
Company
1 2 3 4 5 6 7 8 9 10
Pfizer GlaxoSmithKline Sanofi-Aventis Novartis HoffmannLa Roche AstraZeneca Johnson & Johnson Merck & Co. Wyeth Eli Lilly and Company
28,880 18.0 4.6 26,596 21.8 4.2 25,741 10.5 4.1 23,267 4.2 22,636 2.8 15,683 2.4 14,814 7.5 3.7 3.6 2.5 2.4
NB The top 25 Pharmaceutical Company lists produced by Wood-Mackenzie for the years 2004-2006 can be found at: http://www.p-d-r.com/ranking/ranking.html on the P-D-R website.
Stainless Steel Products for the Pharmaceutical sector include but are not restricted to:Pressure Vessels, process vessels, conveyors, hygienic and WFI (water for injection) pipe work systems, handling equipment, trolleys, bespoke R&D equipment.
Mixing vessel for cancer drug development showing spray ball for CIP
Products evolve from the pharmaceutical industry as its Doctors and Project Managers come up with ideas for their product development and process requirements. Quality planning is essential and identification of stainless steel grades during the design process. Where pressure vessels are being designed and manufactured latest regulations must be adhered to. The designer and manufacturer should give careful consideration to welded joints where welds will need to be smooth, crack and crevice free when in contact with product and for CIP (Cleaning in place) systems. Material finish (Ra) should be given such there is no misunderstanding and the finished product will be fit for purpose and easily cleaned in service. At Midas Technologies we have conducted our own research on finishing stainless steel fabrications from stock materials sheet, plate and sections to establish the best base material stock finishes to use for high quality and economy of manufacture. For instance utilising a stainless steel grade 316L cold reduced sheet (2B) for a vessel body and then electropolishing it gives a superior finish with no mechanical polishing required other than weld seams. Initial stock holder PV protection and careful handling of stainless steel is extremely important so as to minimise scratching and damage that would have to be mechanically rectified by polishing adding unnecessary cost to the
Bulk extract vessel engineering drawings Processing vessels natural extracts for cough mixtures, gripe water etc
product manufacture. Equipment and benches must be clean and free from steel/iron where it could contaminate the material, in any event final mechanical polishing and/ or electro polishing will remove any surface contamination, the product then should be immediately packaged to stop any contamination via air-born oxides or local activities. A common contamination is where un familiar fabricators grind carbon steel close to stainless steel products and should be avoided at all cost. Stainless steel and carbon steel can be fabricated in unison with the correct process and manufacturing procedures in place () Clients should assess fabricators capabilities and available facilities, companies who are ISO 9001:2000 registered will normally be fully compliant with Pharmaceutical Quality Assurance Requirements. The BSSA can help on materials choice and also run fabrication courses with technical information available off the web site, membership is very cost effective. () This is the authors opinion, some clients will not place contracts unless stainless steel is the only material being used for fabrication in the works. Useful information available from web sites at :www.bssa.org.uk www.hse.gov.uk/pubns/indg261.pdf www.fda.gov www.asme.org www.standardsuk.com www.bre.co.uk www.pharma-info.com
Laser Tube Ireland providing strategic solutions to some of todays market problems
With many companies in the stainless industry struggling under what appears to be the perfect storm in economic terms, proper use of emerging technologies can provide some solutions to the myriad of problems out there. While the use of laser technology to cut flat stainless plate materials is well established and integrated into manufacturers and fabricators work practices, the next generation of laser cutters capable of cutting tubular and hollow section materials have yet to reach their full potential. Market forces are demanding companies adjust all their overhead levels. The knock on effect of these decisions can leave companies weak strategically as they no longer have the ability to operate as efficiently, to the same quality standards or capacity levels previously possible. Laser tube Ireland is working with companies to overcome these challenges. By providing our clients with accurately cut, ready to use assemble parts, companies have the ability to reduce and control their costs, guarantee lead times, and in many cases increase the quality of their finished products, thus turning a difficult situation into a strategic advantage over their competitors. Laser cutting is faster, cleaner, and more accurate than anything that can be produced by traditional manufacturing methods. Literally any shape can be machined onto the end of tube or along its length. Sawing, deburring, drilling, punching, milling, notching etc can all be completed in a single fully automated operation. By adopting our capabilities into their business our clients have been able to decrease not only their daily running costs but also capital costs by reducing their existing machinery levels as they can now get finished parts in the quantities they require, within agreed leads times, at set cost levels. It also means customers can take on work without the need for capital investments (even if they could get access to credit) thus not adding capital repayment pressure on the business. We have worked with companies R & D departments on how to get more from the stainless materials they are using, reshaping their thought process on how to achieve
10 STAINLESS STEEL INDUSTRY December 2009
best practice, more efficient results, and more profitable results, this is particularly true for high volume production. Adoption of the technology can change the strategic thinking of companies as they can now gain access to the markets and tender for work that would have previously been impossible because of their size or lack of technology. Integrating the technology into work practices means companies can effectively leapfrog their competitors strategically, financially and in the quality of finished product. No matter what the specific industry you are in, if you use circular or tubular hollow section stainless materials, laser technology can work for you. It may initially take some research but we are here to assist you in any way we can with, pricing, prototypes and advice. Laser Tube Ireland was first to the market in Ireland, we would welcome the opportunity to illustrate our capabilities and how we can make a difference to your business. Please visit our website www.lasertubeireland.com to see the obvious advantages of the technology and the parameters of materials that can be used.
Putting stainless steel in the front line of the war against infection by Dave Crowley of Anopol Ltd
Consider this; in 1928, Alexander Fleming isolated an extract from mould of the genus Penicillium he named it penicillin. After his discovery, Fleming was unsure as to the suitability of penicillin for use in vivo it took the efforts of others such as Ernst Chain and Norman Heatley to turn the Scotsmans remarkable discovery into something of practical purpose in the treatment of human disease. And yet Fleming still made another discovery the use of too little of the new drug or for too short a period of time would be disastrous. He cautioned in many speeches against these parameters as they were exactly the requirements under which the bacteria would be able to develop resistance to antibiotics. MRSA may feel like a new concept to the general public at least, but in actuality, it has been around for almost as long as antibiotics themselves. Medical professionals are now actively encouraged not to give out antibiotics unless its absolutely necessary in an effort to prevent further strains of medically resistant bacteria developing. Naturally, this is a sensible step to try and stem future problems but what of the now, what of bacteria that are already able to cope with the strongest antibiotics we have available to throw at them? Walk into any hospital in the UK and the answer is on almost every wall you approach cleaning. Personal cleanliness, cleanliness of instruments and equipment and of course, the state of the wards themselves and the furniture contained within. Without wishing to put too fine a point on it, it would appear that intensive, well managed cleaning does actually work in preventing the spread of infection. PRIVATE HOSPITALS DONT GET MRSA James Bartholomew, author, The Welfare State Were In writing in The Daily Telegraph, July 2004. Ok, so the above statement may be a slight exaggeration but only slight; these are infection rate comparisons for 2007. *Spire Healthcare is one of the UKs largest operators of private hospitals they acquired Bupas UK hospitals in 2007. Granted, the NHS has more hospitals under its umbrella, but may greatly enhance the anti-bacterial properties of this metal in medical environments. The agency was originally looking at stainless steel and its use in the food processing industry concerns had been raised about the possible build up of salmonella bacteria during the processing of chickens and they examined the differences in bacterial build up on the stainless surface post a number of different treatments. Polishing, sandblasting and grinding were all found to reduce the numbers of bacteria, but one treatment was found to be way more effective than all the others; namely electropolishing. In very simple terms electropolishing involves the component/piece being submerged in a bath of specific chemicals through which an electrical current is passed. The combination of current/chemical removes a microscopic layer from the surface of the part, leaving the finished piece both
Comparative photographs showing bacterial build up. Left electropolished stainless steel. Right - non-electropolished stainless steel (Magnified 500x approx).
Spire Healthcare* C Difficile (per 10,000 bed days) MRSA (per 10,000 bed days) 0.45
NHS 12
0.1
1.5
still on average, 7500 people a year are contracting potentially life threatening, bloodstream infections in state hospitals. Whilst its important to stress that its obviously not possible to state that this could be prevented with a better system of cleaning, the facts would seem to at least strongly suggest that it certainly wouldnt make the figures any worse. Which brings us to stainless steel; as a material, its used for a wide range of medical and pharmaceutical applications, ranging from very small coronary stents, all the way through to furniture found in operating theatres and wards. It has been known for some time that stainless steel is much easier to clean than some alternative surfaces. Research by the United States Department of Agriculture, Agricultural Research Service (USDA-ARS) suggests that a further step
smoother and cleaner than by any other polishing/grinding method where dirt can become entrapped. When bacteria accumulate on a surface, they develop an increasingly complex matrix by attaching to one another and forming a bacterial film which stubbornly resists conventional washing procedures. It has been known for some time that irregularities on the surface can allow bacteria to obtain a tighter grip and accelerate their spread; however, the electropolishing procedure prevents proliferation by offering only a smooth, clean surface with fewer areas for the bacteria to easily take hold. Of course, electropolishing is only of use as long as a strict cleaning regimen is followed post installation. In simple terms though; if an item has already been treated to be more resistant to bacteria taking hold on its surface, then its reasonable to assume any cleaning errors would be far less likely to have serious consequences. Electropolishing may not be necessary for all stainless steel components or items, but the evidence demonstrates that it can certainly give us a head start in the war against infection in many medical and pharmaceutical scenarios. SOURCES: Daily Telegraph onlineHealth Protection Agency Epidemiological Data: Healthcare Associated Infections Commentary for MRSA Bacteraemia December 2008 United States Department of Agriculture Agricultural Research Service Bacterial Bio-films Less Likely On Electropolished Steel (Judy W. Arnold) http://www.nobelprize.com http://en.wikipedia.org/wiki With grateful thanks to Louise Mansergh at Spire Healthcare for data.
February 2009 STAINLESS STEEL INDUSTRY 11
ELECTROPOLISHING OF STAINLESS STEEL SURFACES by Herr Siegfried Piesslinger-Schweiger CEO Poligrat GmbH
Finishing for High Purity and Pharmaceutical demands
Electropolishing enables a stainless steel surface to be produced which will satisfy the highest levels of purity and cleanliness. The effects of electropolishing on the different criteria for hygiene are explained and its practical applications are shown with examples from industry. A prerequisite for ensuring optimum electropolishing results is the careful harmonisation of the material, the construction technique and the fabrication process. PROBLEM DEFINITION Stainless steels in the sense of this report can be taken as non-rusting steels with a minimum of 13% chromium in the alloy. More generally, the chrome content is above 17%, together with additions such as nickel and molybdenum being usual. The microstructure can be ferritic, austenitic, or duplex. Increasingly, austenitic chrome-nickel-molybdenum steels are being used in systems with critical purity demands, where the surface treatment is of decisive importance to the attainable operational results. Electropolishing has proved itself to be an operationally safe and economic process capable of meeting these demands. PURITY CRITERIA The suitability of surfaces for use in systems with high purity demands is dependent on two properties: the surfaces themselves should not transfer any substances to the contact media. no external impurities should adhere to the surfaces, nor should the surfaces enter into catalytic interaction with surrounding substances. The first property termed internal, the second external purity of the surfaces. The internal purity of surfaces is principally determined by the corrosion resistance, the particle emission properties and the diffusion properties of the material. With nonrusting steels these properties are to a large extent determined by the condition of the sub-surface material layer and they can be influenced and significantly improved by electropolishing. With external purity, the adhesion and cleaning properties of stainless steel surfaces and similarly their passivity and catalytic behaviour are largely determined by the energy condition and microstructure of the surfaces. Both properties can be directly influenced to a high degree by electropolishing. EFFECT OF ELECTROPOLISHING During the course of fabrication, engineering surfaces are subjected to a series of treatments, the effects of which lead to alterations in topography, structural texture, alloy composition, purity and energy condition. At the end of the fabrication process the surface produced is generally
12 STAINLESS STEEL INDUSTRY February 2009
one, which, in structure and properties, differs considerably and, in most cases, adversely from the base material. Ground Surface Grinding Defect
These damaged surface layers can be removed, without any further stress by electropolishing down to a depth at which the material is still in a pure, undisturbed form. The surface properties are thereby improved in their entirety, in one single processing stage to an extent not possible with any other process. Micrograph after Micrograph before Electropolish Electropolish
Geometry and topography The structure of a stainless steel surface is principally altered on a micro scale by electropolishing. All roughness and hairline cracks in the structure are smoothed out and removed. At similar roughness index values, the electropolished surface compared with a mechanically fabricated surface, shows a reduction in surface area of approximately 80% with a corresponding reduction of interaction with the environment. Whilst on a micro scale the surface is smooth and closed, on the macro scale it shows a certain residual waviness depending upon the initial surface condition. At the same time it is free of burrs, wafers, doubling and material scaling. Internal purity Mechanical processing produces surface impurities up to a depth of several micrometers. These impurities can only be removed effectively by breaking down the contaminated material layers by electropolishing. The surfaces thus produced will correspond to the degree of purity in the base alloy.
Material structure After removal of the damaged surface layers, the electropolished surface is formed from undisturbed basic structure with its characteristic texture and its original properties. There is an almost complete absence of crystal dislocation as centres for adhesion, desorption, local elements, corrosion nuclei and catalytic reactions. Energy condition With electropolishing, the distressed surface layers are removed without any further energy being introduced into the surface by the treatment. The electropolished surface subsequently exhibits a minimum of potential energy and as a result, a high passivity and resistance to corrosion. Deposit formation as a result of adhesive and catalytic processes is also considerably reduced. Diffusion The diffusion of gases from a surface is largely caused by impurities in the actual surface layers. What principally determines the rate of diffusion is the type of impurity and the frequency of diffusion paths in the form of dislocations in the structure. Experience has shown that the majority of impurities are concentrated the immediate in subsurface layers and these are removed by electropolishing. Electropolishing will also reduce to a minimum the number of diffusion paths in the form of structural defects. PASSIVATION & CORROSION RESISTANCE The corrosion resistance of stainless steel depends, to a large extent, on the formation of a homogenous and dense corrosion-inhibiting layer of chrome oxides, which is commonly known as the passive layer. This requires a metallically pure surface with sufficient chrome content and a ready supply of oxygen. Both of these requirements are ideally met by electropolishing: The electropolished surface is metallically pure and even displays a slight enrichment of chrome in comparison with the base structure. During electropolishing oxygen is released from the material surface, which leads immediately after completion of the electropolishing process to the formation of a homogenous passive layer. Electropolished stainless steel surfaces accordingly show clearly improved corrosion properties in comparison with surfaces treated differently. For demanding applications such as the pharmaceutical industry, corrosion resistance can be further improved by
the use of recently developed chelating passivation techniques, such as POLINOX Protect. An organic passivation fluid is applied to the existing passive layer to form a stable complex with the substrate which gives optimum corrosion resistance.
The highest level of corrosion resistance is given by subsequent controlled heat treatment of the passive layer at approximately 150oC for 5 minutes.
APPLICATIONS Pharmaceutics and biotechnology Particle-free, fibreless and pyrogen-resistant surfaces are required for high-grade pharmaceutical and bio technical production plants. Extensive research and tests aimed at optimising material and surface quality showed highgrade electropolished stainless steel surfaces to be the most operationally safe solution to the problem. Pyrogens (ie. impurities which cause fever) arise principally from protein residues on linings, which evade the effect of the cleaning process. The use of electropolished stainless steel surfaces can ensure a pyrogen-free environment in continuous production. The effectiveness of the measure is dependent on a high-grade electropolishing quality with a material removal of at least 40 m at every point in the system, including the welding joints.
Container
The material to be processed should be trialed and chosen on the basis of its suitability for electropolishing. A homogenous structure and even distribution of the alloying elements are just as essential as processing conditions for successful electropolishing. Non-metallic impurities such as clinker and carbide need to be kept to an absolute minimum in the structure. For this reason unstabilised materials with low carbon content are preferred to stabilised materials. Component construction and jigging will have a decisive influence on the electropolished result. Essentially, the component needs to be capable of being held without gas traps and of draining fully after processing. Particular attention should also be paid to welding technique and mechanical preparatory work before electropolishing. By consulting with your finishing company at the design stage, electropolishing and passivation can make a real contribution efficiency and success of your components.
Vacuum technology In high vacuum and ultra high vacuum conditions, highly pure electropolished surfaces show clearly reduced desorption and gas purifying rates in comparison with mechanically polished, pickled or blasted surfaces. The pumping time necessary to produce the vacuum can be reduced by a factor of ten and the attainable vacuum quality can be improved correspondingly. A spectacular example of the use of electropolished surfaces in a vacuum is the inside of the JET, the European Plasma Fusion Research Centre in Culham, Great Britain.
QUALITY CRITERIA If carried out correctly, electropolishing can significantly enhance the surface quality of the base material and its operational performance. Great care must, however be taken with regard to the design and construction of the component and the electropolishing process itself. Highly pure stainless steel surfaces can only be effectively achieved by electropolishing if the relevant factors are carefully considered. The choice of electrolyte, process parameters and apparatus construction, including pre- and post-treatment, must be carefully matched to the actual material and the required end result. All relevant operational criteria should be carefully monitored and logged.
Industry News
Ticaret invests in new warehouse
Saritas Celik Sanayi ve Ticaret A.S. the largest stainless steel service center of Turkey, East Europe and Middle East has started a new major investment project in Gebze Industrial Zone near Istanbul. The objective is to ensure the company keeps its leading position in the region and become one of the largest stainless steel service and distribution centers worldwide. The new investment is located in the most advanced and prestigious industrial zone in Gebze on a total 160.000 sqm property. The groundbreaking ceremony took place with high level of participation on 15/01/2009. New investment will consist of a high capacity stocking system with high stock level in a wide range of stainless grades including duplex series and new processing lines with latest technology and maximum capabilities. The project will cost around 120 Million USD and this amount may increase in case of further expansion. Investment will be carried on during 2009 till 2011. Current facilities will also be kept in process. Saritas was founded in 1957 and dealing with stainless steel since 1970s. We are focusing on stainless steel flat products since 1980s and invested on the first service center in 1998 in Dudullu Industrial Area, Istanbul. The company supplies stainless steel with wide range of stock from 0,40 mm to 100 mm thickness and has the capability of cutting to length, slitting, grinding, brushing and plasma cutting. Saritas is also ISO 9001, ISO 14001 and OHSAS 18001 certified by TUV Sud. Our company is independent and 100% belongs to Saritas family.
Outokumpu cutbacks
Stainless steel demand has weakened further and Outokumpu's fourth quarter performance will be below earlier indications. The company is taking actions to prepare for a period of possible prolonged demand weakness and will now prioritize profitability improvement and cash generation in the short-term. In order to secure cost efficiency, both fixed and variable costs are addressed. In this respect also personnel reductions are anticipated both on a permanent and on temporary basis. Outokumpu decided to review its investment program in October. Based on the review, the investment program is postponed almost entirely to maximize cash flow and maintain balance sheet flexibility in 2009. Outokumpu's current action plans will reduce its annual fixed costs by at least EUR 50 million in 2009. The aim is to achieve these cost savings through personnel reductions and general cost saving programs. The main actions are the following: A number of short-term measures to save costs and adjust to lower production volumes were agreed at the Tornio plant at the beginning of December. If the market situation continues to be difficult, Outokumpu will take additional actions in Tornio to lower the cost level. Further, due to the low order load and the necessity to save costs Outokumpu will start negotiations with personnel representatives with the aim to reduce about 450 jobs in the company's Swedish production sites. Investment program postponed Outokumpu decided to review its investment program in October as a result of the global financial crisis and suddenly weakening stainless steel demand. Based on the analysis Outokumpu has decided to postpone its investment program almost entirely for at least 12 months. Continuing any of the projects would be subject to a separate decision based on an updated feasibility study. All of these investments continue to have strong strategic rational. Outokumpu's target to balance the product mix by selling more value added special products and ferritic (non-nickel) grades can be achieved in the coming years by higher utilization of current capacity and product mix changes. Consequently, the investments in high-purity ferritic and bright-annealing in Tornio, Finland, special grades in Avesta, Sweden and quarto plate in Degerfors, Sweden are postponed. The investment to expand quarto plate production capacity in New Castle (IN), the US, will be proceeding according to plan.
It is a strange fact that Anopol in Birmingham seems to thrive better when the world of finance is preaching doom and gloom. One cannot find a plausible reason for it, but in all those much publicised years of pending recession, Anopol has experienced increases in activity. This applies particularly to the current crisis of confidence, insofar that 2008 produced record turnover months. August proved to be the best month, due in the main to an extremely complicated on-site project. A large complex stainless steel processing machine had shown problems in service due to corrosion. Following sample tests a decision was
made to electropolish it in its entirety, but there was a problem. The building housing the piece of equipment had been erected around the machine and removing it was not possible within the tight time-scale required. Anopols solution was to construct a large plastic tank in-situ, within the walls of the building and fill it with electropolishing solution. Due to the intricate shape of the machine, specially shaped cathodes required designing and manufacturing. On completion the electropolishing tank was cut into pieces for removal from the building. The whole project from inception to completion took only 3 weeks.
seen on it. We have carefully been able to reproduce that fingerprint on the sculpture. "The sculpture is 300 times larger than the shard it is based upon." Once finished the sculpture will be taken out of the factory in two halves to be assembled. The sculpture has been commissioned by the Jasper Square developers Dransfield Properties, of Barnsley. Dransfield Properties' Amanda Holmes said: "We have delivered works of public art on a number of our developments and we are delighted with Robert Erskine's concept of The Shard which reflects Tunstall's rich heritage".
Corus, Engineering Steels PO Box 50, Aldwarke Lane, Rotherham, S60 1DW. Tel: 01709 371234 Ext 6868 Fax: 01709 826233 E-Mail: [email protected] Eden Material Services (UK) Ltd Factory 42A, No One Industrial Est, Medomsley Road, Consett, DH8 6TT. Tel: 01207 590055 Fax: 01207 590059 G-Tex Stainless Avenue Rd, Rowley Regis, West Midlands, B65 0LP. Tel: 0121 561 4533 Fax: 0121 559 6832 E-mail: [email protected] Web: www.g-tex.com Investment Castings Ltd Birchwood Industrial Estate, 130 Great North Road, Hatfield, Herts, AL9 5JN. Tel: 01707 262871 Fax: 01707 271565 Outokumpu Stainless Ltd ASR Rod Mill, Stevenson Road, Sheffield, S9 3XG. Tel: 0114 242 1124 Fax: 0114 242 2152 E-mail: [email protected] Web: www.outokumpu.com Frank Pickering & Co Ltd Admiral Steel Works, Sedgley Road, Sheffield, S6 2DN. Tel: 0114 234 8721 Fax: 0114 285 2564 Righton Ltd Brookvale Road, Witton, Birmingham, B6 7EY. Tel: 0121 356 1141 Fax: 0121 356 7359 E-mail: [email protected] Web: www.righton.co.uk Rimex Metals (UK) Ltd Aden Road, Ponders End, Enfield, Middlesex, EN3 7SU, UK Tel: +44 (0) 20 8804 0633 Fax: +44 (0) 20 8804 7275 E-mail: [email protected] Web: www.rimexmetals.com Sandvik Materials Technology UK Manor Way, Halesowen, West Midlands, B62 8QZ Twel: 0121 504 5100 Fax: 0121 504 5151 E-mail: [email protected] Web: www.smt.sandvik.com/uk
Schmolz + Bickenbach (UK) Ltd Speedwell Industial Estate, Staveley, Nr Chesterfield, S43 3JW. Tel: 01246 280280 Fax: 01246 280445 Email: [email protected] Web: www.scholz-bickenbach.co.uk Stabarn Ltd Dulverton Road, Birmingham, B6 7EQ. Tel: 0121 326 6119 Fax: 0121 328 4013 E-mail: [email protected] Web: www.stabarn.co.uk Stainless Steel Reinforcement Ltd Unit B37, Barnwell Business Park, Leatherhead Road, Chessington Surrey, KT9 2NY Tel: 0181 391 1252 Fax: 0181 3911802 Stainless Steel Services Ltd Middlemore Road, Birmingham, B21 0BH Tel: 0121 523 8100 Fax: 0121 523 8102 E-mail: info@:stainlesssteelservices.co.uk Web: www.stainlesssteelservices.co.uk Stainless Wire Supplies Ltd Unit 13, Padgets Lane, South Moon Moat, Redditich, B98 0RA. Tel: 01527 527828 Fax: 01527 526064 E-mail: [email protected] Web: www.swsltd.net Staystrip Group Ltd 11-16 Eyre Street, Springhill, Birmingham, B18 7AA. Tel: 0121 455 0111 Fax: 0121 454 5524 ThyssenKrupp Stainless UK Ltd Unit F, Nexus Point, Elliot Way, Holford, Birmingham, B6 7AX. Tel: 0121 331 3620 Fax: 0121 331 3621 E-mail: [email protected] UGITECH UK 14-15 Erdington Industrial Park, Chester Road, Erdington, Birmingham, B24 0RD. Tel: 0121 377 3400 Fax: 0121 382 9339 E-mail: [email protected] Web: www.ugitch.com UKF Stainless Ltd 12 Buntsford Park Road, Bromsgrove, Worcs, B60 3DX. Tel: 01527 578686 Fax: 01527 837792 E-mail: [email protected] Web: www.ukfstainless.co.uk WP Stainless Ltd A division of WPSI Group plc Stainless House, Westgate, Aldridge, West Midlands, WS9 8DJ. Tel: 01922 742420 Fax: 01922 742425 E-mail: [email protected] Web: www.wps-international.com
All information currently available on these pages is now available at www.stainless-steelind.com On the web site you can contact companies and visit their web sites, by simply clicking on the links provided. You can also get your companies details listed on the site by following simple instructions and paying on-line. The entries will also appear here in the printed magazine.
Schoeller-Bleckmann (UK) Ltd European Business Park, Taylors Lane, Oldbury,Warley, West Midlands, B69 2BN. Tel: 0121 552 1535 Fax: 0121 627 9282 E-mail: [email protected] Web: www.schoeller-bleckmann.co.uk
STEELS - AIRCRAFT
Schmolz + Bickenbach (UK) Ltd
STAINLESS REBAR
Ancon Building Products Bllinghaus GmbH & Co. KG Carpenter Technology Corp Outokumpu Stainless Ltd ASR Rod Mill
T-SECTION
BAR
Aalco AK Steel Ltd Ancon Building Products Aubert Duval (UK) Ltd Bird Stainless Ltd Bllinghaus GmbH & Co. KG Carpenter Technology Corp Carrs Special Steels Corus, Engineering Steels Frank Pickering & Co Ltd Righton Ltd Sandvik Materials Technology UK Schmolz +Bbickenbach (UK) Ltd Stabarn Ltd Stainless Steel Services Ltd Stainless wire Supplies Ltd UGITECH UK
POWDER
Aubert Duval (UK) Ltd
FLATS, ANGLES
Bllinghaus GmbH & Co. KG Stabarn Ltd UKF Stainless Ltd
TUBE
Aalco Eden Material Services (UK) Ltd Righton Ltd Sandvik Materials Technology UK Schoeller-Bleckmann (UK) Ltd Stabarn Ltd UKF Stainless Ltd WP Stainless Ltd
ROD
Aalco Carpenter Technology Corp Stabarn Ltd
BILLETS
Aalco Aubert Duval (UK) Ltd Carpenter Technology Corp Carrs Special Steels Corus, Engineering Steels Outokumpu Stainless Ltd - ASR Rodmill Frank Pickering & Co Ltd Sandvik Materials Technology UK Schmolz + Bickenbach (UK) Ltd
FORGINGS
Aubert & Duval UK Ltd Carrs Special Steels Frank Pickering & Co Ltd Sandvik Materials Technology UK
TUBE (perforated)
WP Stainless Ltd
TUBE / PIPE
WP Stainless Ltd
INGOTS
Aubert Duval (UK) Ltd Carrs Special Steels
BLANKS
Aalco AK Steel Ltd Bird Stainless Ltd Brite Band CompanyLtd Carrs Special Steels Frank Pickering & Co Ltd ThyssenKrupp Stainless UK Ltd Stabarn Ltd UGITECH UK
CASTINGS
Aubert & Duval UK Ltd
CAST TUBE
Eden Material Services (UK) Ltd
CHANNELS
Perchcourt Ltd
PIPE
Aalco Group Sandvik Materials Technology UK Stabarn Ltd UKF Stainless Ltd
Manufactured Components
Potter & Soar Ltd Beaumont Road, Banbury, Oxon, OX16 7SD. Tel: 01295 253344 Fax: 01295 272132 E-mail: potter.soar@BTinternet. com Righton Ltd Brookvale Road, Witton, Birmingham, B6 7EY. Tel: 0121 356 1141 Fax: 0121 356 7359 Sandvik Materials Technology UK Manor Way, Halesowen, West Midlands, B62 8QZ. Tel: 0121 504 5100 Fax: 0121 504 5151 E-mail: [email protected] Web: www.smt.sandvik.com/uk Schoeller Bleckmann (UK) Ltd European Business Park, Taylors Lane, Oldbury, Warley, West Midlands, B69 2BN. Tel: 0121 552 1535 Fax: 0121 627 9282 E-mail: [email protected] Spencer Clark Metal Metal Industries plc Greasbrough Street, Rotherham, S60 1RG. Tel: 01709 828600 Fax: 01709 828507 Stainless Steel Fasteners Ltd Broombank Road, Sheepbridge, Chesterfield, S41 9QJ. Tel: 01246 451818 Fax: 01246 455268 Staystrip Goup Ltd 11-16 Eyre Street, Springhill, Birmingham, B18 7AA. Tel: 0121 455 0111 Fax: 0121 454 5524
FABRICATION Specials
Ancon Building Products Greengate Metal components Ltd
TUBULAR COMPONENTS
Aalco Schoeller-Bleckmann (UK) Ltd UKF Stainless Ltd WP Stainless Ltd
FASTENERS
Ancon Building Products Righton Ltd Stainless Steel Fasteners Ltd
VALVES
Aalco
FILTERS
Bridgwater Filters Ltd
FLOORPLATES
Ancon Building Products ThyssenKrupp Stainless UK Ltd
WIRE MESH
Aalco Bridgwater Filters Ltd Potter & Soar Ltd
MANIFOLDS
METAL SPINNING
Metal Spinning Group Ltd
Aalco The Hersham Centre, Hersham Green, Hersham, Surrey KT12 4HP. Tel: 01932 250100 Fax: 01932 250101 E-mail: [email protected] Ancon Building Products President Way, President Park, Sheffield, S4 7UR Tel: 0114 275 5224 Fax: 0114 276 8543 E-mail: [email protected] Web: www.ancon.co.uk Bridgwater Filters Ltd George Street, West Bromwich, West Midlands B70 6NJ. Tel: 0121 525 6901 Fax: 0121 500 5224 E-mail: [email protected] Web: www,bridgwaterfilters.co.uk Brite Band Company Ltd Unit 15 Manywells, Ind Estate, Cullingworth, Bradford, Bd13 5DX. Tel: 01535 271427 Fax: 01535 275676 E-mail:[email protected] Web: www.briteband.co.uk Greengate MetalComponents Ltd Unit 1, Greengate Middleton Jnct, Manchester, M24 1RU Tel: 0161 653 3443 Fax: 0161 643 4995 E-mail: [email protected] Web: www.greengatemetal.co.uk Lincoln Electric (UK) Ltd Address: Mansfield Road, Aston, Sheffield, S26 2BS Tel: 0114 287 2401 Fax: 0114 287 6544 E-mail: [email protected] Web site: www.lincolnelectric.eu
ThyssenKrupp Stainless UK Ltd Unit F, Nexus Point, Elliot Way, Holford, Birmingham, B6 7AX. Tel: 0121 331 3620 Fax: 0121 331 3621 E-mail: [email protected] UKF Stainless Ltd 12 Buntsford Park Road, Bromsgrove, Worcs, B60 3DX. Tel: 01527 578686 Fax: 01527 837792 E-mail: [email protected] Web: www.ukfstainless.co.uk WP Stainless Ltd A division of WPSI Group plc Stainless House, Westgate, Aldridge, West Midlands, WS9 8DJ. Tel: 01922 742420 Fax: 01922 742425 E-mail: [email protected] Web: www.wps-international.com
PERFORATED TUBES
UKF Stainless Ltd
PIPEWORK
Schoeller-Bleckmann (UK) Ltd
SLIT COIL
Staystrip Group
Processing Services
E. HARDING & SONS LTD
FIRST IN STAINLESS STEEL PROCESSING
METAL FINISHERS
UKF Stainless Ltd
PASSIVATING
Anopol Ltd Anopol (South) Ltd Metapic Ltd E F Westaway Ltd
Stainless Steel Processors Plasma Cutting High Definition Plasma Cutting Laser Cutting Shearing Forming Rolling Water Jet Cutting Plate Sawing C.N.C Machining
PICKLING
Anopol Ltd Anopol (South) Ltd Metapic Ltd Poligrat (UK) Ltd Vecom Stainless Finishers Ltd E F Westaway Ltd
www.eharding.co.uk
Aalco The Hersham Centre, Hersham Green, Hersham, Surrey KT12 4HP. Tel: 01932 250100 Fax: 01932 250101 E-mail: [email protected] Anopol Ltd PO Box 177, 70 Bordesley Street, Birmingham,B5 5QJ. Tel: 0121 632 6888 Fax: 0121 631 2274 E-mail: [email protected] Web: www.anopol.co.uk Anopol (South) Ltd Bordon Trading Estate, Bordon, Hants, GU35 9HH. Tel: 01420 488753 Fax: 01420 488239 Bird Stainless Ltd Box Mill, Sheffield Road, Sheffield, S36 6HQ. Tel: 01226 766766 Fax: 01226 766841 Carrs Special Steels Wadsley Bridge, Sheffield, S6 1TL Tel: 0114 285 5866 Fax: 0114 285 5734 (Ingot) Fax: 0114 285 4962 (Bar & Billet) Copeland and Craddock Ltd Radnor Park Trading Est, Back Lane, congleton, CW12 4PX. Tel: 01260 279641 Fax: 01260 276987 E-mail: [email protected] Web: www.copelandandcraddock.co.uk Greengate Metal Components Ltd Unit 1, Greengate Middleton Jnct, Manchester, M24 1RU Tel: 0161 653 3443 Fax: 0161 643 4995 E-mail: [email protected] Web: www.greengatemetal.co.uk E. Harding & Sons Ltd Unit 10/11 Walker Industrial Park, Guide, Blackburn, BB1 2QE Tel: 01254 581276 Fax: 01254 677012 E-mail: [email protected] Web: www.eharding.co.uk John Desmond Impact finishers 58 Weir Road, wimbledon, London Sw19 8UG E-mail: [email protected] Web: www.johndesmond.com Metapic Ltd Birmingham Road North, Whittington Moor, Chesterfield, S41 9BG. Tel: 01246 451710 Fax: 01246 455999 E-mail: [email protected]
Poligrat (UK) Ltd 2 Holder Road, Aldershot, Hants, GU12 4RH. T: 01252 336337 Fax: 01252 22791 Professional Polishing Services Ltd 18B Parkrose Industrial Estate, Middlemore Road, Smethwick, Warley, West Midlands, B66 2DR. Tel: 0121 555 6569 Fax: 0121 555 6613 E-mail: enquiries@ professional polishing.co.uk Professional Polishing Manchester Ltd Hope Industrial Centre, Whalley Road, Ramsbottom, bury, BL0 0ES. Tel: 01706 828684 Fax: 01706 828668 [email protected] Sandvik Materials Technology UK Manor Way, Halesowen, West Midlands, B62 8QZ. Tel: 0121 504 5100 Fax: 0121 504 5151 E-mail: [email protected] Web: www.smt.sandvik.com/uk Sillavan Metal Polishers Ltd Sillavan Works, Wood Street, Bury, Lancs, BL8 2SL. Tel: 0161 797 6666 Fax: 0161 797 3454 E-mail: [email protected] Staystrip Group Ltd 11-16 Eyre Street, Springhill, Birmingham, B18 7AA. Tel: 0121 455 0111 Fax: 0121 454 5524 ThyssenKrupp Stainless (UK) Ltd Unit-F, Nexus Point, Elliott Way, Holford, B6 7AX Tel: 0121 331 3600 Fax: 0121 331 3621 E-mail: [email protected] UKF Stainless Ltd 12 Buntsford Park Road, Bromsgrove, Worcs, B60 3DX. Tel: 01527 578686 Fax: 01527 837792 E-mail: [email protected] Web: www.ukfstainless.co.uk Warley Polishing Company Ltd Units 5, James Scott Road, Cradley, Halesowen, B63 2QT. Tel: 01384 634036 Fax: 01384 411025 E F Westaway Ltd Arden Works, Bacon Lane, Sheffield, S9 3NH Tel: 0114 244 9857 Fax: 0114 243 0682
D S Willetts (stainless) Ltd Murdoch Road, Bilston, West Midlands, WV14 7HG. Tel: 01902 404221 Fax: 01902 405705
PLASMA CUTTING
E. Harding & Sons Ltd D S Willetts (Stainless) Ltd
BEADBLASTING
John Desmond Impact Finishers
BENDING
Greengate Metal Components Ltd E. Harding & Sons Ltd
PROFILE CUTTING
Aalco Group E. Harding & Sons Ltd D S Willetts (stainless) Ltd
COIL SLITTING
Aalco Brite Band Co Ltd
DECOILING
ThyssenKrupp Stainless (UK) Ltd
ELECTROPOLISHING
Anopol Ltd Anopol (South) Ltd Poligrat (UK) Ltd Sandvik Steel
HIREWORK ROLLING
Staystrip Group
VAPOURBLASTING
LASER CUTTING
Greengate Metal Components Ltd E. Harding & Sons Ltd
MECHANICAL POLISHING
Aalco Professional Polishing Services Ltd Professional Polishing Manchester Ltd Sillavan Metal Polishers Ltd ThyssenKrupp Stainless (UK) Ltd Warley Polishing Company Ltd
Processing Equipment
Anopol Ltd PO Box 177, 70 Bordesley Street, Birmingham,B5 5QJ. Tel: 0121 632 6888 Fax: 0121 631 2274 E-mail: [email protected] Web: www.anopol.co.uk Anopol (South) Ltd Bordon Trading Estate, Bordon, Hants, GU35 9HH. Tel: 01420 488753 Fax: 01420 488239 Poligrat (UK) Ltd 2 Holder Road, Aldershot, Hants, GU12 4RH. T: 01252 336337 Fax: 01252 22791
ELECTROLYTES
Poligrat (UK) Ltd
TESTING KITS
Anopol Ltd
PASSIVATING AGENTS
Anopol Ltd Anopol (South) Ltd
MOLYTEST test kit for distinguishing 316 from 304. FERROTEST test kit for checking presence of free iron on stainless steel surfaces ANOPOL LTD Tel: 0121 632 6888
PICKLING PASTES
Anopol Ltd Anopol (South) Ltd Poligrat (UK) Ltd
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December 2008 STAINLESS STEEL INDUSTRY 23
International
Rpt SSI Dec 06 STABARN page 11
AK Steel
Stockholders of: 15-5PH round bars. 17-4PH round and flat bars. Rpt SSI Dec 06 page 5 AK Nitronic 50 round bars. Steel Nitronic 60 round bars. Armco pure iron bars and sheet. Titanium bars. Aluminized Steel Type 2. Auto exhaust ferritic steels in blanks and slit coil. Transformer grade electrical steels. Telephone: 01462 499400 Fax: 01462 896763 E-mail: [email protected] Web: www.aksteel.co.uk
AK Steel Ltd.
003
FS 45311
With continuous investment Year on Year we will always be able to bring you new and exciting finishes and ensure our Service cannot be beaten.
www.professionalpolishing.co.uk