U.S. patent application number 15/922116 was filed with the patent office on 2018-07-19 for steel product and method of producing the product.
The applicant listed for this patent is ONESTEEL REINFORCING PTY LTD. Invention is credited to Graeme McGregor.
Application Number | 20180202014 15/922116 |
Document ID | / |
Family ID | 51688747 |
Filed Date | 2018-07-19 |
United States Patent
Application |
20180202014 |
Kind Code |
A1 |
McGregor; Graeme |
July 19, 2018 |
STEEL PRODUCT AND METHOD OF PRODUCING THE PRODUCT
Abstract
A method of producing a steel product includes heat treating a
mechanically worked low carbon, medium carbon or high strength low
alloy steel product and maintaining or increasing the ductility and
maintaining or increasing the yield stress of the steel.
Inventors: |
McGregor; Graeme; (Burradoo,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ONESTEEL REINFORCING PTY LTD |
Villawood |
|
AU |
|
|
Family ID: |
51688747 |
Appl. No.: |
15/922116 |
Filed: |
March 15, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14784248 |
Oct 13, 2015 |
|
|
|
PCT/AU2014/000416 |
Apr 13, 2014 |
|
|
|
15922116 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C21D 8/0221 20130101;
C21D 9/46 20130101; C22C 38/08 20130101; C22C 38/12 20130101; C21D
8/0247 20130101; C22C 38/002 20130101; C22C 38/54 20130101; C21D
6/005 20130101; C21D 6/004 20130101; C22C 38/50 20130101; C21D
8/0236 20130101; C22C 38/44 20130101; C22C 38/04 20130101; C22C
38/06 20130101; C21D 8/0205 20130101; C22C 38/48 20130101; C21D
6/008 20130101; C21D 8/065 20130101; C22C 38/46 20130101; C22C
38/02 20130101; C22C 38/16 20130101; C21D 7/13 20130101; C22C 38/42
20130101 |
International
Class: |
C21D 8/02 20060101
C21D008/02; C22C 38/54 20060101 C22C038/54; C21D 6/00 20060101
C21D006/00; C22C 38/48 20060101 C22C038/48; C22C 38/46 20060101
C22C038/46; C22C 38/44 20060101 C22C038/44; C22C 38/42 20060101
C22C038/42; C22C 38/16 20060101 C22C038/16; C22C 38/12 20060101
C22C038/12; C22C 38/08 20060101 C22C038/08; C22C 38/06 20060101
C22C038/06; C22C 38/04 20060101 C22C038/04; C22C 38/02 20060101
C22C038/02; C22C 38/00 20060101 C22C038/00; C21D 9/46 20060101
C21D009/46; C21D 8/06 20060101 C21D008/06; C21D 7/13 20060101
C21D007/13; C22C 38/50 20060101 C22C038/50 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 13, 2013 |
AU |
2013205082 |
Claims
1. A method of producing a steel product includes heat treating a
mechanically worked low carbon, medium carbon or high strength low
alloy steel product and maintaining or increasing the ductility and
maintaining or increasing the yield stress of the steel.
2. The method defined in claim 1 also includes maintaining or
increasing the tensile strength of the steel.
3. The method defined in claim 1 wherein the increase in ductility,
measured as elongation, of the heat treated steel relative to that
of the mechanically worked steel is greater than 5%.
4. The method defined in claim 1 wherein the increase in the yield
stress of the heat treated steel relative to that of the
mechanically worked steel is greater than 5%.
5. A method of producing a steel product includes: (a) mechanically
working a low carbon, medium carbon or high strength low alloy
steel feed steel, and (b) heat treating the mechanically worked
feed steel and maintaining or increasing the ductility and
maintaining or increasing the yield stress of the steel; and (c)
forming a steel product.
6. The method defined in claim 5 wherein the mechanical working
step (a) includes cold rolling or drawing or any other suitable
mechanical working step that reduces the transverse cross-sectional
area of the feed steel.
7. The method defined in claim 5 wherein the mechanical working
step (a) includes cold rolling or drawing or any other suitable
mechanical working step that changes the cross-sectional shape of
the feed steel, without necessarily changing the transverse
cross-sectional area, such that there has been energy input
required to cause the shape change.
8. A method of producing a steel product includes: (a) mechanically
working a low carbon, medium carbon or high strength low alloy
steel product, and (b) heat treating the mechanically worked steel
product and increasing the ductility and maintaining or increasing
the yield stress of the steel.
9. The method defined in claim 8 wherein the mechanical working
step (a) includes cold rolling or drawing or any other suitable
mechanical working step that reduces the transverse cross-sectional
area of the steel product.
10. The method defined in claim 8 wherein the mechanical working
step (a) includes cold rolling or drawing or any other suitable
mechanical working step that changes the cross-sectional shape of
the feed steel, without necessarily changing the cross-sectional
area, such that there has been energy input required to cause the
shape change.
11. A method of producing a steel product includes: (a)
mechanically working a low carbon, medium carbon or high strength
low alloy steel feed steel, (b) forming the steel product from the
mechanically worked feed steel, and (c) heat treating the steel
product and increasing the ductility and maintaining or increasing
the yield stress of the steel product.
12. The method defined in claim 11 wherein heat treatment step (c)
also includes heat treating the formed steel product and
maintaining or increasing the tensile strength of the steel
product.
13. The method defined in claim 11 wherein the mechanical working
step (a) includes cold rolling or drawing or any other suitable
mechanical working step that reduces the transverse cross-sectional
area of the feed steel.
14. The method defined in claim 11 wherein the mechanical working
step (a) includes cold rolling or drawing or any other suitable
mechanical working step that changes the cross-sectional shape of
the feed steel, without necessarily changing the transverse
cross-sectional area, such that there has been energy input
required to cause the shape change.
15. A method of producing a steel product that includes selecting a
low carbon, medium carbon or high strength low alloy steel feed
steel as a starting material for the product and selecting
mechanical working and heat treatment time and heat treatment
temperature conditions of the feed steel or a product made from the
feed steel to provide required mechanical properties for the
product and carrying out mechanical working and heat treating steps
and maintaining or increasing ductility and maintaining or
increasing the yield stress of the steel and producing the product
with the required mechanical properties.
16. A mechanically worked and heat treated low carbon, medium
carbon or high strength low alloy steel product made by the method
defined in claim 1.
17. The steel product defined in claim 16 includes any one of wire,
rod, bar, or strip.
18. The steel product defined in claim 17 includes a steel product
that is made from any one of wire, rod, bar, and strip.
Description
[0001] The present invention relates to a steel product for use in
the mining, construction and general manufacturing industries.
[0002] The present invention also relates to a method of producing
the steel product.
[0003] The steel may be any one of low carbon steel, medium carbon
steel and high strength low alloy steel (which is also described in
the steel industry as a microalloy steel).
[0004] The term "low carbon steel" is understood herein to mean
steel having less than 0.3 wt. % C, other elements such as Si and
Mn that are added as deliberate additions to the steel,
residual/incidental impurities and balance Fe.
[0005] The term "medium carbon steel" is understood herein mean
steel having 0.3-2.0 wt. % C, other elements such as Si and Mn that
are added as deliberate additions to the steel, residual/incidental
impurities, and balance Fe.
[0006] The term "residual/incidental impurities" covers elements
such as Cu, Sn, Mo, Al, Zn, Ni, and Cr that may be present in very
small concentrations, not as a consequence of specific additions of
these elements but as a consequence of standard steel making
practices. For example, the elements may be present as a
consequence of the use of scrap steel to produce high strength low
alloy, low carbon and medium carbon steels.
[0007] The term "high strength low alloy steel" is understood
herein to mean steel of the following typical composition, in wt.
%:
C: 0.07-0.30;
[0008] Si: 0.9 or less; Mn: 2.0 or less; Mo: 0.35 or less; Ti: 0.1
or less; V: 0.1 or less; Nb: 0.1 or less; Cu: 0.1 or less; N: 0.02
or less; S: 0.05 or less; Al: 0.05 or less; Residual/incidental
impurities: 1.0 or less; and Fe: balance.
[0009] The term "residual/incidental impurities" in the context of
high strength low alloy steels is understood as described above in
relation to low and medium carbon steels. The concentrations of
elements such as Cu and Mo in the table in the preceding paragraph
are total concentrations, i.e. the concentrations of these elements
as a total of deliberate additions and residual/incidental
impurities.
[0010] The steel product may be any suitable product.
[0011] The steel product may be wire, rod, bar, or strip.
[0012] The steel product may be in the form of a steel product that
is made from any one of wire, rod, bar, and strip.
[0013] The steel product may include any product, including but not
limited to reinforcement bar for concrete construction,
reinforcement mesh for the concrete construction and mining
industries made by welding together spaced-apart parallel line
wires and spaced-apart parallel cross-wires, pipe made from steel
strip, couplers for coupling together any elongate products such as
reinforcing bars, continuous spirals, ligatures for reinforcing
cages for concrete columns and beams, fasteners (including screws,
bolts etc.) made from steel bar, rock bolts made from steel bar,
and other steel products used in tensile or compression or shear or
flexural applications in the concrete construction, construction,
mining or manufacturing industries.
[0014] The present invention is based on a surprising finding that
it is possible to treat steel by heating steel (hereinafter
referred to as "heat treatment") that has been mechanically worked
(e.g. cold formed such as by cold rolling) and: (a) maintain or
increase the ductility (for example, measured as elongation and
described in the specification in terms of elongation and known by
the term Agt (uniform elongation) when referring to reinforcing
steels and often expressed as Agt.sub.(-0.5%)), (b) maintain or
increase the yield stress (YS) (often expressed as Proof Stress
(PS) for reinforcing steels) and (c) maintain or increase the
tensile strength (TS) of the steel. This is a surprising finding
because metallurgy teaches that heat treatment of
mechanically-worked steel results in an increase in ductility and a
decrease in the yield stress and a decrease in the tensile strength
of the steel.
[0015] By way of example, the applicant found that steel that had
been mechanically worked to reduce the transverse cross-sectional
area of the steel by 5-30% and in some instances up to 75% and then
heat treated at a temperature in a range of 150-750.degree. C. for
a time period of 1 minute to 16 hours maintained and in many
instances produced an increase in ductility of at least 25%
relative to that of the mechanically worked steel and an increase
in yield stress of at least 5% relative to that of the mechanically
worked steel.
[0016] In general terms, the applicant found that mechanically
worked steel could be heat treated at higher temperatures and for
shorter times or at lower temperatures and for longer times to
maintain or increase ductility, yield stress, and tensile
strength.
[0017] It is noted that the invention is not confined to mechanical
working that changes the transverse cross-sectional area of a feed
steel or a steel product and also extends to situations where cold
working changes the shape of the feed steel or the steel
product.
[0018] Typically, and without limiting the scope of the present
invention, specific steel chemistries and process routes and
properties are summarized in the following table.
TABLE-US-00001 Steel Process HT Temp and YS (PS) - Elongation
Chemistry Route Cold Work Time MPa (Agt) % HSLA Cold work Less than
150-750.degree. C. Greater Greater and HT 20%- and 5 mins- than 600
MPa than 1.5% could be 16 hrs up to or more than 35% Low C Cold
work 20-25%- 150-750.degree. C. Greater Greater and HT could be and
5 mins- than 500 MPa than 1.5% up to or 16 hrs more than 45% Medium
C Cold work 20-75% 150-750.degree. C. 750-1000 MPa Greater and HT
and 5 mins- than 1.5% 16 hrs Nb - "HT" referred to in the above
Table means "heat treatment".
[0019] The present invention is based on an extensive research and
development program that has focused on testing a substantial
number of samples of low carbon steels, medium carbon steels, and
high strength low alloy steels. The samples included samples that
were mechanically worked under different conditions and heat
treated at different temperatures and for different times. The
research and development program is discussed in a later section of
the specification in more detail.
[0020] The present invention provides a method of producing a steel
product that includes heat treating a mechanically worked steel
product and maintaining or increasing the ductility and maintaining
or increasing the yield stress of the steel.
[0021] The present invention also provides a method of producing a
steel product that includes heat treating a mechanically worked
steel product and maintaining or increasing the ductility and
maintaining or increasing the yield stress and maintaining or
increasing the tensile strength of the steel.
[0022] The present invention also includes a mechanically worked
and heat treated steel product. The steel product may be any one of
the steel products described above, i.e. wire, rod, bar, or strip,
and any steel product that is made from any one of wire, rod, bar,
and strip and including the specific products mentioned above.
[0023] The invention provides an opportunity to use the same
starting material, such as a high strength low alloy steel, low
carbon steel, and medium carbon steel, and produce a range of
required mechanical properties by appropriate selection of
mechanical working and heat treatment time and heat treatment
temperature.
[0024] In this regard, the present invention also provides a method
of producing a steel product that includes selecting a feed steel
as a starting material for the product and selecting mechanical
working and heat treatment time and heat treatment temperature
conditions of the feed steel or a product made from the feed steel
to provide required mechanical properties for the product and
carrying out mechanical working and heat treating steps and
maintaining or increasing the ductility and maintaining or
increasing the yield stress of the steel and producing the product
with the required mechanical properties.
[0025] The invention provides an opportunity for small or large
quantities of readily available steel materials to be used to
manufacture:
(a) high strength (e.g. >750 MPa yield stress) and high
ductility (e.g. Uniform Elongation >1.5% Agt), bar, rod, wire or
mesh; and (b) medium strength (e.g. >500 MPa yield stress) and
high ductility (e.g. Uniform Elongation >1.5% Agt) bar, rod wire
or mesh.
[0026] By way of example, a 750 MPa yield stress type (a) steel in
accordance with the invention represents a potential material
saving of 33% for the same performance as a conventional 500 MPa
yield stress reinforcing steel in tensile applications. Therefore,
the diameter of a reinforcing steel could be reduced from, say, 12
mm to approximately 9.8 mm for the same performance. Alternatively,
using a bar of 12 mm in diameter and with a 750 MPa yield stress
would allow an increase in performance of 50%, and hence e.g. a
better performing concrete column or beam for the same quantity of
steel. A mesh manufactured from the material with the same
properties and used in mining applications represents a potential
material saving of at least 30% for the same performance and with
consequent occupational health and safety benefits, i.e. handling
of a lighter product. Whilst not critical, being able to also
increase the ductility is a potential benefit.
[0027] By way of further example, in the concrete construction
industry, being able to manufacture 500 MPa mesh with >5% Agt
allows approximately a 20% reduction in the amount of steel
required in applications that require moment redistribution, e.g.
many suspended floors. Steel fixing in Australia is currently
charged at a $/tonne rate, and therefore a reduction in the amount
of steel to be fixed provides an opportunity to significantly
reduce the installed cost of reinforcing. This same reduction would
apply to high strength bar or wire reinforcing.
[0028] By way of further example, using a high tensile strength
(650 MPa or greater yield stress), ductile mesh manufactured in
this manner would potentially allow in the order of 20-25%
reduction in the mass of steel required to reinforce a concrete
slab on ground or tilt-up concrete products, for example.
[0029] Each of these above-described high tensile strength or
medium tensile strength products have an added advantage of
providing an opportunity to significantly reduce embodied energy
(greenhouse gases) in the product and the potential to reduce
concrete use in columns and beams and associated reductions in
transport and other materials handling costs.
[0030] Elongation is a measure of ductility. Elongation is
expressed herein as Uniform Elongation--Agt. The term "Uniform
Elongation" is understood herein to be a measure of the ability of
steel to deform both elastically and plastically before reaching
its maximum tensile strength. The numerical amounts for elongation
reported in the specification are the elongation of steel in
percentage terms measured after the maximum tensile strength of the
steel has been reached and dropped to 99.5% of the maximum tensile
strength and expressed as A.sub.gt(-0.5%). This method is used for
reliability of measurement. Total elongation is also used as a
measure of ductility of steel products, particularly sheet.
[0031] The increase in elongation of the heat treated steel
relative to that of the mechanically worked steel may be greater
than 5%.
[0032] The increase in elongation of the heat treated steel may be
greater than 10%.
[0033] The increase in elongation of the heat treated steel may be
greater than 15%.
[0034] The increase in elongation of the heat treated steel may be
greater than 20%.
[0035] The increase in elongation of the heat treated steel may be
greater than 30%.
[0036] The increase in elongation of the heat treated steel may be
greater than 50%.
[0037] The increase in elongation of the heat treated steel may be
greater than 100%.
[0038] The increase in elongation of the heat treated steel may be
greater than 150%.
[0039] The increase in elongation of the heat treated steel may be
greater than 200%.
[0040] The increase in the yield stress of the heat treated steel
relative to that of the mechanically worked steel may be greater
than 5%.
[0041] The increase in the yield stress of the heat treated steel
may be greater than 10%.
[0042] The increase in the yield stress of the heat treated steel
may be greater than 15%.
[0043] The increase in the yield stress of the heat treated steel
may be greater than 20%.
[0044] The increase in the yield stress of the heat treated steel
may be greater than 30%.
[0045] The increase in the yield stress of the heat treated steel
may be greater than 40%.
[0046] The heat treatment step may be carried out at any suitable
temperature. There are a number of factors that may have an impact
on the selection of the heat treatment temperature in any given
situation. One factor is heat treatment time. The applicant has
also found that each heat treatment temperature has a time window
within which the yield stress and ductility are increased to a
level above a desired minimum. This window narrows as the heat
treatment temperature increases. Another factor is the steel
composition. Another factor is the target properties, such as
ductility and yield stress.
[0047] The heat treatment step may be carried out at a temperature
below the austenitising temperature of the steel. It is noted that
in any given situation the actual temperature of the steel during
the heat treatment will be a time-temperature dependent
relationship and a function of the steel composition. Therefore,
the temperature of the furnace may be above the austenitising
temperature of the steel.
[0048] The heat treatment step may be carried out at a temperature
below 1000.degree. C.
[0049] The heat treatment step may be carried out at a temperature
below 800.degree. C.
[0050] The heat treatment step may be carried out at a temperature
below 750.degree. C.
[0051] The heat treatment step may be carried out at a temperature
below 700.degree. C.
[0052] The heat treatment step may be carried out at a temperature
below 600.degree. C.
[0053] The heat treatment step may be carried out at a temperature
below 550.degree. C.
[0054] The heat treatment step may be carried out at a temperature
below 500.degree. C.
[0055] The heat treatment step may be carried out at a temperature
below 450.degree. C.
[0056] The heat treatment step may be carried out at a temperature
below 400.degree. C.
[0057] The heat treatment step may be carried out at a temperature
below 300.degree. C.
[0058] The heat treatment step may be carried out at a temperature
below 250.degree. C.
[0059] The heat treatment step may be carried out at a temperature
above 200.degree. C.
[0060] The heat treatment step may be carried out at a temperature
above 150.degree. C.
[0061] The heat treatment step may be carried out at a temperature
above the austenitising temperature of the steel provided the heat
treatment time is selected to be sufficiently short to maintain or
increase the yield stress and maintain or increase the ductility
relative to the starting points for yield stress and tensile
strength and ductility.
[0062] The heat treatment step may be carried out for any suitable
time. There are a number of factors that may have an impact on the
selection of the heat treatment time. As discussed above in
relation to heat treatment temperature, these factors include heat
treatment temperature and steel composition and target properties
and productivity.
[0063] The heat treatment step may be carried out for less than 16
hours.
[0064] The heat treatment step may be carried out for less than 10
hours.
[0065] The heat treatment step may be carried out for less than 6
hours.
[0066] The heat treatment step may be carried out for less than 5
hours.
[0067] The heat treatment step may be carried out for less than 4
hours.
[0068] The heat treatment step may be carried out for greater than
1 hour.
[0069] The heat treatment step may be carried out for greater than
45 minutes.
[0070] The heat treatment step may be carried out for greater than
30 minutes.
[0071] The heat treatment step may be carried out for greater than
10 minutes.
[0072] The heat treatment step may be carried out for greater than
5 minutes.
[0073] The heat treatment step may be carried out for greater than
1 minute.
[0074] The heat treatment step may be carried out for greater than
30 seconds.
[0075] The heat treatment step may be carried out in any suitable
atmosphere. The atmosphere may be an oxidising atmosphere or a
reducing atmosphere. By way of particular example, the heat
treatment step may be carried out in air.
[0076] The heat treatment step may be carried out without a
protective atmosphere. This is an important advantage of the
invention.
[0077] The heat treatment step may be carried out using any
suitable means. Specifically, any suitable source of heat energy
may be used to carry out the heat treatment.
[0078] The mechanically worked steel product may be any suitable
form of product. The mechanically worked steel product may be in
the form of any one of wire, rod, bar, or strip.
[0079] The steel product may be in the form of any one of wire,
rod, bar, or strip.
[0080] The rod and bar products may range from products which have
small to large aspect ratios of length to diameter. In other words,
the rod and bar products may range from products which have
diameters that are close to the length of the products to products
that have diameters or transverse cross-sectional areas that are
significantly less than the length of the products.
[0081] The steel product may be in the form of a steel product that
is made from any one of wire, rod, bar, and strip. A non-exclusive
range of steel products is set out above. One particular steel
product of interest to the applicant is reinforcement mesh for the
concrete construction and mining industries made by welding
together spaced-apart parallel line wires and spaced-apart parallel
cross-wires. Another particular steel product of interest to the
applicant is reinforcing bar of all kinds, such as in straight
lengths and formed into ligatures or continuous spirals or other
commonly available shapes (noting that there are many such shapes).
The invention and the properties achieved by the invention are not
limited by the shape of the steel product.
[0082] The mechanically worked steel product may be a cold rolled
or drawn or any other suitable mechanically worked product that
results in a change of cross-sectional shape of the product,
without necessarily changing the transverse cross-sectional area,
such that there has been energy input required to cause the shape
change. For example, the shape change may be from a circular to an
oval transverse cross-section of the same cross-sectional area as
the circular shape.
[0083] The mechanically worked steel product may be a cold rolled
or drawn or any other suitable mechanically worked product that has
a reduced transverse cross-sectional area after it has been
mechanically worked.
[0084] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 2% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0085] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 5% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0086] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 10% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0087] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 15% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0088] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 20% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0089] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 40% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0090] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 50% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0091] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 60% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0092] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 70% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0093] The method may include cooling the heat treated product from
the heat treatment temperature at any suitable cooling rate. For
example, the heat treated product may be quenched by being
water-cooled. By way of further example, the heat treated product
may be cooled in ambient air. The applicant has found that, in
general, the cooling rate does not have a significant impact on
properties, namely ductility, yield stress and tensile strength.
However, the applicant has found that quenching the heat treated
product may have a significant impact on the properties in some
situations, such as when quenching from heat treatment temperatures
of at least 750.degree. C. after a particular time. In one example,
after approximately 8 minutes at 750.degree. C. there was a sudden
increase in tensile strength and a reduction in yield stress and
A.sub.gt. This response is typical of a steel that is heat treated
at a temperature above the austenitising temperature. In this
example, there was a heat treatment window of up to 8 minutes for
which subsequent quenching had no impact on properties.
[0094] The steel may be a low carbon steel, as described above.
[0095] The steel may be a medium carbon steel, as described
above.
[0096] The steel may be a high strength low alloy steel, as defined
above.
[0097] The high strength low alloy steel may contain greater than
0.040 wt. % V.
[0098] The high strength low alloy steel may contain greater than
0.050 wt. % V.
[0099] The high strength low alloy steel may contain greater than
0.060 wt. % V.
[0100] The high strength low alloy steel may contain greater than
0.005 wt. % N.
[0101] The high strength low alloy steel may contain greater than
0.015 wt. % N.
[0102] The high strength low alloy steel may contain greater than
0.018 wt. % N.
[0103] The high strength low alloy steel may contain other alloying
elements, such as Nb.
[0104] The present invention provides a method of producing a steel
product that includes: [0105] (a) mechanically working a feed
steel, [0106] (b) heat treating the mechanically worked feed steel
and maintaining or increasing the ductility and maintaining or
increasing the yield stress of the steel; and [0107] (c) forming a
steel product.
[0108] The method may include multiple sequences of steps (a) and
(b) and (c).
[0109] The present invention provides a method of producing a steel
product that includes: [0110] (a) mechanically working a steel
product, and [0111] (b) heat treating the mechanically steel
product and maintaining or increasing the ductility and maintaining
or increasing the yield stress of the steel.
[0112] The method may include multiple sequences of steps (a) and
(b).
[0113] The present invention provides a method of producing a steel
product that includes: [0114] (a) mechanically working a feed
steel, [0115] (b) forming the steel product, and [0116] (c) heat
treating the steel product and increasing or maintaining the
ductility and maintaining or increasing the yield stress of the
steel product.
[0117] The method may include multiple sequences of steps (a) and
(b) and (c).
[0118] The present invention provides a method of producing a steel
product that includes: [0119] (a) mechanically working a feed
steel, [0120] (b) forming the steel product, and [0121] (c) heat
treating the formed steel product and maintaining or increasing the
ductility and maintaining or increasing the yield stress and
tensile strength of the steel product.
[0122] The method may include multiple sequences of steps (a) and
(b) and (c).
[0123] The increase in elongation of the heat treated steel may be
greater than 5% relative to that of the mechanically worked feed
steel.
[0124] The increase in elongation of the heat treated steel may be
greater than 10%.
[0125] The increase in elongation of the heat treated steel may be
greater than 20%.
[0126] The increase in elongation of the heat treated steel may be
greater than 30%.
[0127] The increase in elongation of the heat treated steel may be
greater than 50%.
[0128] The increase in elongation of the heat treated steel may be
greater than 100%.
[0129] The increase in elongation of the heat treated steel may be
greater than 150%.
[0130] The increase in elongation of the heat treated steel may be
greater than 200%.
[0131] The increase in the yield stress of the heat treated steel
may be greater than 10%.
[0132] The increase in the yield stress of the heat treated steel
may be greater than 20%.
[0133] The increase in the yield stress of the heat treated steel
may be greater than 30%.
[0134] The increase in the yield stress of the heat treated steel
may be greater than 40%.
[0135] The method may also include forming the steel product into
another steel product.
[0136] The feed steel may be any one of low carbon steel, medium
carbon steel, and high strength low alloy steel.
[0137] The feed steel may be in any suitable form. The feed steel
may be in the form of any one of wire, rod, bar, or strip.
[0138] It is noted that the mechanical working step may comprise
reducing the transverse cross-sectional area, i.e. the diameter, of
wire, rod and bar.
[0139] It is also noted that the mechanical working step may
comprise reducing the transverse cross-sectional area, i.e. the
thickness, of the strip.
[0140] It is also noted that the mechanical working step may result
in a change of cross-sectional shape of the product, without
necessarily changing the transverse cross-sectional area, such that
there has been energy input required to cause the shape change.
[0141] The steel product may be any suitable form of product.
[0142] The steel product may be in the form of a steel product that
is made from any one of wire, rod, bar, and strip.
[0143] The mechanical working step (a) may include cold rolling or
drawing or any other suitable mechanical working step that reduces
the transverse cross-sectional area of the feed steel.
[0144] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 2% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0145] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 5% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0146] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 10% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0147] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 15% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0148] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 20% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0149] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 40% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0150] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 50% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0151] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 60% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0152] The reduced transverse cross-sectional area of the
mechanically worked steel product may be at least 70% less than the
transverse cross-sectional area of the steel product before the
mechanical working.
[0153] The heat treatment step may be carried out at a temperature
below the austenitising temperature of the steel.
[0154] The heat treatment step may be carried out at a temperature
below 1000.degree. C.
[0155] The heat treatment step may be carried out at a temperature
below 800.degree. C.
[0156] The heat treatment step may be carried out at a temperature
below 750.degree. C.
[0157] The heat treatment step may be carried out at a temperature
below 700.degree. C.
[0158] The heat treatment step may be carried out at a temperature
below 600.degree. C.
[0159] The heat treatment step may be carried out at a temperature
below 550.degree. C.
[0160] The heat treatment step may be carried out at a temperature
below 500.degree. C.
[0161] The heat treatment step may be carried out at a temperature
below 450.degree. C.
[0162] The heat treatment step may be carried out at a temperature
below 400.degree. C.
[0163] The heat treatment step may be carried out at a temperature
below 300.degree. C.
[0164] The heat treatment step may be carried out at a temperature
below 250.degree. C.
[0165] The heat treatment step may be carried out at a temperature
above 200.degree. C.
[0166] The heat treatment step may be carried out at a temperature
above 150.degree. C.
[0167] The heat treatment step may be carried out for less than 16
hours.
[0168] The heat treatment step may be carried out for less than 10
hours.
[0169] The heat treatment step may be carried out for less than 6
hours.
[0170] The heat treatment step may be carried out for less than 5
hours.
[0171] The heat treatment step may be carried out for less than 4
hours.
[0172] The heat treatment step may be carried out for greater than
1 hour.
[0173] The heat treatment step may be carried out for greater than
45 minutes.
[0174] The heat treatment step may be carried out for greater than
30 minutes.
[0175] The heat treatment step may be carried out for greater than
10 minutes.
[0176] The heat treatment step may be carried out for greater than
5 minutes.
[0177] The heat treatment step may be carried out for greater than
1 minute.
[0178] The heat treatment step may be carried out for greater than
30 seconds.
[0179] The heat treatment step (b) may be carried out in any
suitable atmosphere.
[0180] The present invention also provides a steel product made by
the above method.
[0181] The steel product may have a yield stress of at least 500
MPa yield stress and a Uniform Elongation of at least 1.5% Agt.
[0182] The present invention also provides a mechanically worked
and heat treated high strength low alloy steel product that has a
steel composition, an elongation and a yield stress as described
above.
[0183] The steel product may have a tensile strength as
described.
[0184] The present invention also provides a mechanically worked
and heat treated low carbon steel product that has a steel
composition, an elongation and a yield stress as described
above.
[0185] The steel product may have a tensile strength as
described.
[0186] The present invention also provides a mechanically worked
and heat treated medium carbon steel product that has a steel
composition, an elongation and a yield stress as described
above.
[0187] The steel product may have a tensile strength as
described.
[0188] The steel product may be in the form of a steel product that
is made from any one of wire, rod, bar, and strip as described
above.
[0189] By way of particular example, the steel product is a mesh
product that includes parallel line wires and parallel cross-wires
welded together at the intersections of the wires, with the wires
being steel wires, with the wires being at least 3 mm in diameter,
and with the wires having been mechanically worked and heat treated
prior to being welded together to form the mesh, such that the
wires have a yield stress of at least 650 MPa and a Uniform
Elongation of at least 1.5% Agt.
[0190] By way of further particular example, the steel product is a
mesh product that includes parallel line wires and parallel
cross-wires welded together at the intersections of the wires, with
the wires being at least 3 mm in diameter, with the wires being
steel wires, with the wires having been mechanically worked prior
to being welded together to form the mesh, and with the mesh being
heat treated, such that the wires having a yield stress of at least
650 MPa and a Uniform Elongation of at least 1.5% Agt.
[0191] By way of particular example, the steel product is a
ligature formed from a steel wire that is at least 3 mm in
diameter, and with the wire having been mechanically worked and
heat treated prior to being formed into the ligature, such that the
wires have a yield stress of at least 650 MPa and a Uniform
Elongation of at least 1.5% Agt.
[0192] By way of particular example, the steel product is a
ligature formed from a steel wire that is at least 3 mm in
diameter, and with the wire having been mechanically worked prior
to being formed into the ligature, with the ligature being heated
treated, such that the wires have a yield stress of at least 650
MPa and a Uniform Elongation of at least 1.5% Agt.
[0193] The present invention is described further with reference to
the accompanying FIGS. 1-33 which are graphs of different
combinations of yield stress (Proof Stress--MPa), tensile strength
(MPa), elongation (measured as Uniform Elongation--A.sub.gt), and
heat treatment time for low carbon steel, medium carbon steel and
high strength low alloy samples treated in accordance with the
invention.
[0194] The present invention is based on an extensive research and
development program that focused on testing a substantial number of
samples of low carbon steel, medium carbon steel and high strength
low alloy. The samples included samples mechanically worked under
different conditions and heat treated at different temperatures and
for different times. A key finding of the research and development
program was that mechanical working of the steel samples was
critical to maintaining or obtaining improvements in elongation in
subsequent heat treatment of the samples and also obtaining
improvements in or maintaining yield stress and tensile strength in
subsequent heat treatment of the samples.
[0195] The research and development program was carried out on
steel wire suitable for use in the manufacture of reinforcing mesh
and other reinforcement products for the mining and construction
industries. The steel wire was made from low carbon steel, medium
carbon steel, and high strength low alloy steel. The steel wire was
made by rolling a larger diameter steel rod or wire to smaller
diameters.
[0196] The following is a summary of the research and development
program in relation to low carbon steel, medium carbon steel, and
high strength low alloy steel. [0197] Steel compositions--High
strength low alloy steel, low carbon steel and medium carbon steel.
Examples of the steel compositions are set out below.
TABLE-US-00002 [0197] High Strength Low Alloy C Mn Si P S Cu Ni Cr
Mo V Al Nb Ti CE .17 1.10 .2 .013 .040 .28 .07 .11 .01 .102 .002
.001 .001 .42 .18 1.06 .25 .014 .046 .28 .07 .10 .01 .093 .002 .001
.001 .42 Low Carbon C P Mn Si S Ni Cr Mo Cu Al-T B .06 .006 .50 .15
.009 .006 .012 .001 .014 .002 .0003 .18 .010 .71 .20 .012 .005 .001
.008 .001 .0003 Medium Carbon C P Mn Si S Ni Cr Mo Cu Al-T B .31
.018 .70 .24 .012 .002 .010 .001 .004 .001 .0003
[0198] Initial rod product--conventional AS 1442 or similar rolling
procedure in a rod mill to produce a range of different diameter
rod samples--the rod samples were then cold rolled to smaller
diameter wires to form test samples. The samples included (a) 10 mm
diameter rod rolled to 9.5 mm wire, (b) 8 mm diameter rod rolled to
7.7 mm, 7.6 mm, 7.5 and 6.75 mm wire, (c) 10.5 mm rod rolled to 9.5
mm, (d) 8.5 mm rod rolled to 6.75 mm, (e) 12 mm diameter rod rolled
to 10.7 mm wire, (f) 8.5 mm diameter rod rolled to 7.6 mm wire, (g)
5.5 mm diameter rod rolled to 4.75 mm wire with was subsequently
straightened, (h) 5.5 mm diameter rod rolled to 4.75 mm wire which
was subsequently straightened using a smaller diameter
straightening roll than the straightening roll used for the item
(h) samples, and (i) 5.5 mm diameter rod rolled to 3.06 mm wire.
[0199] Heat treatment furnace--a fan forced air furnace and a
resistance heated furnace. [0200] Heat treatment temperatures--see
Figures. [0201] Heat treatment times--see Figures. [0202] Air cool
for samples having test data reported in FIGS. 1-21 and 26-33 and
water quench for samples having test data reported in FIGS. 22-25.
[0203] Sample size--approximately 300 mm long [0204] Testing
procedures--tensile tests on Instron machine and elongation
determined via an extensometer. The results in the Figures include
graphs of proof stress (PS), with yield stress reported as Proof
stress, elongation reported as Uniform Elongation
(A.sub.gt(-0.5%)), and tensile strength (TS).
[0205] The results of the research work are summarised in part in
FIGS. 1-33 of the specification which are described and discussed
below. It is noted that FIGS. 1-25 focus on work on high strength
low alloy steel ("HSLA") samples, FIGS. 26-32 focus on low carbon
steel samples, and FIG. 33 focuses on medium carbon steel
samples.
[0206] FIG. 1 is a graph of elongation (Agt) versus heat treatment
time (0-30 minutes) for HSLA samples heat treated at 300, 400, 500,
600, and 700.degree. C., with the samples comprising 9.5 mm
diameter wire samples cold rolled from 10 mm diameter rod in
accordance with the invention. It is evident from FIG. 1 that the
ductility of the samples increased with heat treatment time at each
heat treatment temperature, with the rate of increase in ductility
increasing with heat treatment temperature.
[0207] FIG. 2 is a graph of yield stress (Proof Strength--MPa)
versus heat treatment time (0-30 minutes) for HSLA samples heat
treated at 300, 400, 500, 600, and 700.degree. C., with the samples
comprising 9.5 mm diameter wire samples cold rolled from 10 mm
diameter rod in accordance with the invention. It is evident from
FIG. 2 that there was an increase in yield stress of the cold drawn
samples at short heat treatment times at each of the heat treatment
temperatures. The yield stress of the samples heat treated at the
higher temperatures decreased (e.g. 500, 600, and 700.degree. C.)
as the heat treatment times increased. However, there was no
decrease in yield stress with heat treatment time for the samples
that were heat treated at lower temperatures (300 and 400.degree.
C.). The increase in yield stress was achieved with relatively
short heat treatment times across the range of heat treatment
temperatures. This is potentially significant in terms of
processing times and costs.
[0208] FIG. 3 is a graph of tensile strength (MPa) versus heat
treatment time (0-30 minutes) for samples heat treated at 300, 400,
500, 600, and 700.degree. C., with the samples comprising 9.5 mm
diameter HSLA wire samples mechanically worked by being cold rolled
from 10 mm diameter rod in accordance with the invention. The cold
rolling amounts to a 9.75% reduction in transverse cross-sectional
area. It is evident from FIG. 3 that there was an increase in
tensile strength of the cold rolled samples at short (less than 4
minutes) heat treatment times at each of the heat treatment
temperatures. The tensile strength of the samples that were heat
treated at the higher temperatures (e.g. 500, 600, and 700.degree.
C.) decreased as the heat treatment times increased. However, there
was no decrease in tensile strength with heat treatment time for
the samples that were heat treated at lower temperatures (300 and
400.degree. C.). In addition, the increase in tensile strength was
achieved with relatively short heat treatment times across the
range of heat treatment temperatures. This is potentially
significant in terms of processing times and costs.
[0209] FIG. 4 includes a graph of elongation (measured as Uniform
Elongation--Agt) versus heat treatment time (0-5 hours) for 9.5 mm
diameter HSLA wire samples cold rolled from 10 mm diameter rod and
heat treated at 300.degree. C. in accordance with the invention.
The cold rolling amounts to a 9.75% reduction in transverse
cross-sectional area. This graph is described as the "N10PLUS"
curve in the Figure. FIG. 4 also includes comparative data for 6.75
mm diameter low carbon steel wire samples cold rolled from 8.5 mm
diameter rod and heat treated in the same way. The cold rolling
amounts to a 37% reduction in transverse cross-sectional area. This
graph is described as the "6.75EX8.5" curve in FIG. 4. FIG. 4
illustrates increases in ductility that might be expected as a
consequence of the heat treatment of either steel samples.
[0210] FIG. 5 includes graphs of yield stress (reported as Proof
Stress--MPa) versus heat treatment time (0-5 hours) for the FIG. 4
samples (HSLA and low carbon steel) heat treated at 300.degree.
C.
[0211] FIG. 6 includes graphs of tensile strength (MPa) versus heat
treatment time (0-5 hours) for the FIG. 4 samples (HSLA and low
carbon steel) heat treated at 300.degree. C.
[0212] It is evident from FIGS. 4-6 that there was an increase in
each of ductility, yield stress, and tensile strength of the
N10PLUS HSLA samples whereas there was the conventional response of
an increase in ductility and a decrease in yield stress and tensile
strength of the 6.75EX8.5 low carbon steel samples. An interesting
point in relation to the N10PLUS samples is that the results were
achieved at a low heat treatment temperature of 300.degree. C.
[0213] FIGS. 4, 5 and 6 include dotted line sections. The
experimental work reported in these Figures was very early work and
the applicant chose the heat treatment times of 1.15, 2 and 4 hours
because conventional wisdom indicates that at least 1.2 hours would
be required to produce a normal reaction for a low carbon steel,
i.e. an increase in ductility and a decrease in yield stress and
tensile strength--a normal recovery heat treatment reaction. When
the applicant treated the N10PLUS samples and realized there was a
strength increase, the applicant then investigated the shorter heat
treatment times for this material. This also prompted the applicant
to look at shorter heat treatment times for the 6.75 mm material
(and subsequently all others) and the applicant found an increase
for the low carbon steels at the shorter times. FIGS. 26, 27 and 28
demonstrate the increase in ductility, yield stress and tensile
strength. This was a different material rolled to 6.75 mm and hence
the different starting strengths. FIGS. 29-32, which were low
carbon steels treated at 500.degree. C. for the short times showed
the same increases in ductility, yield stress and tensile strength
for short heat treatment times.
[0214] FIG. 7 is a graph of elongation (Agt) versus heat treatment
temperature (0-500.degree. C.) for HSLA samples heat treated for 4
hours, with the samples comprising 7.5 mm, 7.6 mm, and 7.7 mm
diameter wire samples cold rolled from 8 mm diameter rod in
accordance with the invention. The samples were cold rolled to
different extents, with the highest reduction being around 12% in
transverse cross-sectional area. It is evident from FIG. 7 that
there was an increase in ductility in the cold drawn samples at
heat treatment temperature greater than 200.degree. C. and that the
ductility increased as the heat treatment temperature
increased.
[0215] FIG. 8 is a graph of yield stress (Proof Stress MPa) versus
heat treatment temperature (0-500.degree. C.) for HSLA samples heat
treated for 4 hours, with the samples comprising 7.5 mm, 7.6 mm,
and 7.7 mm diameter wire samples cold rolled from 8 mm diameter rod
in accordance with the invention. The samples were cold rolled to
different extents, with the highest reduction being around 12% in
transverse cross-sectional area. It is evident from FIG. 8 that the
yield stress of each of the cold drawn samples initially increased
and then decreased as the heat treatment temperature increased. The
yield stress was higher for the samples having higher cold
reductions. The shapes of the graphs in FIG. 8 indicate that there
is a window of heat treatment temperatures, namely a window in the
range of 150-400.degree. C., in which there was a significant
increase in yield stress of the samples. The yield stress of the
samples was higher across the whole heat treatment temperature
range than the yield stress of the samples prior to heat
treatment.
[0216] FIG. 9 is a graph of tensile strength (MPa) versus heat
treatment temperature for HSLA samples heat treated for 4 hours,
with the samples comprising 7.5 mm, 7.6 mm, and 7.7 mm diameter
wire samples cold rolled from 8 mm diameter rod in accordance with
the invention. The samples were cold rolled to different extents,
with the highest reduction being around 12% in transverse
cross-sectional area. It is evident from FIG. 9 that the tensile
strength of each of the cold rolled samples initially increased and
then decreased as the heat treatment temperature increased. The
tensile strength was higher for the samples having higher cold
reductions. The shapes of the graphs in FIG. 9 indicate that there
was a window of heat treatment temperatures, namely a window in the
range of 150-350.degree. C., in which there was a significant
increase in tensile strength of the samples.
[0217] FIG. 10 is a graph of elongation (Agt) versus heat treatment
time (0-7 hours) for HSLA samples heat treated at 100.degree. C.,
with the samples comprising 7.5 mm, 7.6 mm, and 7.7 mm diameter
wire samples cold rolled from 8 mm diameter rod. The samples were
cold rolled to different extents, with the highest reduction being
around 12% in transverse cross-sectional area. It is evident from
FIG. 10 that there was an overall slight decrease in ductility in
the cold drawn samples across the range of heat treatment times.
This decrease is consistent with a strain ageing mechanism.
Basically, the ductility change was conventional and the teaching
is that the heat treatment temperature of 100.degree. C. was too
low. The ductility was higher for the samples having lower cold
reductions.
[0218] FIG. 11 is a graph of yield stress (Proof Strength--MPa)
versus heat treatment time (0-7 hours) for HSLA samples heat
treated at 100.degree. C., with the samples comprising 7.5 mm, 7.6
mm, and 7.7 mm diameter wire samples cold drawn from 8 mm diameter
rod in accordance with the invention. The samples were cold drawn
to different extents, with the highest reduction being around 12%
in transverse cross-sectional area. It is evident from FIG. 11 that
there was an increase (albeit not substantial) in yield stress in
the cold drawn samples across the range of heat treatment times.
The yield stress was higher for the samples having higher cold
reductions.
[0219] FIG. 12 is a graph of tensile strength (MPa) versus heat
treatment time (0-7 hours) for HSLA samples heat treated at
100.degree. C., with the samples comprising 7.5 mm, 7.6 mm, and 7.7
mm diameter wire samples cold rolled from 8 mm diameter rod in
accordance with the invention. The samples were cold rolled to
different extents, with the highest reduction being around 12% in
transverse cross-sectional area. It is evident from FIG. 12 that
there was a slight change in tensile strength in the cold rolled
samples across the range of heat treatment times. The tensile
strength was higher for the samples having higher cold
reductions.
[0220] FIG. 13 is a graph of elongation (Agt) versus heat treatment
time (0-16 hours) for HSLA samples heat treated at 300.degree. C.,
with the samples comprising 7.5 mm, 7.6 mm, and 7.7 mm diameter
wire samples cold rolled from 8 mm diameter rod in accordance with
the invention. The samples were cold rolled to different extents,
with the highest reduction being around 12% in transverse
cross-sectional area. It is evident from FIG. 13 that after an
initial sudden decrease in ductility (which is consistent with
normal ageing) there was a significant initial increase in
ductility in a relatively short heat treatment time (up to 30
minutes) at 300.degree. C. for each of the samples and that the
ductility tended to level out after around 3 hours of heat
treatment at that temperature. The ductility was higher for the
samples having lower cold reductions.
[0221] FIG. 14 is a graph of yield stress (Proof Stress--MPa)
versus heat treatment time (0-16 hours) for HSLA samples heat
treated at 300.degree. C., with the samples comprising 7.5 mm, 7.6
mm, and 7.7 mm diameter wire samples cold rolled from 8 mm diameter
rod in accordance with the invention. The samples were cold rolled
to different extents, with the highest reduction being around 12%
in transverse cross-sectional area. It is evident from FIG. 14 that
there was a significant initial increase in yield stress in a
relatively short heat treatment time (0-45 minutes) at 300.degree.
C. for each of the samples and that the yield stress tended to
level out after around 45 minutes of heat treatment at that
temperature. The yield stress was higher for the samples having
higher cold reductions. The yield stress of the samples was higher
across the whole heat treatment temperature range than the yield
stress of the samples prior to heat treatment.
[0222] FIG. 15 is a graph of tensile strength (MPa) versus heat
treatment time (0-16 hours) for HSLA samples heat treated at
300.degree. C., with the samples comprising 7.5 mm, 7.6 mm, and 7.7
mm diameter wire samples cold rolled from 8 mm diameter rod in
accordance with the invention. The samples were cold rolled to
different extents, with the highest reduction being around 12% in
transverse cross-sectional area. It is evident from FIG. 15 that
there was a significant initial increase in tensile strength in a
relatively short heat treatment time (0-45 minutes) at 300.degree.
C. for each of the samples and that the tensile strength tended to
level out after around 45 minutes of heat treatment at that
temperature. The tensile strength was higher for the samples having
higher cold reductions. The tensile strength of the samples was
higher across the whole heat treatment time range than the tensile
strength of the samples prior to heat treatment.
[0223] FIG. 16 is a graph of elongation (Agt) versus heat treatment
time (0-30 minutes) for HSLA samples heat treated at 300.degree.
C., with the samples comprising 7.5 mm, 7.6 mm, and 7.7 mm diameter
wire samples cold rolled from 8 mm diameter rod in accordance with
the invention. These samples were cold rolled and heat treated
under the same conditions as the FIG. 13 samples. The samples were
cold rolled to different extents, with the highest reduction being
around 12% in transverse cross-sectional area. This graph focuses
on the first 30 minutes of heat treatment time highlighted in the
discussion of FIG. 13. It is evident from FIG. 16 that after an
initial decrease in ductility (which is consistent with normal
ageing) there was a steady increase in ductility with heat
treatment time at 300.degree. C. for each of the samples, with the
ductility being higher for the samples having lower cold
reductions.
[0224] FIG. 17 is a graph of yield stress (Proof Stress--MPa)
versus heat treatment time (0-30 minutes) for HSLA samples heat
treated at 300.degree. C., with the samples comprising 7.5 mm, 7.6
mm, and 7.7 mm diameter wire samples cold rolled from 8 mm diameter
rod in accordance with the invention. The samples were cold rolled
to different extents, with the highest reduction being around 12%
in transverse cross-sectional area. These samples were cold rolled
and heat treated under the same conditions as the FIG. 14 samples.
This graph focuses on the first 30 minutes of heat treatment time
highlighted in the discussion of FIG. 14. It is evident from FIG.
17 that there was generally a steady increase in yield stress with
heat treatment time at 300.degree. C. for each of the samples. The
yield stress was higher for the samples having higher cold
reductions. The increase in yield stress is well above what would
be expected from normal strain ageing. Normal strain ageing is
detrimental because it leads to a reduction in ductility.
[0225] FIG. 18 is a graph of tensile strength (MPa) versus heat
treatment time (0-30 minutes) for HSLA samples heat treated at
300.degree. C., with the samples comprising 7.5 mm, 7.6 mm, and 7.7
mm diameter wire samples cold rolled from 8 mm diameter rod in
accordance with the invention. The samples were cold rolled to
different extents, with the highest reduction being around 12% in
transverse cross-sectional area. These samples were cold rolled and
heat treated under the same conditions as the FIG. 15 samples. This
graph focuses on the first 30 minutes of heat treatment time
highlighted in the discussion of FIG. 15. It is evident from FIG.
18 that there was a steady increase in tensile strength with heat
treatment time at 300.degree. C. for each of the samples. The
tensile strength was higher for the samples having higher cold
reductions.
[0226] FIG. 19 is a graph of elongation (Agt) versus heat treatment
time (0-30 minutes) for HSLA samples heat treated at 500.degree.
C., with the samples comprising 7.5 mm, 7.6 mm, and 7.7 mm diameter
wire samples cold rolled from 8 mm diameter rod in accordance with
the invention. The samples were cold rolled to different extents,
with the highest reduction being around 12% in transverse
cross-sectional area. It is evident from FIG. 19 that after an
initial decrease in ductility (which is consistent with normal
ageing) there was a steady increase in ductility with heat
treatment time at 500.degree. C. for each of the samples, with the
ductility being higher for the samples having lower cold
reductions.
[0227] FIG. 20 is a graph of yield stress (Proof Stress--MPa)
versus heat treatment time (0-30 minutes) for HSLA samples heat
treated at 500.degree. C., with the samples comprising 7.5 mm, 7.6
mm, and 7.7 mm diameter wire samples cold rolled from 8 mm diameter
rod in accordance with the invention. The samples were cold rolled
to different extents, with the highest reduction being around 12%
in transverse cross-sectional area. It is evident from FIG. 20 that
there was an initial increase in yield stress at the heat treatment
temperature of 500.degree. C. for each of sample, with the yield
stress of each sample reaching a maximum yield stress after 10
minutes. The yield stress of each sample decreased with heat
treatment times greater than 10 minutes. The yield stress was
higher for the samples having higher cold reductions. The yield
stress of the samples was higher across the whole heat treatment
temperature range than the yield stress of the samples prior to
heat treatment.
[0228] FIG. 21 is a graph of tensile strength (MPa) versus heat
treatment time (0-30 minutes) for HSLA samples heat treated at
500.degree. C., with the samples comprising 7.5 mm, 7.6 mm, and 7.7
mm diameter wire samples cold rolled from 8 mm diameter rod in
accordance with the invention. The samples were cold rolled to
different extents, with the highest reduction being around 12% in
transverse cross-sectional area. It is evident from FIG. 21 that
there was an initial increase in tensile strength at the heat
treatment temperature of 500.degree. C. for each sample, with the
tensile strength of each sample reaching a maximum tensile strength
after 10 minutes, and the tensile strength of each sample
decreasing with heat treatment times greater than 10 minutes. The
tensile strength was higher for the samples having higher cold
reductions.
[0229] FIG. 22 is a graph of elongation (Agt) versus heat treatment
time (0-20 minutes) for 6.75 mm diameter HSLA wire samples cold
rolled from 8 mm diameter rod and heat treated at 750.degree. C.
over a time period up to 20 minutes and then water quenched in
accordance with the invention. The cold rolling amounts to a 29%
reduction in transverse cross-sectional area. It is evident from
FIG. 22 that after an initial decrease in ductility (which is
consistent with normal strain ageing) there was a steady increase
in ductility with heat treatment time at 750.degree. C. until 7
minutes, followed by a sudden decrease in ductility and a sudden
increase before levelling out at around 10-12 minutes. It is
evident from FIG. 22 that water quenching heat treated samples had
no detrimental impact on the ductility at heat treatment times
between 2 and 7 minutes. It is evident from a comparison of the
results in FIG. 22 and the results in FIG. 19 for 7.5, 7.6, 7.7 mm
material cold rolled from 8 mm diameter rod and heat treated at
500.degree. C. that the ductility of the 6.75 mm material of FIG.
22 was higher than for the 7.5, 7.6, 7.7 mm material of FIG. 19.
This finding is contrary to the evidence for the 7.5, 7.6, 7.7 mm
material shown in FIG. 19 where the ductility decreased with
increasing cold reduction. This may be a consequence of the higher
heat treatment temperature for the 6.75 mm material generating
greater ductility.
[0230] FIG. 23 is a graph of yield stress (Proof Strength--MPa) and
tensile strength (MPa) versus heat treatment time (0-20 minutes)
for 6.75 mm diameter HSLA wire samples cold rolled from 8 mm
diameter rod and heat treated at 750.degree. C. and then water
quenched in accordance with the invention. It is evident from FIG.
23 that water quenching samples that were heat treated for up to 7
minutes and then quenched had an improvement in yield stress and
tensile strength. Heat treatment times less than 8 minutes followed
by quenching resulted in a significant increase in tensile strength
and a significant reduction in yield stress. It is evident from
FIG. 23 that there was a heat treatment time window of up to 7
minutes at the heat treatment temperature in which there was an
improvement in yield stress and tensile strength. Quenching does
not destroy mechanical properties. An advantage of quenching is
that the product is immediately available.
[0231] FIG. 24 is a graph of elongation (Agt) versus heat treatment
time (0-20 minutes) for 6.75 mm diameter HSLA wire samples cold
rolled from 8 mm diameter rod and heat treated at 500.degree. C.
and then water quenched in accordance with the invention. It is
evident from FIG. 24 that after an initial decrease in ductility
(which is consistent with normal strain ageing) there was a steady
increase in ductility with heat treatment time at 500.degree. C. It
is evident from FIG. 24 that water quenching heat treated samples
had no detrimental impact on ductility at heat treatment times
greater than 5 minutes. In addition, it is also evident that the
higher heat treatment temperature of 750.degree. C. for the samples
referred to in the preceding paragraph generated approximately 2%
greater ductility than for the samples heat treated at 500.degree.
C.
[0232] FIG. 25 is a graph of yield stress (Proof Strength--MPa) and
tensile strength (MPa) versus heat treatment time (0-20 minutes)
for 6.75 mm diameter HSLA wire samples cold rolled from 8 mm
diameter rod and heat treated at 500.degree. C. and then water
quenched in accordance with the invention. It is evident from FIG.
25 that water quenching heat treated samples had substantially no
impact on yield stress and tensile stress. In other words, at this
heat treatment temperature there is no downside in water quenching
treated steel. It is noted nevertheless that these heat treatment
conditions produced an increase in yield stress and tensile
strength.
[0233] FIGS. 26-31 focus on the results of research and development
work on low carbon steel samples.
[0234] FIG. 26 is a graph of elongation (Agt) versus heat treatment
time (0-30 minutes) for samples heat treated at 500.degree. C.,
with the samples comprising 9.5 mm and 6.75 mm diameter low carbon
steel wire samples cold rolled from 10 mm diameter and 8.5 mm rod
respectively in accordance with the invention. The cold rolling
amounts to a 18% and 37% reduction in transverse cross-sectional
area, respectively. It is evident from FIG. 26 that after an
initial decrease in ductility (which is consistent with normal
strain ageing) there was a steady increase in ductility with heat
treatment time at 500.degree. C.
[0235] FIG. 27 is a graph of yield stress (Proof Strength--MPa)
versus heat treatment time (0-30 minutes) for samples heat treated
at 500.degree. C., with the samples comprising 9.5 mm and 6.75 mm
diameter low carbon steel wire samples cold rolled from 10.5 mm
diameter and 8.5 mm rod respectively in accordance with the
invention. The cold rolling amounts to a 18% and 37% reduction in
transverse cross-sectional area, respectively. It is evident from
FIG. 27 that the yield stress of the more heavily mechanically
worked sample (i.e. the 6.75 mm sample) initially increased (up to
2 minutes heat treatment time) and then decreased with heat
treatment time, with a period of 7 minutes treatment time passing
before the yield stress decreased to the initial start strength,
i.e. cold worked strength. The initial increase in yield stress is
a surprising result and indicates that there is a heat treatment
window in which it is possible to achieve an increase in yield
stress. It is also evident from FIG. 27 that the yield stress of
the less heavily mechanically worked sample (i.e. the 9.5 mm
sample) was not adversely affected by heat treatment for up to 8
minutes. When considered in conjunction with FIG. 26, the yield
stress results reported in FIG. 27 are a significant result because
the results indicate that it is possible to heat treat such heavily
worked steel and achieve the FIG. 26 increase in ductility without
a loss of yield stress and more importantly with a possible
increase in yield stress.
[0236] FIG. 28 is a graph of tensile strength (MPa) versus heat
treatment time (0-30 minutes) for samples heat treated at
500.degree. C., with the samples comprising 9.5 mm and 6.75 mm
diameter low carbon steel wire samples cold rolled from 10.5 mm
diameter and 8.5 mm rod respectively in accordance with the
invention. The cold rolling amounts to a 18% and 37% reduction in
transverse cross-sectional area, respectively. It is evident from
FIG. 28 that the tensile strength of the less heavily mechanically
worked sample (i.e. the 9.5 mm sample) initially increased (up to 8
minutes heat treatment time) and then decreased with heat treatment
time. The initial increase in tensile strength is a surprising
result and indicates that there is a heat treatment window in which
it is possible to achieve an increase in tensile strength. When
considered in conjunction with FIGS. 26 and 27, the FIG. 28 result
is a significant result because it indicates that it is possible to
heat treat such heavily worked steel and achieve the FIG. 26
increase in ductility and the FIG. 27 increase in yield stress
without a loss of tensile strength.
[0237] FIG. 29 is a graph of yield stress (Proof Strength--MPa),
tensile strength (MPa), and elongation (A.sub.gt) versus heat
treatment time (0-15 minutes) for samples heat treated at
500.degree. C., with the samples comprising 10.7 mm diameter low
carbon steel wire samples cold rolled from 12 mm diameter rod in
accordance with the invention. The cold rolling amounts to a 20%
reduction in transverse cross-sectional area of the samples. The
plots for each parameter are shown as lines of best fit for the
actual data points. It is evident from FIG. 29 that yield stress,
tensile strength and ductility increased steadily with heat
treatment time. The increase in yield stress is a surprising
result. The yield stress of the samples was higher across the whole
heat treatment temperature range than the yield stress of the
samples prior to heat treatment.
[0238] FIG. 30 is a graph of yield stress (Proof Strength--MPa),
tensile strength (MPa), and elongation (A.sub.gt) versus heat
treatment time (0-15 minutes) for samples heat treated at
500.degree. C., with the samples comprising 8.5 mm diameter low
carbon steel wire samples cold rolled from 7.6 mm diameter rod in
accordance with the invention. The cold rolling amounts to a 20%
reduction in transverse cross-sectional area of the samples. The
plots for each parameter are shown as lines of best fit for the
actual data points. It is evident from FIG. 30 that yield stress
and tensile strength initially increased with heat treatment time
and reached a peak around 5 minutes and then gradually decreased
with longer heat treatment times. The initial increase in yield
stress is a surprising result and indicates that there is a heat
treatment window in which it is possible to achieve an increase in
yield stress. The yield stress of the samples was higher across the
whole heat treatment temperature range than the yield stress of the
samples prior to heat treatment. It is also evident from FIG. 30
that ductility increased steadily with heat treatment time.
[0239] FIG. 31 is a graph of yield stress (Proof Strength--MPa),
tensile strength (MPa), and elongation (A.sub.gt) versus heat
treatment time (0-15 minutes) for samples heat treated at
500.degree. C., with the samples comprising 4.75 mm diameter low
carbon steel wire samples cold rolled from 5.5 mm diameter rod in
accordance with the invention. The wire samples were passed through
a straightener before being heat treated. The cold rolling amounts
to a 25% reduction in transverse cross-sectional area of the
samples. The plots for each parameter are shown as lines of best
fit for the actual data points. It is evident from FIG. 31 that
yield stress and tensile strength initially increased quite quickly
with heat treatment time and reached a peak around 2-3 minutes and
then gradually decreased with longer heat treatment times. The
initial increase in yield stress is a surprising result and
indicates that there is a heat treatment window in which it is
possible to achieve an increase in yield stress. The yield stress
of the samples was higher across the whole heat treatment
temperature range than the yield stress of the samples prior to
heat treatment. It is also evident from FIG. 31 that ductility
increased steadily with heat treatment time.
[0240] FIG. 32 is a graph of yield stress (Proof Strength--MPa),
tensile strength (MPa), and elongation (A.sub.gt) versus heat
treatment time (0-15 minutes) for samples heat treated at
500.degree. C., with the samples comprising 4.75 mm diameter low
carbon steel wire samples cold rolled from 5.5 mm diameter rod in
accordance with the invention. The wire samples were passed through
a straightener before being heat treated. The cold rolling amounts
to a 25% reduction in transverse cross-sectional area of the
samples. The only difference between the experimental procedure for
this experiment and the experiment reported in FIG. 31 relates to
the type of straightener used. The straightening roll was a smaller
diameter straightening roll than the straightening roll used for
the item (h) samples. The plots for each parameter are shown as
lines of best fit for the actual data points. It is evident from
FIG. 32 that yield stress and tensile strength initially increased
quite quickly with heat treatment time and reached a peak around
2-3 minutes and then gradually decreased with longer heat treatment
times. The initial increase in yield stress is a surprising result
and indicates that there is a heat treatment window in which it is
possible to achieve an increase in yield stress. The yield stress
of the samples was higher across the whole heat treatment
temperature range than the yield stress of the samples prior to
heat treatment. It is also evident from FIG. 32 that ductility
increased steadily with heat treatment time. The experimental
results in FIGS. 31 and 32 are very similar, save that the yield
stress, tensile strength and elongation are somewhat higher with
the FIG. 31 straightener than the FIG. 32 straightener.
[0241] FIG. 33 is a graph of yield stress (Proof Strength--MPa),
tensile strength (MPa), and elongation (A.sub.gt) versus heat
treatment time (0-15 minutes) for samples heat treated at
500.degree. C., with the samples comprising 3.06 mm diameter medium
carbon steel wire samples cold rolled from 5.5 mm diameter rod in
accordance with the invention. The cold rolling amounts to a 69%
reduction in transverse cross-sectional area, respectively, of the
samples. The plots for each parameter are shown as lines of best
fit for the actual data points. It is evident from FIG. 33 that
yield stress initially increased quite quickly with heat treatment
time and reached a peak around 3 minutes and then gradually
decreased with longer heat treatment times. The initial increase in
yield stress is a surprising result and indicates that there is a
heat treatment window in which it is possible to achieve an
increase in yield stress. The yield stress of the samples was
higher across the whole heat treatment temperature range than the
yield stress of the samples prior to heat treatment. It is also
evident from FIG. 33 that ductility increased steadily with heat
treatment time.
[0242] The experimental work carried out by the applicant indicates
that there is no difference in the way in which the invention works
with ribbed and smooth wires treated in accordance with the
invention.
[0243] In general terms, as illustrated by the results of the
research work summarised in the Figures, the applicant found
surprisingly that the ductility (measured as elongation), the yield
stress, and the tensile strength of the wire of high strength low
alloy, medium carbon, and low carbon steels could be increased as a
consequence of a combination of mechanical working and heat
treatment. The finding is a significant finding for the following
reasons: [0244] It is possible to significantly reduce the amount
of steel required to manufacture products without a loss of force
capacity of the steel in the products. The reduced amount of steel
required for products improves the economics of construction and
reduces the carbon footprint. [0245] There is an opportunity for
higher strength and ductility products. [0246] There is a
possibility of changing the design and resultant cost of composite
products that are made from the steel products. One example is
steel reinforced concrete products used in the construction
industry. The invention may make it possible to reduce the amount
of steel and/or the amount of concrete used in these products or to
increase the structural performance of these products for a given
amount of steel. [0247] The method is inexpensive in that it can be
carried out with low capital and operating costs.
[0248] The present invention can be used at different stages in the
manufacture of end-use products and therefore provides considerable
flexibility. For example, steel wire can be processed in accordance
with the invention to increase the yield stress and ductility of
the wire and then coiled.
[0249] The coiled product can be formed into end use products such
as spirals, ligatures etc. Alternatively, standard wire can be
produced and coiled and then processed to produce products such as
mesh sheets and ligatures etc. and these products can be processed
in accordance with the invention to increase the yield stress and
ductility of the products.
[0250] Many modifications may be made to the invention described
above without departing from the spirit and scope of the
invention.
[0251] By way of example, the research and development program
reported above has focused on wire. However, the view of the
applicant is that the results are found with wire should translate
to rod, bar, and strip steel products.
* * * * *