Wire rods are made using billet as the base material. The billet undergoes the following process to transform into wire rod - straightening, shot blast cleaning, heating, rough rolling, intermediate rolling, fine rolling. Wire rods typically range in diameter from 5 mm to 20 mm. After the fine rolling operation, the wire rods are bundled into coils. These coils form the base material for making other finished products. Some of them are:
Depending on the type of application the wire rods have different chemical compositions. For e.g.:
General use wire rod is usually made of low carbon steel and is zinc plated to prevent corrosion. Welding wire are low carbon steels with sulfur content less than 0.023%. Fastener contain carbon less than 0.5%. Construction industry wire rods are made of high carbon steels.
The coils are stored in the yard before they are taken for further processing. The coils tend to rust over a period. Rusting occurs due to prolonged exposure of coils to atmospheric conditions such as moisture/ rainfall. Because of rusting the coils don’t look appealing for the customers. They prefer to buy them in their original rolled (un rusted) condition.
Currently, the rust is not removed and the coils are sold as it is acceptable (as stated above) by BIS and ASTM standards. Rust removal process is difficult, especially in mass production scenarios where coils are manufactured in thousands of tons.
Rusting is not a reason for rejection of the coils, however, the weight, dimensions, cross-sectional area and tensile properties of a hand-wire-brushed test specimen has to meet the requirements Section 12 of ASTM A 615-96a specification which is equivalent to the clause mentioned BIS 1786-2008 clause 4.3.1. In case the requirements are not met the coils are rejected.
We are therefore interested in a solution with the following requirements: