Diversified and upgraded needs for stainless Steel

- Sanyo Always meets user's needs with high quality products.

 
Year of Foundation                    1933. 11
Total Works Area                      815,545 m2
Total Number of Employees            2491
Product Line           
                     Bearing Steel
                     Alloy Steel
                     Carbon Steel
                     Free cutting steels
                     Stainless Steel

                     Heat Resistance Steel
                     Tool steels
                     Electromagnetic materials
                     Super Alloy
                     Steel powder
Monthly production      
                     Rod and wire    71,000 ton
                     Tube and pipe   15,000 ton
                     Totaly Monthly   86,000 ton
 

 

 ISO9001 2000 Certification

Registered Scope

Party

Date Of Reissue

Certified By

Design and Development, and Production of Bars, Wires & Wire Rods and Seamless Pipes and Tubes made of Special Steels and Non-Ferrous Metals (Nickel Metal & Nickel Alloys)

Head Office and Works, Tokyo Office, Osaka Office, Nagoya Office, Hiroshima Office, Kyusyu Sales Office

Apr. 25, 2002

JICQA

Production of Formed & Fabricated Products of Special Steels

Formed & Fabricated Products Department

Apr. 25, 2002

JICQA

ISO14001 Certification

Registered Scope

Party

Date Of Reissue

Certified By

Activities related to the manufacturing of special steel and non-ferrous metal

Head Office and Works

Apr. 14, 1997

JICQA

JICQA:JIC Quality Assurance Ltd.
   

 

 
High Clean Stainless Steel developed by Sanyo Special Steel features remarkable corrosion resistance, excellent workability, owing to higher quality, High Clean Stainless Steel, with the minimum impurities and maximum cleanliness, is the fruit of Sanyo’s renowned high technology and high productivity.

 

  

 

 With a long history of R & D activities and production efforts, Sanyo Special Steel has completed high quality High Clean Stainless Steel, using such high performance equipments as large capacity UHP electric arc furnaces, continuous caster, RSW billet rolling mill, bar and wire rod rolling mill, hot extrusion presses and cold pilger mills.

 

  

 

“HIGH CLEAN”, the evidence of superb technology and equipment

 
High Clean Stainless Steel is a high quality stainless steel with the impurities reduced to a minimum.
 
Major production techniques are
    1.   Steel making – Stabilized production by large-capacity UHP electric arc furnace
        -improved cleanliness by ladle furnace refining and vacuum degassing process
        -Mass production system by large-section vertical continuous casting
    2. Cogging – High efficient production of billets and tube rounds through the processes ranging from cogging to PSW billet rolling.
    3. Rolling – High precision finishing by state-of-the-art continuous bar and wire rod rolling
    4. Tube making – Production of seamless tubes by Ugine-Sejournet hot extrusion press
    5. Inspection – Higher quality assurance system with a great variety of nondestructive test equipment including hydrostatic tester, water immersion ultrasonic inspection machine, eddy current inspection machine.
 
High Clean Stainless Steel is the outcome of a combined use of all these innovative technologies and equipment unique to Sanyo.
Sanyo has been constantly seeking higher quality by strenuous basic and application R & D activities in conformity to users’ exacting requirements.

 
   

 

Highj quality assortments for the optimum selection according to specific requirements

Type             Properties

Corrosion resistance

Heat treatment

Magnetism

Thermal expansion

Austenitic(18Cr-8Ni)

Very Good

Solution treated

No (Yes, depending on cases)

Large

Duplex

Very Good

Solution treated

Yes

Medium

Ferritic (18Cr)

Good

Annealed

Yes

Small

Martensitic (13Cr)

Good

Annealed, quenched and tempered

Yes

Small

Precipitation hardening

Good

Solution treated, precipitation hardened

Yes (No, depending on cases)

Small

Superalloy

Very Good

Solution treated

No

Medium

 

 

 
 

Austenitic Group

The typical grade of the austenitic group is 18Cr-8Ni SUS304.

This group features superb ductility, toughness, and excel in cold workable and weldability. It is also provided with great corrosion resistance and very good properties even under low and high temperature environment.

These properties ensure application over extensive fields, ranging from the household appliances to the industrial use including buildings, auto parts, chemical and food industry, as well as unclear power plants and many other plants.

Dulpex Group

The typical grade includes SUS329J1.

The stainless steel of this group comprises a combination of austenitc and ferritic structures. High chromium content ensure very good resistance against pitting corrosion, intergranular corrosion and stress corrosion cracking of this group. Inherently with its higher strength than the austenitic group, this is rarely hardened by heat treatment.

These advantages are effectively employed extensively in chemical, petrochemical and pulp industries.

 

  

 

 

 

Ferritic Group

The typical group is the 18Cr SUS430.

The stainless steel of this group is hardly hardened by heat treatment, and can be used as annealed. It is also superior in workability and corrosion resitance to martensitic group, and its weldability is relatively very good. Because of this advantages, these products are extensively used for applications where normal corrosion resistance is required. Since nickel is not included, they are less expensive than those of the austenitic group. Application is found in kitchen wares, auto parts, water heaters, electric appliances and a variety of plant equipment.

Ferritic group also provides a superb feature of soft magnetic materials. We have successfully combined this feature with powerful corrosion resistance to develop QMR series magnetic stainless steel. These materials are used, for example, to manufacture the solenoid valves for hydraulic and air compressors and mechatronics-related parts.

Martensitic Group

Typical grades of this group are 13Cr SUS410 and 403.

The stainless steel of this group does not include nikel, so it is less expensive. Sicne it hardens by quenching, a great variety of mechanical properties are obtained by a combination of the chemical composition and heat treatment condition. These advantages ensure an extensive range of applications. It is mainly employed for machine structural parts requiring high strength, corrosion resistance, and heat resistance, typically exemplified by shafts, bolts, valves, nozzles, turbine blades, etc.

 

 

 

 

Precipitation Hardening Group

Precipitation hardening elements such as aluminum and copper have been added, besides such major elements as chromium and nikel.

As annealed condition, the product is very good in cold workability, and is superior in toughness, corrosion resistance and weldability to martensitic product. The product finds its application in the field where these advantages are fully employed; it is used, for example, as springs, hydraulic equipment parts, pump shafts, jet engine parts and structural materials of aircraft and rockets.

Superalloys, Other Newly Developed Alloys

The superalloy features extremely powerful strength and remarkable oxidization resistance under high temperature environment and stress corrosion cracking, pitting corrosion, intergranular stress corrosion.

Sanyo has also developed special alloys which exhibit marvelous performances under the critical environment which defy use of ordinary stainless steel. These alloys are extensively employed in a variety of application fields including chemical, petrochemical, nuclear and aircraft industries.

 

 

CHEMICAL COMPOSITION

 

Austenitic Group

 

 

Duplex Group
 

 

 

Ferritic Group

 

 

Martensitic Group

 

 

Precipitation Hardening Group

 

 

Super Alloys

 

 

 

PRODUCT RANGE
   

 

Rolled and forged bars

 

 

Cold Finished bars

 

 

Wire rods

 

 

Seamless tube

 

 

    

 

HIGH CLEAN BEARING STEEL - Bearings, for problems awaiting solution since 2500 years ago.

Tracing back the history to the days of ancient Greece, humans were making efforts to find out better ways to transport massive building stones and stone statues to construct shrines. The solution to this problem was to place rollers under the stone to carry them by sliding. This is, so to speak, an origin of bearings. As centuries rolled by, a prototype of the current ball bearing was born as a shaft bearing of stage coach at the dawn of the Industrial Revolution. The role bearings played as driving force in a new era is quite unfathomable.
Since then, bearings have been applied to automobiles, industrial machinery and so on. Bearings occupy an important position in the field of super precision equipment and electronic devices. To improve the state-of-the-art technology into further advanced one, bearing steel is still confronted with a great deal of demands. There is an infinite expanse of the area in which Sanyo Special Steel has to contribute.
  

 

State-of-the-art Technology in Each Process

 
The High Clean Bearing Steels are produced in the latest process closely linked with advanced technology to improve the quality characteristics and reliability required by bearing steels. To meet user needs ever changing with times, Sanyo Special Steel has been making steadfast efforts in R & D activities such as basic researches and application studies in search for higher quality. Bearing steel is repeatedly subjected to severe compressive and impact load for a long time in its application. It is essential for bearing steel to have high hardness enough to stand the load as well as a long rolling contact fatigue life.
 

High Carbon Chromium group(JIS G 4805)

 
The steel in this group is relatively inexpensive since they to not contain much expensive alloying elements. High hardness is readily achieved by quenching. Good mashinability is assured by spherodized annealing of the material. Hardenability increases in the order of SUJ1<2<4<3<5, which implies appropriate steel grades for different dimensions and wall thickness of bearings.

 
Chemical Composition
Grade C Si Mn P S Cr Mo
SUJ1 0.95~1.10 0.15~0.35 < 0.50 < 0.25 < 0.25 0.90~1.20 -
SUJ2 0.95~1.10 0.15~0.35 < 0.50 < 0.25 < 0.25 1.30~1.60 -
SUJ3 0.95~1.10 0.40~0.70 0.90~1.15 < 0.25 < 0.25 0.90~1.20 -
SUJ4 0.95~1.10 0.15~0.35 < 0.50 < 0.25 < 0.25 1.30~1.60 0.10~0.25
SUJ5 0.95~1.10 0.40~0.70 0.90~1.15 < 0.25 < 0.25 0.90~1.20 0.10~0.25
Remarks:1. Either Ni or Cu as impurities must not exceed 0.25%. Cu of wire rod must not exceed 0.20%. Mo of SUJ1, SUJ2 and SUJ3 must not exceed 0.08%2. Elements other than those given in the above Table may be added up to 0.25%
Grade Characteristics Application
SUJ1 This is usually replaced by SUJ2 because of poor hardenability due to low Cr content. Ball or roller with a diameter of 7mm or less.
SUJ2 Representative grade in high carbon chromium group. It accounts for over 90% of this group. Ussed for almost all the balls and rollers having a diameter of 25mm or less and races having a wall thickness of 25mm or less.
SUJ3 Higher intermediate hardenability between SUJ2 and SUJ3 Used for balls and rollers having a diameter of 25mm or more, and races having a thick wall.
SUJ4 Having intermediate hardenability between SUJ2 and SUJ3 Bearings having dimensions between SUJ2 and SUJ3 ones.
SUJ5 Increased hardenability by addition of Mo to SUJ3

Used for large diameter balls and rollers and heavy-wall races where use of SUJ3 will result in insufficient core hardness after heat treatment
 
Heat treatment conditions and hardenss

Grade

 Normalizing(℃)

Annealing(℃)

Quenching(℃)

Tempering(℃)

 Quenched and tempered hardness (HRC)

SUJ1

 840~900 760~800 780~820 Water cooling 150~180 > 61

SUJ2

 840~900 760~800 800~840 Oil cooling 150~180 > 62

SUJ3

 840~900 760~800

790~830 Oil cooling

 150~180 > 63

SUJ4

 840~900 760~800

800~840 Oil cooling

 150~180 > 63

SUJ5

 840~900 760~800

790~830 Oil cooling

 150~180 > 63
Case hardening alloy steels

 
In addition to the most common high Carbon Chromium types, bearing steels include case hardening alloy steels and corrosion and heat resistant steels.
 
When case-hardening alloy steels are carburized and hardened, the bearings exhibit equivalent surface hardness and wear resistance to those of high carbon chromium bearing steels with relatively soft and tough core.
High-Ni case hardening alloy steels are used for large-sized thick-walled bearings such as those for rolling mills where both high hardenability and impact toughness are required.
SCr420, SCM420, SNCM220, SNCM420, SNCM815.
Corrosion and heat resistant steels

 
Stainless bearing steel are used in the corrosion environment, highly oxidizing environment where lubricants cannot be used such as in chemical and food industries, or for medical appliances.
Heat resistant steels are used for high temperature bearings. After long-time exposure to high temperature, its hardness does not significantly decrease with good dimensional stability and long rolling contact fatique life.
SUS420J2, SUS440C, 440M, QD51, M50
 
Chemical composition
Grade C Si Mn P S Ni

Cr

 Mo W V
S53C 0.50~0.56 0.15~0.35 0.60~0.90 < 0.030 < 0.035 - - - - -
SCr420H 0.17~0.23 0.15~0.35 0.55~0.90 < 0.030 < 0.030 - 0.85~1.25 - - -
SCM420H 0.17~0.23 0.15~0.35 0.55~0.90 < 0.030 < 0.030 - 0.85~1.25 0.15~0.35 - -
SNCM220H 0.17~0.23 0.15~0.35 0.60~0.95 < 0.030 < 0.030 0.35~0.75 0.35~0.65 0.15~0.30 - -
SNCM420H 0.17~0.23 0.15~0.35 0.40~0.70 < 0.030 < 0.030 1.55~2.00 0.35~0.65 0.15~0.30 - -
SNCM815 0.12~0.18 0.15~0.35 0.30~0.60 < 0.030 < 0.030 4.00~4.50 0.70~1.00 0.15~0.30 - -
M50(AISI) 0.75~0.85 0.20~0.60 0.15~0.35 0.030~0.060 0.030~0.060   3.75~4.50 4.00~4.45 - 0.90~1.10
T1(AISI) 0.65~0.80 0.20~0.40 0.10~0.40 < 0.030 < 0.030   3.75~4.50 - 17.25~18.75 0.90~1.30
SUS440C 0.95~1.20 < 1.00 < 1.00 < 0.030 < 0.030   16.00~18.00 < 0.75 - -

 
Table of Comparision with JIS

JIS

 AISI, SAE ASTM BS DIN GOST ISO

SUJ1

 51100 - - - - -

SUJ2

 52100 - 535A99 100Cr6 IIIX15 1

SUJ3

 - A485Grade1 - - - 2

SUJ4

 - - - - - -

SUJ5

 - - - - - -

 
PRODUCT RANGE OF BEARING STEEL

 
 

Hot rolled bar

Diameter

 Length
13~210mm 3~7m
 

Forged Bar

Diameter

 Length
120~850mm 2~9m
 

Cold finished bar

Diameter

 Finished diameter (mm) Length(m) Remarks
Turned 70 ~ 830 1.0 ~ 9.0 Bar weight < 13 tons
Peeled product 10 ~ 205 3.0 ~ 7.0  
Cold drawn 6 ~ 75 3.0 ~ 6.0  
Centerless ground 4 ~ 80 2.0 ~ 4.0  
 

Super-precision rolled bar

Diameter

As hot rolled(®)

Heat treated
16 to 60 inclusive + 0.1 mm + 0.15mm
over 60 to 85 inclusive + 0.17 % +(0.17% + 0.05mm)
 

Wire rod

Diameter

 Coil Weight
Ø5.5 ~ 40mm 2t or 1t
 

Specification of wire rod

Weight

 1000, 2000kg
Inner diameter > 1000mm
Outer diameter > 1400mm
Height < 900mm Coil weight 1t
< 1800mm Coil weight 2t
Coiling direction Counter clockwise
   
 

Wire

Diameter

 Coil Weight
Ø4.4 ~ 20mm 1t
 

Wire specifications

Diameter

 Outer diameter (mm) Inner diamter(m) Height
4 to 4.5 inclusive 625 ~ 825 390 ~ 590 < 900mm
over 4.5 to 8.9 inclusive 800 ~ 1000 520 ~ 720 < 900mm
over 8.9 to 13.5 inclusive 1050 ~ 1250 745 ~ 945 < 900mm
over 13.5 to 20.0 inclusive 1155 ~ 1355 870 ~ 1070 < 900mm

 

Cut ring

Production process

 Outer diameter (mm) Wall thickness(mm) Width(mm)
Seamless Tube 

Cut

 60~170 5~30 > 25

Cut ▶ Outer diameter sizing

 60~170 5~30 > 25

Cut ▶ Cold roll forming

 75~250 5~25 20~100

 

  

 

Forged ring

 

 Outer diameter(mm) Inner diameter(mm) Width(mm)
 Forged ring 30 ~ 80 > 10 10 ~ 45
Cold roll formed 40 ~ 120 > 15 10 ~ 45

 

HEAD OFFICE & WORKS

 

3007 Nakashima, Shikama-ku, Himeji-shi, Hyogo 672-8677  Japan

 

Tel(+81) 792-35-6143, Fax (+81) 792-33-1005

 

 
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