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Optimisation of High Yield Steel Coil Processing Characteristics / BENJAMIN VALENTINE

Swansea University Author: BENJAMIN VALENTINE

Abstract

Ribbed steel for the reinforcement of concrete has a characteristic high yield strength of at least 500 N/mm2, bonds well to concrete, and is ductile. Reinforcing steel is produced at Celsa Steel UK in coils approximately 1.5 km in length, which are post processed by customers to create reinforcemen...

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Published: Swansea University, Wales, UK 2023
Institution: Swansea University
Degree level: Master of Research
Degree name: MSc by Research
Supervisor: Coleman, M., Sackett, E., Thomas, S., and Hagg, C.
URI: https://cronfa.swan.ac.uk/Record/cronfa69345
first_indexed 2025-04-24T11:07:25Z
last_indexed 2025-04-25T05:20:58Z
id cronfa69345
recordtype RisThesis
fullrecord <?xml version="1.0"?><rfc1807><datestamp>2025-04-24T12:07:23.5882429</datestamp><bib-version>v2</bib-version><id>69345</id><entry>2025-04-24</entry><title>Optimisation of High Yield Steel Coil Processing Characteristics</title><swanseaauthors><author><sid>9e615c7d04b5e43e07a34f198a8c5aff</sid><firstname>BENJAMIN</firstname><surname>VALENTINE</surname><name>BENJAMIN VALENTINE</name><active>true</active><ethesisStudent>false</ethesisStudent></author></swanseaauthors><date>2025-04-24</date><abstract>Ribbed steel for the reinforcement of concrete has a characteristic high yield strength of at least 500 N/mm2, bonds well to concrete, and is ductile. Reinforcing steel is produced at Celsa Steel UK in coils approximately 1.5 km in length, which are post processed by customers to create reinforcement structures used in construction projects. Post processing involves straightening and bending to make complex shapes, so consistent steel properties are required for high rates of production. Variations in the properties of a two-tonne coil can be caused during the manufacturing process and effect post processing as customers&#x2019; machines need frequent adjustments to shape the steel into the correct dimensions. When the coil needs too much adjustment, the coil is scrapped. This thesis identifies and evaluates the key properties effecting reinforcing steel post processing, then discusses the manufacturing processes that could be improved to better control the consistency of these properties.Through analysis of Celsa Steel UK&#x2019;s historical data on yield strength in coils, it was found that sections of steel on the external layers of coils have up to 95 MPa greater yield strength than steel in the core of the coil. Increased cooling rate on the outside of the coil, compared to the core, is suggested to cause this variation.Scanning electron microscopy techniques were used to compare grain size, microstructure, composition, and texture between steel samples collected from customers of Celsa Steel UK. Samples that were rejected by customers were compared with samples that behaved consistently. Microstructure and composition were relatively consistent between all samples while grain size varied between 3 &#xB5;m and 5 &#xB5;m. This grain size variation is likely to be related to varying cooling rates. Texture was relatively randomised in all samples, and many showed a slight preference in the &lt;110&gt; orientation, indicating a weak rolling texture.As there were no significant differences in the above microstructural properties, an FEA Ansys model was constructed to investigate the effect of cross-sectional consistency on the bending behaviour during customer post processing. Simulations of bending a 12mm reinforcing steel bar with 0.8mm variation in perpendicular cross-sectional diameters showed 1.46 mm out of plane deflection, 100 mm from bend. For a 500 mm by 500 mm square, this out of plane behaviour would deform the shape by 73 mm perpendicular to the intended plane, similar to that seen by customers.</abstract><type>E-Thesis</type><journal/><volume/><journalNumber/><paginationStart/><paginationEnd/><publisher/><placeOfPublication>Swansea University, Wales, UK</placeOfPublication><isbnPrint/><isbnElectronic/><issnPrint/><issnElectronic/><keywords>Steel, Metallurgy, Microscopy, Quenching, Bending</keywords><publishedDay>27</publishedDay><publishedMonth>3</publishedMonth><publishedYear>2023</publishedYear><publishedDate>2023-03-27</publishedDate><doi/><url/><notes/><college>COLLEGE NANME</college><CollegeCode>COLLEGE CODE</CollegeCode><institution>Swansea University</institution><supervisor>Coleman, M., Sackett, E., Thomas, S., and Hagg, C.</supervisor><degreelevel>Master of Research</degreelevel><degreename>MSc by Research</degreename><degreesponsorsfunders>Celsa Steel UK Group, European Social Fund</degreesponsorsfunders><apcterm/><funders>Celsa Steel UK Group, European Social Fund</funders><projectreference/><lastEdited>2025-04-24T12:07:23.5882429</lastEdited><Created>2025-04-24T11:59:38.4064306</Created><path><level id="1">Faculty of Science and Engineering</level><level id="2">School of Engineering and Applied Sciences - Materials Science and Engineering</level></path><authors><author><firstname>BENJAMIN</firstname><surname>VALENTINE</surname><order>1</order></author></authors><documents><document><filename>69345__34090__7aadefd712044cd191680c4fc3efa2f3.pdf</filename><originalFilename>2021_Valentine_B.final.69345.pdf</originalFilename><uploaded>2025-04-24T12:06:39.3221343</uploaded><type>Output</type><contentLength>19967596</contentLength><contentType>application/pdf</contentType><version>E-Thesis &#x2013; open access</version><cronfaStatus>true</cronfaStatus><documentNotes>Copyright: The Author, Benjamin Valentine, 2021</documentNotes><copyrightCorrect>true</copyrightCorrect><language>eng</language></document></documents><OutputDurs/></rfc1807>
spelling 2025-04-24T12:07:23.5882429 v2 69345 2025-04-24 Optimisation of High Yield Steel Coil Processing Characteristics 9e615c7d04b5e43e07a34f198a8c5aff BENJAMIN VALENTINE BENJAMIN VALENTINE true false 2025-04-24 Ribbed steel for the reinforcement of concrete has a characteristic high yield strength of at least 500 N/mm2, bonds well to concrete, and is ductile. Reinforcing steel is produced at Celsa Steel UK in coils approximately 1.5 km in length, which are post processed by customers to create reinforcement structures used in construction projects. Post processing involves straightening and bending to make complex shapes, so consistent steel properties are required for high rates of production. Variations in the properties of a two-tonne coil can be caused during the manufacturing process and effect post processing as customers’ machines need frequent adjustments to shape the steel into the correct dimensions. When the coil needs too much adjustment, the coil is scrapped. This thesis identifies and evaluates the key properties effecting reinforcing steel post processing, then discusses the manufacturing processes that could be improved to better control the consistency of these properties.Through analysis of Celsa Steel UK’s historical data on yield strength in coils, it was found that sections of steel on the external layers of coils have up to 95 MPa greater yield strength than steel in the core of the coil. Increased cooling rate on the outside of the coil, compared to the core, is suggested to cause this variation.Scanning electron microscopy techniques were used to compare grain size, microstructure, composition, and texture between steel samples collected from customers of Celsa Steel UK. Samples that were rejected by customers were compared with samples that behaved consistently. Microstructure and composition were relatively consistent between all samples while grain size varied between 3 µm and 5 µm. This grain size variation is likely to be related to varying cooling rates. Texture was relatively randomised in all samples, and many showed a slight preference in the <110> orientation, indicating a weak rolling texture.As there were no significant differences in the above microstructural properties, an FEA Ansys model was constructed to investigate the effect of cross-sectional consistency on the bending behaviour during customer post processing. Simulations of bending a 12mm reinforcing steel bar with 0.8mm variation in perpendicular cross-sectional diameters showed 1.46 mm out of plane deflection, 100 mm from bend. For a 500 mm by 500 mm square, this out of plane behaviour would deform the shape by 73 mm perpendicular to the intended plane, similar to that seen by customers. E-Thesis Swansea University, Wales, UK Steel, Metallurgy, Microscopy, Quenching, Bending 27 3 2023 2023-03-27 COLLEGE NANME COLLEGE CODE Swansea University Coleman, M., Sackett, E., Thomas, S., and Hagg, C. Master of Research MSc by Research Celsa Steel UK Group, European Social Fund Celsa Steel UK Group, European Social Fund 2025-04-24T12:07:23.5882429 2025-04-24T11:59:38.4064306 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering BENJAMIN VALENTINE 1 69345__34090__7aadefd712044cd191680c4fc3efa2f3.pdf 2021_Valentine_B.final.69345.pdf 2025-04-24T12:06:39.3221343 Output 19967596 application/pdf E-Thesis – open access true Copyright: The Author, Benjamin Valentine, 2021 true eng
title Optimisation of High Yield Steel Coil Processing Characteristics
spellingShingle Optimisation of High Yield Steel Coil Processing Characteristics
BENJAMIN VALENTINE
title_short Optimisation of High Yield Steel Coil Processing Characteristics
title_full Optimisation of High Yield Steel Coil Processing Characteristics
title_fullStr Optimisation of High Yield Steel Coil Processing Characteristics
title_full_unstemmed Optimisation of High Yield Steel Coil Processing Characteristics
title_sort Optimisation of High Yield Steel Coil Processing Characteristics
author_id_str_mv 9e615c7d04b5e43e07a34f198a8c5aff
author_id_fullname_str_mv 9e615c7d04b5e43e07a34f198a8c5aff_***_BENJAMIN VALENTINE
author BENJAMIN VALENTINE
author2 BENJAMIN VALENTINE
format E-Thesis
publishDate 2023
institution Swansea University
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
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description Ribbed steel for the reinforcement of concrete has a characteristic high yield strength of at least 500 N/mm2, bonds well to concrete, and is ductile. Reinforcing steel is produced at Celsa Steel UK in coils approximately 1.5 km in length, which are post processed by customers to create reinforcement structures used in construction projects. Post processing involves straightening and bending to make complex shapes, so consistent steel properties are required for high rates of production. Variations in the properties of a two-tonne coil can be caused during the manufacturing process and effect post processing as customers’ machines need frequent adjustments to shape the steel into the correct dimensions. When the coil needs too much adjustment, the coil is scrapped. This thesis identifies and evaluates the key properties effecting reinforcing steel post processing, then discusses the manufacturing processes that could be improved to better control the consistency of these properties.Through analysis of Celsa Steel UK’s historical data on yield strength in coils, it was found that sections of steel on the external layers of coils have up to 95 MPa greater yield strength than steel in the core of the coil. Increased cooling rate on the outside of the coil, compared to the core, is suggested to cause this variation.Scanning electron microscopy techniques were used to compare grain size, microstructure, composition, and texture between steel samples collected from customers of Celsa Steel UK. Samples that were rejected by customers were compared with samples that behaved consistently. Microstructure and composition were relatively consistent between all samples while grain size varied between 3 µm and 5 µm. This grain size variation is likely to be related to varying cooling rates. Texture was relatively randomised in all samples, and many showed a slight preference in the <110> orientation, indicating a weak rolling texture.As there were no significant differences in the above microstructural properties, an FEA Ansys model was constructed to investigate the effect of cross-sectional consistency on the bending behaviour during customer post processing. Simulations of bending a 12mm reinforcing steel bar with 0.8mm variation in perpendicular cross-sectional diameters showed 1.46 mm out of plane deflection, 100 mm from bend. For a 500 mm by 500 mm square, this out of plane behaviour would deform the shape by 73 mm perpendicular to the intended plane, similar to that seen by customers.
published_date 2023-03-27T05:27:56Z
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score 11.444473

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