Product Applications

Sunflag steel caters to the demands of various core sectors of the economy like Automobiles, Railways, Defense, Tractors and agricultural implements, and Engineering industry. The specialty steels for various applications are being produced by us as per National and International Standards conforming to DIN, SAE/AISI/ASTM, EN, GIS, GOST, IS grades.

Our main products comprise of the following :

  Spring Steel: This steel is used for manufacturing various types of springs and components for suspension mechanism in Automobiles and Railways. Springs are in the form of Leaf spring made out of flat bars or coil spring made out of round bars. Stabiliser bars/anti-roll bars and torsion bars for automobiles can also be manufactured out of our round bars.

A very high degree of quality, reliability and service life achieved in springs manufactured from our steel helped us in establishing our market leadership.
Sunflag Steel a pioneer in making Spring Steel, has come up with products in this category, which ensure the required fatigue life to springs used in vehicles, in the most demanding situations.

Grades :

EN45A as per BS 970 55SI7, 60SI7, 65SI7, 50CR4V2, 60CR4V2 as per IS 3195 65SI7, 50CRV4, 51CRMOV4, 60SICR7 as per DIN 17221 SUP6, SUP9, SUP9A, SUP11A as per JIS G 4801, SAE8650H

  Forging Quality Steel (Carbon steel and Alloy steel) : Forging quality steels are defined as those having following important metallurgical properties.
i)   Good surface quality
ii)  Good internal quality
iii)  Fine and uniform austenitic grain size
iv)  Good response to heat treatment
v)   Good impact toughness
vi)  Good cleanliness

Forging is a process of converting steel or metal bar or billet into a designed shape at a higher strain rate. As per the temperature of forging it can be classified as under:
i) Hot forging -- normally performed at a temperature of around 1200oC.
ii) Warm forging -- normally performed at a temperature of 650o-750oC i.e. below the recrystallisation temperature depending on steel grade.
iii) Cold forging -- Performed at room temperature without any heating. Due to high strain rates employed, the quality requirements of steels for forging application are critical, Also due to the critical nature of the actual end use forging quality steels demand a close control over the manufacturing process at all stages.

  Some of the popular forging applications are as under
Gears, Axles, Crankshafts, Connecting Rods, Pinions, Crown Wheels, Camshafts etc.
Automobile industry is the single largest user of forgings. Forgings are generally used in the transmission system of an automobile, where large forces get transferred between different parts, hence they are of vital importance.

These steels are widely used in auto, defence, railways and various manufacturing industries.
Following are the major categories of Forging Quality Steels
Plain Carbon, Carbon Maganese, Plain Chrome, Chrome - Maganese, Chrome Moly, Chrome - Nickel - Moly.

Grades :

5120,5140,5145,5150,5160,4118,4130,4135,4140,4145,4150 A182 F12 C1 II,
4340, 8620, 8640, 8627, 8615, 8617, 4027H, 4037H as per AISI / SAE


  Special / Semi Free Cutting Steel: Free Cutting or Free Machining Steels are those with enhanced machinability. The term machinability is manifested by following main characteristics :
a)  Speed of machining
b)  Surface finish of the machined components
c)  Tool life of the cutting tools employed for machining operation.
In any commercial machining operation an optimum performance of a free cutting steel in relation to above three parameters is highly desirable.
Presence of elements such as Sulphur (S), Lead (Pb), Tellurium(Te), Selenium (Se), Bismuth (Bi) in steel, impart the properties necessary for free machining. The presence of these elements basically ensures easy dispersal of chips during machining, thereby reducing the machining force, and improving tool life and surface finish of the machined component.
Sulphur and sulphur+lead bearing free cutting steels are widely used in engineering industry where the criteria for free machining have to be necessarily satisfied.
Presence of sulphur in steel leads to formation of manganese sulphides which are basically responsible for free machining properties.
Maganise is an essential alloying element in Free Cutting Steel apart from sulphur. It is the composition and morphology of manganese sulphides which decides the machining performance of a Free Cutting Steel.
The composition of Manganese Sulphides (MnS) is controlled by the individual levels of manganese and sulphur, Mn/S ratio and the deoxidation practice employed in the manufacture of steel.
The morphology of MnS is defined by the parameter length/width ratio, popularly known as L/W ratio for sulphides. Other elements such as phosphorous, nitrogen, oxygen also play a supplementary role in deciding the overall machining performance of free cutting steel.

Grades of Special Free Cutting Steels: 11C10S25, 220M07, EN1A-Pb, 12L14, SUM24L, 9SMn28K, 9SMnPb28K, 1215.
Grades of Semi Free Cutting Steels: SU1A28, R10S10U, 45S20U, SAE1117, SAE1118, SAE1137, SAE1141, SAE1144, EN8M.

  Ball Bearing Steel: Ball bearing is a vital component used in transmission of dynamic loads in machine parts that continously move. A bearing helps reduce the friction force between the moving parts, allowing smooth transfer of motion.
Due to its typical application, the bearing is under continous fatigue strain during service and its maintenance is of vital importance in its overall service life. All bearings carry a guarantee of life in service.
Automobiles, railways, earth moving, defense, aircraft are the major application areas for bearings. Apart from these, areas of power generation, compressors and any other moving machinery parts call for application of bearings.

Grades :

SAE52100, 100Cr6, 103Cr2, SUJ 2, EN31.

  Microalloyed Steel: Microalloyed Steels were developed in Germany in the Year 1972, with the primary aim of saving in the cost of Heat Treatment. The conventional heat treatments like Normalising, Hardening & Tempering were intensive.
The Microalloyed steels were developed, to avoid the heat treatment after Hot Forming Operation. The Strength Properties obtained in the Microalloyed Steels are matching with the properties obtained in the Conventional Steels after hardening & tempering. The Microalloyed Steels now find wide acceptance as against the conventional Alloy Steels.
These Steels are now used by the Automobile sector for Fracture Splitable Connecting Rods, Crank Shafts, Ball Joints, Transmission Assemblies, etc.
The fatigue strengths of the Microalloyed Steels are generally comparable to those of the Quenched and Tempered Steels of the same hardness. The Microalloyed Steels offer suitable replacements for Quenched and Tempered Steels for Automobile components, which require moderate strength and fatigue properties.

Grades :

C70S6, 38MnSiVS5, 30MnVS6, SAE 11V41, SAE 1137V, S48CS1V.

  Stainless Steel: Stainless steel is steel containing 10.5% or more of chromium, which imparts it with corrosion resistant properties, by the formation of an impervious layer of chromium oxide on the surface.
Stainless Steel finds many applications, which include: Construction industry, Boiler industry, Pumps and Shaft applications, Flangs, Surgical applications, Cutlery, Weaving and Knitting Wires, High Temperature Corrosion Resistance Chemical and Petrochemical industries, Springs etc.
Types of Stainless Steel : Martensitic, Austenitic, Ferritic, Deplex, Precipitation Hardened.

Grades : AISI 302, 302HQ, 303, 304, 304L, 304N, 304LN, 308, 308LE, 309, 310, 316, 316L, 316Ti, 316N, 316LN, 317, 321, 347, 201, 204Cu, 410, 416, 414, 420, 431, 409(Cb), 430, 430L, 446, 17-4 PH (Type 630), 15-5 PH (Type XM-12), W.No. 1.4542

  Cold Forging Quality Steels: This process is mainly used for manufacturing fasteners and similar components.
Cold forging and cold extrusion are the two main processes used for manufacturing these type of components.
These components are mainly used in the automotive industry.
The starting raw material for these components is in the form of wire rods.
The cold forging or cold extrusion process imparts following advantages to the components manufacturing:
1. Good surface finish.
2. High as forged strength.
3. No trimming and scaling loss
4. Better yield
5. Ready to use surface quality especially for process of plating which is necessary to ensure corrosion resistance.
6. Good productivity, which is essential due to large volume requirements.
These process characteristics necessitate a proper manufacturing quality of cold forging quality wire rods. The important features of these quality requirements area as under:
1. Excellent surface quality ensuring zero defect situation so that forged components have no defects.
2. Good control over ovality to ensure smooth forging process.
3. Good control over mechanical properties such as tensile strength and reduction area to ensure proper cold forgeability and productivity.
4. Completely descaled surface to avoid forging defects such as scale pits and resultant surface roughness.
5. Suitable metallurgical structure to ensure proper machinability level.
6. Good and uniform response to heat treatment since the components are always treated in bulk.

Grades : SAE/AISI 10B21, AISI 15B25, 19MnB4M, SAE/AISI 15B41, AISI 10B36M, DIN 36CrB4, 51B37.



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