Title of Invention

HIGH DIMENSIONAL CORED WIRES CONTAINING OXYGEN REMOVERS AND PROCESS FOR MAKING THE SAME

Abstract Conventionally de-oxidation of steel was carried out by the addition of ferro-alloys or aluminium ingots, bars or solid aluminium wire. For bars and ingots the recovery (i.e. ratio of actual quantity and theoretical amount of aluminium) was poor, resulting in greater aluminium consumption. In case of aluminium wire, the recovery was better, but feeding time was more and often the wire could not reach the depth of molten steel bath. The present invention attempts to overcome the above drawbacks and provides high dimensional cored wires containing oxygen removers formed from cold-rolled steel sheet, said oxygen remover or de-oxidant material being in finely divided granular or powdery form coated with a protective coating material such as herein described, the diameter of the said cored wires varying between 13 and 4 0 mm, preferably between 19 and 34 mm, and the coated de-oxidant material filled in the core is held in place in compacted form by the seaming locks provided during formation of the said cored wires after filling. This invention also describes a process for producing the above cored wires containing the de-oxidant coated with a protective coat in a compacted form ensuring better recovery and rapid feeding of the de-oxidant in predetermined amounts.
Full Text The present invention relates to high dimensional cored
wires containing oxygen removers and process for making the same.
More particularly this invention pertains to high dimensional
cored wires filled with an oxygen removing material selected from
the group of aluminium, -titanium, zirconium and calcium silicide,
preferably fine granules of reactive aluminium powder, having a
coat of inorganic or/and organic material, or even without a
coating and simple granules, and a process for preparing such
high dimensional cored wires.
De-oxidation plays an important role in the process of steel
making, for which a number of deoxidants have been conventionally
used. The term de-oxidant means a chemical compound, alloy or
element which will remove the active oxygen present in the liquid
metal and form an oxide as its final product, usually as a
distinct phase and easily separable from the liquid metal Oxygen,
if present in steel in the active/elemental form will result in
pinholes and blowholes in the cast product as well as obstruct
the process of continuously casting the steel in the modern
continuous casting machines. Steel makers are in regular searen
of a better and more economical method for removing the oxygen in
the steel, which will ultimately reduce the consumption of
deoxidants.
For doing the primary de-oxidation or the bulk removal of
oxygen, (primary killing) in the steel from a higher level of,
say, 800-2000 ppm and above, to a lower level of to around

100-200 ppm, alloys such as "Ferro-Silicon", "Ferro-Manganese",
"Silico-Manganese" and "Coke" are used, though in bulk, and these
materials have served the purpose fairly well. These ferro-
alloys or compounds have limitation on the extent to which they
can be used in steel making and are limited to the extent of the
specification that is allowed in the steel. In almost all grades
of steel, silicon and manganese elements are used in various
forms for the primary deoxidation along with aluminium in various
forms such as bars, ingots, cubes or solid wires, etc.
For secondary treatment of steel for the purpose of removing
the remnant of oxygen, a number of de-oxidants selected from the
group of aluminum, titanium and calcium silicide has been used.
However, aluminium has been found to be the most suitable
de-oxidant for two reasons, e.g. (i) affinity of aluminium for
active oxygen, and (ii) the requirement of presence of aluminium
in predetermined amounts in some grades of steel in the cast
product. Aluminium is capable of removing oxygen present in
molten steel at very low levels of around 4 p.p.m. or even less.
It is also the most economical de-oxidiser element, alloy or
compound known at present.
Previously, primary deoxidation was carried out by the addition
of aluminium ingots or bar3 and solid wires of dimension of
13 mm, and secondary or final deoxidation by adding ingots, notch
bars and sometimes even solid aluminium wire. Addition through
solid aluminium represents a higher percentage of recovery of

aluminium compared to bars and ingots. In this specification,
unless otherwise specified, the term 'recovery' defines the
ratio of the acual quantify of aluminium to be added to remove
the active oxygen to the theoretical amount of aluminium required.
For bars and ingots, the recovery was very poor and accordingly
consumption of aluminium increased. In case of solid aluminium
wire, though the recovery was better than bars and ingots, but
feeding time was more. The normal size of the aluminium wire that
can be injected into the molten steel is around 3, 6, 9, 13
16 mm. For the high dimensional wires proposed in the present
invention, feeding of solid aluminium wire as available new
becomes very difficult to feed with the conventional wire feeders.
The other problem encountered with solid aluminium wire is
that due to the high temperatures encountered in steel making,
aluminium becomes very soft due to the high temperatures and is
not able to penetrate deeply into the molten steel bath which
consequently results in lower recovery.
The present invention aims at overcoming the foregoing
shortcomings of the prior art and carry out production of steel
more effectively maintaining an optimum level of aluminium in
steel.
This invention also has the objective to further enhance the
recovery of aluminium, simultaneously reducing the quantum of
consumption and time of feeding of aluminium to liquid metal.

A further object of the present invention is to provide a
technique to use aluminium scraps as de-oxidant after converting
them into granules followed by coating with a protective material
like graphite, low density polythene, polyamide, low molecular
weight vinyl acetate paolymer, talc, steatite, calcium silicide,
powdered lime, and the like to prevent fusion or adhesion of the
granular particles into a single mass while being pressed and
drawn in the wire. It is also possible to use the aluminium
granules without coating.
A still further object of this invention is to provide high
dimensional cored wires containing aluminium granules coated
with graphite which while being drawn, the contents become tightly
packed, thereby imparting dimensional rigidity and stiffness to
the wire.
Another object of the present invention is to provide a
process for preparing high dimensional cored wires containing
de-oxidants in granular form and coated with a protective coating
to prevent sticking and fusing into a single mass while being
pressed and drawn into wire.
The foregoing objectives are fulfilled by the present invention
which relates to high dimensional cored wires containing oxygen
removers formed from cold-rolled steel sheet, said oxygen removers
or deoxidant material being in finely divided granular or powdery
form coated with a protective coating material such as herein

described, the diameter of said cored wires varying between
13 and 40 mm, preferably between 19 and 34 mm, and the coated
de-oxidant material filled in the core is held in place in
compacted form by the seaming locks provided during the formation
of the said wire after filling. The wire can also be made by
totally welding the sheath so that there is no seam.
The subject invention also relates to a process for preparing
high dimensional cored wires containing oxygen removers as defined
above, comprising the steps of -
(a) slitting cold-rolled steel sheet of thickness
varying between 0.2 and upto 1 mm and required width of
90-110 mm, providing for the double seaming locks;
(b) feeding the slit coils into forming rolls which
gives the slits the desired near round shape with diamten
of 13 to 40 mm, preferably between 19 and 34 mm;
(c) filling reactive aluminium powder/granules or other
de-oxidants from bunkers or feeders into the blank spaces
of the wire;
(d) sealing the powder/granule filled wire, either singly
or doubly, by the time it conies out of the last forming roll;
(e) coiling the thus formed wire over a mandrel with inner

diameter varying from 200 ram to 2.5 metres in diameter,
generally of around 1 metre in diameter, depending on customer
requirement;
(f) applying a thin film of oil or anti-rust solution to
the exposed surface or outer layer of the coil to prevent
rust formation, and
(g) strapping and/or wrapping the coils with plastic/stretch
film for preventing moisture ingress and then placing over
wooden or steel pallets.
As pointed out earlier, de-oxidants may be selected from
metallic, aluminium, titanium, zirconium and calcicum silicade,
but aluminium has been found to give best results as the oxide
f—
formed may be removed easily due to phase separation and ite
refractoriness. Aluminium is used in granular or powdery form,
coated with graphite. Scrap aluminium obtained from discarded
used beverage cans, sheets/foils/strips/old electrical cable and
the like are smelted or shredded and converted into granular form
followed by application of a protective coating material like
graphite, talc, lime stone dust, calcite, steatite, LDP (low
density polyethylene) and the like to prevent fusion or adhesion
of granules at the time of being pressed and drawn in the wire.
The lacquer coating on the used be verage cans also serve the
purpose of protective coating. Size of aluminium granules should
be optimally be around 40 mesh, but finer or coarser size

granules may just as well be used; however, care should be taken
to prevent handling loss. While drawing the aluminium granule-
filled wire, the contents become tightly packed, thereby imparting
dimensional rigidity and stiffness to the wire, ensuring ease of
handling the coil.
Deoxidation with aluminium by changing the form of aluminum
addition, which is carried out by injecting high diemnsional
cored wire filled with highly reactive aluminium in fine gran
form and coated with an organic material like graphite for better
recovery and achieving the optimum level of oxygen and aluminium
with lesser consumption of aluminium are a unique feature of this
invention. The coating is not limited to organic materials but
can also include inorganic coating materials like calcium oxide,
talc, chalk powder, and the like. De-oxidation in accordance with
the present invention can be carried out both in the primary and
the secondary levels, as per requirement of the steel maker.
As pointed out earlier, aluminium powder is converted into
fine granules and then coated with an inert organic coating
material like graphite flakes or any organic or inorganic coatina
material to prevent the aluminium powder from sticking and fusing
into a single mass while being pressed and drawn in the wire.
While drawing the aluminium powder filled wire, the contents
become tightly packed, thereby imparting dimensional rigidity

and stiffness to the wire. This also ensures ease of handling the
coil.
A notable feature of this invention is to use scrap aluminium
of any grade in granular or powdered form as the de-oxidant,
suitably coated with organic or inorganic coating material as
described hereinbefore. Use of scrap/waste aluminium bodies
effectively adds to the economy of the overall process.
As an additional feature of this invention, winding of the
powder filled coil is subjected to 'coreless coiling' so that the
coil can be uncoiled from inner diameter of the stationary coil,
generally called a "flipping coil", either vertical or horizontal.
The coil can also be made into a spool with a core made of either
wooden, synthetic, metal any such material.
The novel product of this invention, namely, high dimensional
cored wire filled with fine granules of aluminium powder coated
with graphite and securely held inside, is provided with seaming
locks. By 'high dimensional' it is implied that dimensions of the
cored wire ranges between 13 and 40 mm, optimally between 19 mm
and 34 mm, and the internal diameter of the wound wire over the
mandrel may vary between 200 mm to 2.5 meters and the weight of
each coil may range between 1 MT to around 20 BT, depending on
customer requirement.
The present invention will be further illustrated by the

experimental data included in the following Example, but it is to
be understood that the invention is not restricted to the results
given therein.


Various advantages of the products of the present invention
may be briefly outlined as under :
1. An increasing amount of de-oxidant like aluminium can be
filled per unit length of wire, and as more material is
compacted per meter of wire of larger dimension, the cost
of the steel sheathing becomes less.
2. There is substantial rise in the feeding rate, thereby
saving feeding time and resulting in an enhanced time available
for steel making.
3. Due to larger dimension, better rigidity and stiffness, the
high dimensional wire allows for deeper penetration into
steel, thereby resulting in better recovery and homogenization
of aluminium.
4. Graphite coated fine granules of aluminium is used as filler
material for making high dimensional cored wire (known as
"REACTIVE ALUMINIUM"), which results in an estimated 15-25%
higher recovery than the conventional solid aluminium wire.
5. Since the aluminium cored wire is of "flipping type", there
is a saving on the conversion cost in converting the solid
aluminium wire into "flipping type".
6. Lesser consumption of aluminium in-turn will reduce the

production cost of steel, particularly in view of the use or
scrap aluminium of any grade and coated with protective
coating material.
7. Less consumption of packing material brings down production
cost.
As the present invention may be embodied in several forms
without departing from the spirit or essential characteristics
thereof, it should also be understood that the above-described
experimental data are not limited by any of the details of
the foregoing description, unless otherwise specified, but
rather should be construed broadly within its spirit and
ambit as defined in the claims appended hereinafter, and
therefore all changes and modifications that fall within
the meets and bounds of the claims, or equivalences of such
meets and bounds, are therefore intended to be embraced by
the appended claims.

I claim :
1. High dimensional cored wires containing oxygen removers formed from
cold-rolled steel sheet, said oxygen remover or de-oxidant material being in finely
divided granular or powdery form coated with a protective coating material such
as herein described, the diameter of the said cored wires varying between 13 and
40 mm, preferably between 19 and 34 mm, and the coated de-oxidant material
filled in the core is held in place in compacted form by the seaming locks provided
during formation of the said cored wires after filling.
2. High dimensional cored wires as claimed in Claim 1, wherein finely divided
granules of aluminium powder coated with graphite is used as the de-oxidant.
3. High dimensional cored wires as claimed in Claims 1 and 2, wherein there
is used scrap aluminium sheets, foils, strips and the like as the de-oxidant,
shredded and converted into granular/powdery form, followed by application of
a protective coating material like graphite, talc, steadite, lime stone dust, calcite,
LDP and the like to prevent fusion or adhesion of granules at the time of being
pressed and drawn in the wire.
4. High dimensional cored wires as claimed in Claim 3, wherein while drawing

aluminium powder/granule filled wire, the contents become tightly packed,
thereby imparting dimensional rigidity and stiffness to the wire, ensuring ease of
handling the coil.
5. A process for preparing high dimensional cored wires containing oxygen
removers as claimed in the preceeding claims, comprising the steps of-
(a) slitting cold-rolled steel sheet of thickness varying between 0.2
and upto 1 mm and required width of 90-110 mm, providing for
the double seaming locks;
(b) feeding the slit coils into forming rolls which gives the slits the desired
near round shape with diameter of 13 to 40 mm, preferably between
19 and 34 mm;
(c) filling reactive aluminium powder/ granules or other de-oxidants from
bunkers or feeders into the blank spaces of the wire;
(d) sealing the powder/granule filled wire, either singly or doubly, by
the time it comes out of the last forming roll;

generally of around 1 metre in diameter;
(f) applying a thin film of oil or anti-rust solution to
the exposed surface or outer layer of the coil to prevent
rust formation, and
(g) strapping and/or wrapping the coils with plastic/streteh
film for preventing moisture ingress and then placing over
wooden or steel pellets.

6. A process as claimed in Claim 5, wherein the thickness
cold-rolled steel sheet (DD and soft grade) varies between
and 1 mm, and weight of each coil varies between 1MT and 20MT
7. A process as claimed in Claims 5 and 6, wherein the diameter
of the formed wire varies between 13 and 40 mm, preferably
between 19 and 34 mm.
8. A process as claimed in Claims 5 to 7, wherein winding of the
de-oxidant filled coil is subjected to coreless winding thereby
allowing the said coil to be unwinded or uncoiled from the inner
diameter of the stationary coil.
9. A process for preparing high dimensional cored wires containing oxygen removers, substantially as hereinbefore described.
10. High dimensional cored wires containing oxygen removers, substantially as hereinbefore described with particular reference to the illustrative example.


Conventionally de-oxidation of steel was carried out by the
addition of ferro-alloys or aluminium ingots, bars or solid
aluminium wire. For bars and ingots the recovery (i.e. ratio of
actual quantity and theoretical amount of aluminium) was poor,
resulting in greater aluminium consumption. In case of aluminium
wire, the recovery was better, but feeding time was more and
often the wire could not reach the depth of molten steel bath.
The present invention attempts to overcome the above drawbacks
and provides high dimensional cored wires containing oxygen
removers formed from cold-rolled steel sheet, said oxygen remover
or de-oxidant material being in finely divided granular or powdery
form coated with a protective coating material such as herein
described, the diameter of the said cored wires varying between
13 and 4 0 mm, preferably between 19 and 34 mm, and the coated
de-oxidant material filled in the core is held in place in
compacted form by the seaming locks provided during formation of
the said cored wires after filling.
This invention also describes a process for producing the
above cored wires containing the de-oxidant coated with a protective
coat in a compacted form ensuring better recovery and rapid
feeding of the de-oxidant in predetermined amounts.

Documents:

00725-kol-2006-abstract.pdf

00725-kol-2006-claims.pdf

00725-kol-2006-correspondence-1.1.pdf

00725-kol-2006-description(complete).pdf

00725-kol-2006-form-2-1.1.pdf

00725-kol-2006-form-5.pdf

0725-kol-2006-assignment.pdf

0725-KOL-2006-CORRESPONDENCE OTHERS 1.2.pdf

0725-kol-2006-correspondence others.pdf

0725-kol-2006-description (provisional).pdf

0725-kol-2006-form1.pdf

0725-kol-2006-form2.pdf

0725-kol-2006-form3.pdf

0725-KOL-2007-CORRESPONDENCE OTHERS 1.2.pdf

725-KOL-2006-(18-07-2012)-CORRESPONDENCE.pdf

725-KOL-2006-(18-07-2012)-OTHERS.pdf

725-KOL-2006-CORRESPONDENCE.pdf

725-KOL-2006-DESCRIPTION (PROVISIONAL).pdf

725-KOL-2006-EXAMINATION REPORT.pdf

725-kol-2006-FORM 18.pdf

725-KOL-2006-FORM 3.pdf

725-KOL-2006-FORM 5.pdf

725-KOL-2006-GPA.pdf

725-KOL-2006-GRANTED CLAIMS.pdf

725-kol-2006-GRANTED SPECIFICATION.pdf

725-KOL-2006-GRANTED-ABSTRACT.pdf

725-KOL-2006-GRANTED-DESCRIPTION (COMPLETE).pdf

725-KOL-2006-GRANTED-FORM 1.pdf

725-KOL-2006-GRANTED-FORM 2.pdf

725-KOL-2006-PA.pdf

725-KOL-2006-REPLY TO EXAMINATION REPORT.pdf

725-KOL-2006.pdf


Patent Number 249245
Indian Patent Application Number 725/KOL/2006
PG Journal Number 41/2011
Publication Date 14-Oct-2011
Grant Date 12-Oct-2011
Date of Filing 20-Jul-2006
Name of Patentee GODA SURYA NARAYAN
Applicant Address BB-8, 7&8 AREA, CIVIL TOWNSHIP, ROURKELA, 769004, ORISSA
Inventors:
# Inventor's Name Inventor's Address
1 GODA SURYA NARAYAN BB-8, 7&8 AREA, CIVIL TOWNSHIP, ROURKELA, 769004, ORISSA
PCT International Classification Number C23C8/12
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA