CARBON CORED WIRE
A Game-Changer in Steelmaking
A Game-Changer in Steelmaking
Carbon cored wire is a kind of cored wire used to adjust carbon volume in the production of high-carbon steels, alloy steels, and ductile iron during metallurgical processes,
including ladle metallurgy and secondary steelmaking. The precise addition of carbon helps in achieving desired metallurgical properties such as hardness, tensile strength,
and ductility. This is essential for producing steel that meets specific industry standards and applications.
Carbon cored wire consists of a steel stripe filled with a carbon powder core. The wire is produced by encasing the carbon powder within a thin steel strip,
which is then rolled and welded into a cylindrical shape. The carbon powder can be tailored to specific requirements, allowing for precise adjustments to the composition of
the molten metal.
Feeding Process: Carbon cored wire is introduced into the molten metal using an automated wire feeding system. The system controls the rate and amount of carbon cored wire fed into
the molten metal, ensuring precise additions. As the Carbon cored wire enters the high-temperature environment, the steel sheath melts rapidly, releasing the carbon into the molten
metal.
Chemical Reaction: Upon release, the carbon core dissolves into the molten metal. The high temperature of the molted metal facilitates quick and efficient dissolution, ensuring that the added carbon
is uniformly distributed throughout the metal. This controlled addition minimizes oxidation and other unwanted reactions, maximizing the efficiency of the process.
Carbon cored wire technology has revolutionized steel production by providing a precise, efficient, and cost-effective method for adding carbon to molten metal in steelmaking
processes and enhancing the control over the final composition and properties of steel.
Applications of Carbon cored wire in steelmaking The main functions of Carbon cored wire in steelmaking
Applications of Carbon cored wire in steelmaking 1. Precise Addition of Carbon:
Control of Carbon Content: Carbon cored wire allows for precise control over the carbon content in the molten steel, essential for achieving the desired mechanical properties and
specifications of the final product.
Homogeneous Distribution: The carbon is uniformly distributed throughout the molten metal, ensuring consistency in the composition and properties of the steel.
2. Reduction of Non-Metallic Inclusions:
Cleaner Steel: The use of carbon cored wire helps in reducing non-metallic inclusions, which can compromise the mechanical properties and quality of the steel.
Improved Mechanical Properties: Cleaner steel with fewer inclusions leads to better mechanical properties such as strength, ductility, and toughness.
3. Enhanced Efficiency and Yield:
Minimized Carbon Loss: Traditional methods of adding carbon can result in significant losses due to oxidation. Cored wire minimizes these losses, ensuring more efficient use of
materials.
Optimized Alloying: The precise addition of carbon and other alloying elements optimizes the alloying process, leading to better yield and less waste.
4. Cost-Effectiveness:
Reduced Material Wastage: The efficient and precise addition process reduces wastage of carbon and other materials, leading to cost savings.
Lower Labor Costs: Automation of the wire feeding process reduces the need for manual intervention, lowering labor costs and improving production efficiency.
5. Improved Product Quality:
Consistency and Uniformity: The precise control over the addition process ensures consistent and uniform quality in the final steel product.
Enhanced Properties: The optimized carbon content and reduced inclusions improve the mechanical and physical properties of the steel, making it suitable for high-performance applications.
6. Flexibility and Versatility:
Adaptability to Different Processes: Carbon cored wire can be used in various metallurgical processes, including ladle metallurgy, secondary steelmaking, and refining.
Customization: The composition of the cored wire can be tailored to specific requirements, allowing for the addition of other alloying elements in addition to carbon.
7. Environmental Benefits:
Reduced Emissions: The controlled addition of carbon via cored wire generates fewer emissions of dust and fumes, contributing to a cleaner and safer working environment.
Sustainability: Reduced waste and improved efficiency make the process more environmentally sustainable.
8. Process Simplification:
Streamlined Operations: The use of cored wire simplifies the metallurgical process, allowing for real-time adjustments and fine-tuning of the steel composition.
Automation: The wire feeding process can be fully automated, leading to more efficient and reliable operations.
The advantages of using Carbon cored wire Why metallurgical factories are using Carbon cored wire in steelmaking and foundry process
The advantages of using Carbon cored wire
Precision and Efficiency
2. Homogeneity and Quality
3. Environmental and Economic Impact
How to use Carbon cored wire in steelmaking
How to use Carbon cored wire in steelmaking
To use Carbon cored wire in steelmaking, your factory needs to have a wire feeding machine that can deliver the cored wire to the ideal position in the molten steel.
There are two popular methods of using Carbon cored wire: inner tap and outer tap:
1. The inner tap method is to feed the cored wire directly into the ladle;
2. The outer tap method is to place the coiled wire on the turntable of the pay-off device and feed it into the ladle through a catheter.
You can also control the feeding amount and speed of the cored wire by using a display counter and a speed controller on the Wire feeding machine.
Where to buy high-quality Carbon cored wire and how much does it cost
Where to buy high-quality Carbon cored wire and how much does it cost
If your production needs high-quality Carbon cored wire, you can check out the KADEMAR Group, which is a leading supplier of cored wires for steel industry.
KADEMAR Group supplies various types of cored wires, including Carbon cored wire, produced according to the ISO standards and the individual Customers' orders.
The price of Carbon cored wire may vary depending on the market conditions, the specifications, the quantity, and the delivery terms.
If you will contact KADEMAR Group, you can receive more professional information about Carbon cored wire. Send your request via email:
CHEMICAL SPECIFICATION OF Carbon CORED WIRE
CHEMICAL SPECIFICATION OF Carbon CORED WIRE
We are committed to meeting both standard and unique requirements of our customers by offering the ability to produce carbon cored wire with various parameters tailored to specific needs. Our manufacturing process allows for precise adjustments in chemical composition, physical dimensions, and other specifications to provide the highest quality and performance for your specific applications.
Carbon CORED WIRE Composition
C: ............................................................ 99,5 %
Powder filling density:............................ 190 gr
Wire Diameter:........................................ 13 mm
Powder weight (per coil):..................... 1025 kg
Total weight (per coil): ........................ 1650 kg
Coil inner diameter: ............................. 600 mm
Coil external diameter: ...................... 1150 mm
Coil height:.......................................... 1150 mm
Steel thickness:..................................... 0,4 mm
Wire steel quality: Cold rolled DIN EN 10130 Grade DC 01
Type of Cored Wire: horizontal and vertical
ADDITIONAL INFORMATION
Chemical Analysis Method: ................... LECO
Marking: ...... drawing filler's symbols on the coil
Label: ................................ attached to each coil
Terms of delivery: FOB, CIF, CFR, CPT, DAP according to Incoterms-2010
Type of transport: ........... by truck, by container
Loading time: ............................ 5 working days
Net Weight (per coil): ..................... +/- 1650 kg
Gross Weight (per coil): ................. +/- 1670 kg
Safety measures: use appropriate personal protective equipment (PPE).
PACKAGE
STORAGE
Coil of Carbon cored wire is packed into a waterproof bag and fixed on a metal base. Our packaging of Carbon cored wire has several advantages for a Customer:
Storage conditions of Carbon metal cored wire: In original packaging and dry storage is 12 months from the date of production.
for a Customer:
1. Protection:
The waterproof bag protects Carbon cored wire from moisture, which can degrade its quality and effectiveness.
1.Quality Assurance:
Proper storage in original packaging and dry conditions helps maintain the quality and effectiveness of the wire, ensuring optimal performance when used.
2. Easy of Transport and Storage:
The metal base provides stability, making it easier to transport and store the coil without damage.
2. Cost-Effective:
The specified shelf life of 12 months allows for bulk purchasing and storage, potentially leading to cost savings. It also reduces the need for frequent reordering.
3. Consistent Quality:
This packaging method helps maintain the consistent quality of the Carbon cored wire by preventing exposure to harmful environmental factors.3. Consistent Results:
Proper storage conditions ensure consistent wire performance, leading to predictable and reliable results in the steel refining process.
4. Efficient Use:
Coils can be delivered either horizontally or vertically depending on the kind of the injection facility. They can always be connected for a non-stop injection.
4. Extended Shelf Life:
The wire can be stored for up to 12 months without degradation, offering flexibility in usage and inventory management.
*Customization:
Other types of packaging are available upon request including coil size, metal base, and protective wrapping. These advantages of our packaging can lead to cost savings, improved product performance, and greater satisfaction for the Customer.
5. Safety:
Dry storage conditions reduce the risk of any moisture-related damage or safety hazards.
FAQ
FAQ
What is Carbon cored wire used for in steelmaking?
- Carbon cored wire is used to adjust the carbon content in the production of high-carbon steels, alloy steels, and ductile iron during metallurgical processes, such as
ladle metallurgy and secondary steelmaking. This precise addition helps achieve desired metallurgical properties like hardness, tensile strength, and ductility.
How does Carbon cored wire improve steel quality?
- Carbon cored wire improves steel quality by enabling precise control over the carbon content, which ensures uniform distribution of carbon in the molten steel.
This reduces non-metallic inclusions and improves the mechanical properties and overall consistency of the steel.
What are the benefits of using carbon cored wire in steel production?
- Benefits include precise control of carbon content, reduction of non-metallic inclusions, enhanced efficiency and yield, cost-effectiveness, improved product quality,
flexibility and versatility, environmental benefits, and process simplification.
How is carbon cored wire manufactured?
- Carbon cored wire is made by encasing carbon powder within a thin steel strip, which is then rolled and welded into a cylindrical shape.
This allows for precise adjustments to the composition of the molten metal during steelmaking.
What are the chemical specifications of carbon cored wire?
- The typical chemical composition of Carbon cored wire includes 99.5% carbon, with a powder filling density of +/-190 grams, wire diameter of 13 mm, and other specifications
tailored to meet specific requirements.
How does carbon cored wire contribute to reducing impurities in steel?
- Carbon cored wire helps in reducing impurities such as sulfur and phosphorus through chemical reactions that form compounds like calcium sulfide, thereby improving
the cleanliness and quality of the steel.
What are the advantages of Carbon cored wire over traditional carbon addition methods?
- Advantages include minimized carbon loss due to oxidation, more efficient material usage, precise control over the addition process, and reduced waste, leading to better
yield and consistent steel quality.
What is the process of feeding carbon cored wire into molten steel?
- Carbon cored wire is introduced into the molten steel using an automated wire feeding system, which controls the rate and amount of cored wire fed.
The steel sheath melts rapidly in the high-temperature environment, releasing the carbon into the molten steel for uniform distribution.
How does carbon cored wire affect the mechanical properties of steel?
- The precise addition of carbon enhances the mechanical properties of steel, such as hardness, tensile strength, and ductility, by ensuring uniform carbon distribution
and reducing non-metallic inclusions.
What types of Carbon cored wire are available?
- Carbon cored wire is available in various specifications, including different wire diameters, powder filling densities, and compositions tailored to specific steelmaking needs.
It can also be produced for horizontal and vertical feeding systems.
How can Carbon cored wire be customized for specific steelmaking needs?
- Carbon cored wire can be customized in terms of chemical composition, physical dimensions, and other specifications to meet the unique requirements of different steelmaking
processes and applications.
What are the environmental benefits of using carbon cored wire?
- The controlled addition of carbon via cored wire generates fewer emissions of dust and fumes, contributing to a cleaner and safer working environment.
It also reduces material waste, making the process more environmentally sustainable.
How does carbon cored wire help in achieving consistent steel composition?
- The precise control over the addition process ensures that the carbon is uniformly distributed throughout the molten steel, leading to consistent composition and properties
in the final product.
What industries benefit the most from using carbon cored wire?
- Industries such as automotive, construction, aerospace, and any sector that requires high-quality, high-performance steel benefit from using carbon cored wire in their
steelmaking processes.
How is carbon cored wire packaged and stored?
- Carbon cored wire is packed into waterproof bags and fixed on a metal base to protect it from moisture. It should be stored in its original packaging and in dry conditions
to maintain its quality and effectiveness.
What is the shelf life of carbon cored wire?
- The shelf life of carbon cored wire is typically up to 12 months when stored in original packaging and under dry conditions.
How does the use of carbon cored wire impact production costs?
- The use of carbon cored wire reduces material wastage, lowers labor costs due to automation, and improves overall production efficiency, leading to significant cost savings.
Can carbon cored wire be used in all types of steelmaking processes?
- Yes, carbon cored wire can be used in various steelmaking processes, including ladle metallurgy, secondary steelmaking, and refining.
What safety measures should be taken when handling Carbon cored wire?
- Safety measures include using appropriate personal protective equipment (PPE), ensuring proper storage conditions to avoid moisture damage, and following handling
guidelines to prevent accidents during the feeding process.
Where can high-quality Carbon cored wire be purchased?
- High-quality carbon cored wire can be purchased from KADEMAR Group, which offers a range of cored wire products manufactured according to ISO standards and
tailored to specific customer requirements. For more information, you can contact Kademar via email at export@kademar.com.