VARIOUS SLAB (RM) DEFECTS

VARIOUS SLAB (RM) DEFECTS

Pin Holes Star Cracks Transvers Cracks

Deep Oscillation Marks Longitudinal Mid-Face Crack

SLAB (RM) DEFECTS IN HOT ROLLED PLATES

Body Sliver

Transverse Crack near plate edge Longitudinal Crack in Hot Rolled Plate
1. Process related Defect

Defect name Occurrence status Root cause

Lamination 1. Thin and long split near the 1. It occurs if deoxidized formation and Non
center of thickness of the front Metallic Inclusion remain inside of Slab, and if
side surface of Plate. it is not fully compressed when rolling. It
becomes bigger if rolling pressure is low.
2. It tends to occur on Thick Plate.
2. It occurs as split status due to bending
3. This can be checked by UT.
stress by shearing machine.

Skin Hole It is such as Through Hole is shown like 1.Tube shaped foam or surface foam is
tiny crack, and it is one of pockmarked exposed to outside of scale layer at RHF
shape which is connected all in one. Slab reheating.
2. It shows such as compressed defect at
Rolling in case it is exposed and oxidized by
Slab Scarfing.
 Defect name Occurrence status Root cause
Blister (Bulge ) It blisters or bursts in the center of H2 is trapped in non metallic inclusion
plate, hemi spherically, or inside Slab, and so inner pressure is
transversely. increasing. Thus, when rolling, it blisters
as non compressed status, or it bursts.
( It occurs mainly in soft steel.)
2. Casting Process related Defect

Defect name Occurrence status Root cause

Longitudinal Crack Split defect which appears on the Thermal gradient during casting.
Plate surface or the other side
longitudinally.

Transverse Crack Split defect which appears on the Thermal gradient during casting.
Plate surface transversely.
 Defect name Occurrence status Root cause
Star Crack Split defect which appears to be Crack like defect at corner of Slab
star shape like on the surface of develops Star like Crack at Plate Rolling.
Plate.

Skid-Mark It occurs such as Charge like It appears during Rolling that Skid Mark
mainly on the center of of Slab occurs through being scratched
transverse over the upper side of by Skid due to malfunction of Guide-Roll
Plate. of Pinch-Roll in Casting Machine.
 Defect name Occurrence status Root cause
Top & Tail Transverse Crack Split defect which appears on When Rolling, It occurs on improper
Top or Tail of the Plate scarfing section or Burr area after
transversely. cutting of Slab.

Scarfing

∼
Side Crack It occurs on Edge area of the It occurs due to the stress that Skin
Plate transversely within the Hole, or Blow Hole, etc receives at the
average of 20mm. time of cutting.
 Defect name Occurrence status Root cause
Scarfing Seam It occurs on Edge area of the It occurs due to excessive Scarfing which
Plate longitudinally. (short line is done for removal of crack at Edge area
type) of the Slab.

Scarfing

Mold Powder Defect White or yellow colored powder Largely, it occurs at the First or Last of
remains on the surface of Plate. Slab after change of T/D, and it occurs
due to mixture of Mold Powder and
solid shell.
 Defect name Occurrence status Root cause
Scab It occurs at random location of It occurs due to the defect of Scarfing, or
the Plate. due to remaining of Melting stuff which
comes from 2nd cutting of Slab.

Edge Burst Appear Edge or on the plate From the Inner Bubble of Slab
surface
3. Plate Rolling Process related Defect

Defect name Occurrence status Root cause

Primary Scale When Slab is reheated in RHF, 1 Scale during RHF reheating is not
some Scale occurs. This Scale fully removed while Descaling.
remains locally on the surface of 2. Scale coheres in concave portion
Plate, and becomes compressed.
of Center Wave or Edge Wave,
If it is removed, then, the shape
of “ “ appears on the during Rolling.
Plate.

Secondary Scale 1. It occurs at thin plate(below 1. Secondary Scale occurs when the
10mm thickness) with 0.8~1m wave risen plate is corrected by Hot
distance interval toward Leveling at rolling, and then High
perpendicular angled wise of Temp’ Oxidized Scale is
rolling, circular arc wise, and
straight line wise. It has a accumulated and embedded in the
reddish brown color, and has projected section.
maximum 0.25mm level of depth 2. At thin plate’s last stage of rolling,
of dent. It occurs when the rolling is done
2. It occurs on top/bottom without full Descaling due to
surface of the plate. temp’ dropping, etc.
 Defect name Occurrence status Root cause
Multi Line Seam It occurs at Edge of Mother At rolling of the Plate, it’s an overlap
Plate rolling direction wise. due to temp’ difference of inner and
outer of the Plate.

Foreign material defect Unknown material or metal is At rolling, it occurs that some unknown
compressed in the surface of material falls on top of plate, and it is
Plate. compressed in it.

∂
 Defect name Occurrence status Root cause
Hot Leveling Mark Uneven shaped mark ( ) Roll of Hot Leveler is spalled and worn out locally.
occurs on the surface of plate This causes unknown material to be attached on
with a regular interval. the surface
Of Roll, and makes it deformed and printed
unevenly.
1. Scale attached to Leveling Roll and shaped like
“ “
2. Locally worn out of Leveling Roll due to
Irregularity of hardness and material appears
on the surface like

Scratch Mainly it appears on the bottom It occurs if Roll of Roller Table has a defect, or if
surface of Plate as Scratch mark. there is a projection on Apron, or it occurs by Skid
on Cooling Bed.
 Defect name Occurrence status Root cause
Rolling Scab Scab occurs at the Edge of Mother It occurs that Edge area is compressed by overlapping
Plate. with plate surface when Crop area of the Plate is
contacted with Side Guide.

Negative Width of Plate Total width of Plate is shorter than 1. Width sizing Rolling is missed.
order specification, and so it has a
negative width on the Plate. 2. Side Guide is abnormal.
 Defect name Occurrence status Root cause
Negative Length of Plate Thickness and Width are within 1. Rolling is missed.
the specification of Mother Plate
dimension, but by the result of 2. Plate Design is missed.
measuring, the Length appears
shorter than planned sizing of the
Plate.

Negative
Length

Overall thickness of the plate is 1. Pressing is missed.

out of acceptable
Total Thickness defect tolerance.( within ±3.0mm,)
2. Malfunction of Gauge and machine
* More than ±3.0mm is a miss.
 Defect name Occurrence status Root cause
Partial Thickness defect Plate is partially out of acceptable 1. Pressing is missed and Heating is not in spec.
tolerance. ( Also applicable in case
that one Mother Plate is designed 2. A.G.C and Roundability of Roll is out of spec.
for one Plate.

LCL UCL

(mm) -1.6 1.6 (mm)

Negative Width of Top & Top & End of Plate are shorter 1. Pressing is missed, and Roll Crown decreases.
End than planned width of mother
plate, and so good plate cannot be 2. Design is missed and material is abnormal.
produced.

3. Side Guide is abnormal.

 Defect name Occurrence status Root cause
Positive Width In case that width is longer than 1 Pressing is missed, and Roll Crown is excessive.
order spec, and so length of plate 2. Design is missed, and material is abnormal.
is short. 3. Side Guide is abnormal.

Thickness Off Spec after In case that it is partially out of It occurs by change of thermal tissue and cubic
Heat Treatment acceptable tolerance of thickness volume due to Heat Stress.
 Defect name Occurrence status Root cause
Miss Roll Shape is extremely defective, and 1. Malfunction of equipment
so none of plate are produced. 2. Rolling is missed.

Evenness After Rolling, in case that evenness 1. Rolling is missed and Roll Crown is improper.
defect(longitudinal wise) longitudinal wise of Plate is out of 2. Cooling method and Pass Line is improper.
specification.
 Defect name Occurrence status Root cause
Evenness After Rolling, in case that 1. Level of cooling water over the top & bottom of
defect(Transverse wise) evenness transverse wise of plate plate is
is out of specification. not proper.

Mother Plate Camber Camber occurs at Mother Plate 1. Side Guide is abnormal.
status, and its width is shorter than 2. Abnormal worn out of Roll
planned even if it cut partially. 3. Bad Roll Balancing
 Defect name Occurrence status Root cause
Rolling Error In case that shape of plate is 1. Rolling is missed
bad, it can not be used, and so, 2. Malfunction of equipment and operation miss
it is scrapped, or in case that 3. Material is not confirmed and design is missed.
thickness or width is far from
planned dimension.
4. Shearing Process related Defect

Defect name Occurrence status Root cause

Transfer defect It occurs on mainly thin plate that 1. In case that corner of plate is crashed or
the front and rear edge area or jammed with R/T Guide
corner of the plate are crushed or is 2. It occurs when front or rear plate collides
bent.
each other due to malfunction of information
tracking, and R/T manual
operation miss.
3. It occurs when Plate is moving, it collides
against structure.

Pinch Roll Mark Surface of Pinch Roll is pressed by 1. Pinch Roll processing is defective, and the
unknown material and is defective. uneven shape of Roll surface is printed on plate
This causes surface of plate to be surface like “ “.
shaped unevenly like “ “. 2. Burr or Chip, which occurs during Shearing
(DSS/SS), and remains on top of plate, is pressed
on Pinch Roll, and then, it is printed on surface
of plate.
 Defect name Occurrence status Root cause
Transverse Shearing Transverse shearing surface has It occurs when the clearance of Double Side Shear is
surface defect additional fold, or it is loose poor, or Blade of Knife is defective.
downward sharply.

Transverse Direction

Longitudinal Shearing Longitudinal shearing surface has It occurs when the clearance of Dividing Shear is poor,
surface defect a additional fold, or it is loose or Blade of Knife is defective.
downward sharply.

Longitudinal Direction Longitudinal Direction

 Defect name Occurrence status Root cause

Shear Camber There is no Camber on Plate 1. Malfunction of DSS equipment and operation,
condition, but after shearing, it and partially worn out of Pinch Roll
is bent longitudinally. 2. Shearing trouble
3. Incomplete Holding of Shearing Plate

Evenness defect of Mainly at thin plate, both Edge 1. It occurs that poor evenness of the Plate, or
machine shearing or either Edge of Plate is Cutting defect of Scrap Knife cause Scrap Trouble.
crushed up and down. 2.Scrap trouble area get jammed with cutting
surface due to Charging power of the Plate, and
then the surface of the plate is crushed.
 Defect name Occurrence status Root cause
Negative width of the When Mother plate is inspected, 1. At Shearing line, width setting of the plate is
Plate actual width of FG after missed.
shearing becomes negative in 2. Measuring and Shearing is missed.
comparison with order 3. In case of re-shearing due to defective cutting
specification. surface which caused by malfunction of
equipment and defective cutting knife.

Negative Length of the When Mother plate is inspected 1. Measuring is missed.

Plate and measured, it is found after 2. In case of re-shearing on defective surface due
shearing that actual length of to cutting
FG was sheared negatively in miss.
comparison with order
specification. 3. Pinch Roll & Dividing Shear are abnormal.
Measuring Roll setting is missed.
 Defect name Occurrence status Root cause

Perpendicular defect After cutting, it is out of 1. Material Alignment is insufficient.

perpendicular tolerance. 2. Cutting is missed, and Roller Table is worn out.
3. Malfunction of equipment and material holding
is incomplete at Shearing process.

X ≤ Perpendicular tolerance
5. Correction Process related Defect

Defect name Occurrence status Root cause

Scratch It appears on top or bottom of 1. It occurs on the bottom of Plate if there is a
the plate as Scratch mark, or projection on Roller/Apron of R/T after cooling
Dent mark. bed.
2. When Plate is moved to shear, correction line
by Magnet Crane, it occurs at the time of
sliding of Magnet Pot on Plate.
Dent mark occurs on the surface of plate
through some material attached to Magnet
Pot. It occurs if plate is sliding on the another
plate.

Cold Leveling Mark Uneven shaped mark ( ) Roll of Hot Leveler is spalled and worn out locally.
scatters on the surface of plate This causes unknown material to be attached on
with a regular interval. the surface Of Roll, and makes it deformed and
printed unevenly( ).
1. Scale attached to Leveling Roll and shaped like
“ “.
2. Locally worn out of Leveling Roll due to
irregularity of hardness and material appears
on the surface like “ “.
 Defect name Occurrence status Root cause
Gas Cutting surface Surface is dent like 1. When the speed is irregular at Gas cutting.
defect “ “ by fuel intake.
2. When the flame status is not uniform.

Normal dimensional plate could 1. CNC data input is missed.

Gas measurement be produced but it was cut
2. Dimension is misred at manual measurement.
defect shorter than aim dimension, and
so the result was negative.

1. Hammering and Label Tracking is missed.

Hammering or Labeling is not
Hammering, Label done, or it needs correction for
2. Plate number confirmation is missed.
correction plate which is required for
repair at correction shop. Letter of label is omitted.

1. Marking tracking is missed.

Marking is not done, or it
Marking correction needs correction for plate which
2. Plate number confirmation is missed.
is required for repair at
correction shop. Letter of label is omitted.
 Defect name Occurrence status Root cause
1. It occurs because quality design is missed.

2. In case that chemistry was not hit at SMP

Chemistry rejection Chemistry is out of specification, operation.
and rejected. So, It is separated.

3. In case it occurs by Side Concentration.

It occurs when the test sample is produced for new

Mechanical property was not
Material rejection design production, or increase of dimensional
passed by Material Test.
capability.
It occurs when material test was not passed.

Left over of good plate or NCO

after completion of order O/R required plate due to small Lot/Size
Over Roll production production

1. Surplus is produced if design yield ratio is low

In case Left over plate is due to NCO
Surplus production
produced in addition to ordered Slab matching.
plate. 2. Surplus is produced if Slab unit weight is over.