1. What is the difference between ferrite, Austenite, and martensite in steel?

Phase Crystal Structure Stability Hardness & Formation

Ductility

Ferrite BCC (Body-Centered Stable at room Very soft and Forms during slow cooling
Cubic) temperature highly ductile of steel

Austenite FCC (Face-Centered Stable at high Ductile, non- Exists above ~727°C in
Cubic) temperatures magnetic carbon steels

Martensite BCT (Body-Centered Metastable Extremely hard Forms by rapid quenching

Tetragonal) (quenched phase) and very brittle of austenite

Pearlite Alternating layers of Stable at room Moderate hardness Forms by slow cooling of
ferrite & cementite temperature and ductility austenite around 727°C

Cementite Orthorhombic (Fe₃C – Stable at room Very hard and Forms from carbon
iron carbide) temperature brittle combining with iron during
cooling

CE Range Weldability Preheat Recommendation

<0.35 Excellent Generally not required
0.35-0.45 Good Consider preheat for thicker sections or critical applications
0.45-0.55 Fair Preheat recommended for most applications
>0.55 Poor Significant preheat or alternative welding processes may be necessary
2. Explain the difference between TTT and CCT diagrams.
Answer:
• TTT (Time-Temperature-Transformation) diagrams show the transformation of austenite under
isothermal conditions.
• CCT (Continuous Cooling Transformation) diagrams represent transformations that occur
during continuous cooling, which is more practical for industrial processes.

3. what are the effects of chromium, nickel, molybdenum, and carbon on stainless steel?
Answer:
1. Chromium provides corrosion resistance,
2. Nickel stabilizes the austenitic phase,
3. Molybdenum increases corrosion resistance particularly against pitting and crevice corrosion
4. Carbon affects the hardness and strength but can also lead to carbide precipitation which might
reduce corrosion resistance.

4. What is powder metallurgy, and where is it typically used?

Answer: Powder metallurgy involves shaping metal powders into desired forms and then heating them
to just below their melting point to bond them without melting. It's used in applications where
precision, uniformity, and the production of complex shapes or parts from difficult-to-machine
materials are needed, like in automotive parts, aerospace components, and electronic devices.

5. Describe the process of annealing and its purpose.

Answer: Annealing involves heating a metal to above its recrystallization temperature, maintaining that
temperature, and then cooling it slowly. This process relieves internal stresses, increases ductility, and
refines the grain structure to improve machinability and mechanical properties.

6. What are the key considerations in selecting materials for high-temperature applications?
Answer: Factors include thermal expansion, thermal conductivity, resistance to oxidation, creep
resistance, and maintaining mechanical properties at elevated temperatures. Refractory metals like
tungsten or alloys like Inconel might be chosen.

7. How do you ensure quality control in metallurgical processes?

Answer: Through non-destructive testing (NDT) methods like ultrasonic testing, radiography, magnetic
particle inspection, and by implementing statistical process control to monitor production parameters.
Practical and Problem-Solving:
8. What steps would you take to analyze a metal fatigue issue?
Answer: Analyze the fracture surface for signs of fatigue, examine the stress conditions under which
the part failed, review any previous similar failures, conduct material testing for fatigue properties, and
consider redesigning for reduced stress concentrations or using different materials.

9. How would you handle a situation where there's a discrepancy in material specifications versus
actual product performance?
Answer: Verify testing methods, re-test samples if possible, check for any processing errors, review the
material's supply chain for deviations, and consult with suppliers or metallurgists for a deeper
investigation.
General and Behavioral:
10. Tell me about a time when you had to innovate or improve a metallurgical process.
Look for: Examples where the candidate has shown initiative, used their metallurgical knowledge to
solve problems or improve efficiency.
1) What is the raw material needed for steel production?
Steel is made when iron is combined with carbon and other elements like-
• Water
• Flux ( Limestone and Dolomite)
• Refractories
• Silica or Sand
• Water
• Ferro alloys

2) How molten iron or base material for steel is made?

To prepare molten iron you use limestone and coke, and you put into the top of a blast furnace. After
that, you expose the base material to the air until its very hot, out of which the molten iron is prepared,
and ultimately this iron is used to make steel.

3) What are the types of steel?

• Stainless Steel
• Carbide Steel
• Carbon Steel
• High-speed Steel
• Cobalt Steel

4) Explain what is the difference between hot rolled steel and cold rolled steel?
Aspect Hot Rolled Steel Cold Rolled Steel
Manufacturing Rolled at a temperature above 1700°F Rolled at room temperature (below
Temperature (recrystallization temperature of steel) recrystallization temperature)

Cost Cheaper to produce More expensive than hot rolled steel

Dimensional Less precise due to shrinkage during More precise with better dimensional tolerance
Accuracy cooling

Surface Finish Rough surface, not as smooth Smoother surface, better finish
Shape Consistency May shrink or warp during cooling Maintains shape with no shrinkage
Edges and Corners Rounded edges and corners Square edges and corners
Applications Suitable for welding and construction Used in applications where high precision and
(e.g., railroad tracks, I-beams, surface finish are required (e.g., suspension
structural parts) bridges, automotive parts)
5) What is the amount of steel does BOS (Basic Oxygen Steelmaking) Vessel can take?
BOS is the central bulk production process for refining iron into steel. It can take up to 350 tonnes of
molten iron at a time and convert it into steel in less than 30 minutes.

6) Explain what is Blast furnace?

Blast furnace is a technique used to raise the temperature up to 2200 degree C in the furnace. This high
temperature is required for the chemical reduction, as well as for melting of the sinter and iron ore.

7) What is the use of Tundish in the steel plant?

In steel production plant, tundish is a reservoir that enables the steel to flow at a regulated rate through
gas tight refractory tubes and into a series of water-cooled copper moulds.

8) What are the different shapes or forms does steel are prepared?
Steel is prepared into various sections like
• Plates and Tubes
• Strip and Profiles
• Rails
• Rods
• Wire and Bar

9) What are the main challenges does steel industry is facing now?
The main challenges that steel industry is facing now is
• Overcapacity
• High raw material cost
• Price volatility

10) What are alloying agents?

To change the chemical structure of steel and, to enhance its properties over carbon steel or to alter
them to meet the requirements of a particular application alloying agents are used. For instance, if you
have a chromium about 12% of the content, chromium significantly improves corrosion resistance.
Such corrosion resistance steel is referred as stainless steel.
11) What are the impurities added in the steel?
Impurities percentage is very minimal, and it is added according to the requirements
• Silicon
• Sulphur
• Carbon
• Phosphorous
• Manganese, etc.

12) What are PCI stands for?

PCI stands for Pulverized Coal Injection Method.

13) Mention what is the melting point of steel?

Melting point of steel is approximately, 1370 degree C, although its melting point differs according to
the type of alloy mixed in it, which gives the strength, corrosion free and other properties to the steel.

14) What does “tool steel” contains?

Tool steels contain molybdenum, tungsten, cobalt and vanadium in different quantities to increase the
heat resistance and the durability, making them ideal for cutting and drilling equipment.

15) Explain what is the thermal lance?

Thermal lance is a tool that heats and melts iron in the presence of pressurized oxygen to produce high
temperatures required for cutting

16) What is the main hazardous thing in Steel Plant?

The hazardous thing that one have to take care while working in Steel Plant is
• Heat
• Dust
• Noise
• Liquid metal and Slag
• Gas Poisoning
• Moving equipment’s
• Moving locomotives
• Fire and Explosion
17) What are the types of Stainless Steel?
The main types of stainless steel are
• Ferritic
• Austenitic
• Martensitic

18) What forms of corrosion you will see in stainless steel?

The type of corrosion you will see in stainless steel are
• Pitting Corrosion
• Crevice Corrosion
• General Corrosion
• Stress Corrosion
• Intergranular Corrosion
• Galvanic Corrosion

19) What are the factors that matter for choosing stainless steel?
The factors that mater before choosing stainless steel are
• Temperature of the operation
• How corrosive is the surrounding
• Type of welding carried out
• Cost and Availability
• What type of strength is required
• Costing

20) What are different ways of doing QC(Quality Control) for steel?
1. Using Microscope: A cross section of highly polished sample is observed under 100-500
magnification diameters. It will reveal the presence of alloy metals in it and help to determine
the strength and behaviour of steel under set condition
2. Rockwell and Brinell hardness tests: This test is done to check the hardness of steel by
impressing into the test specimen.
3. Charpy and Izod test: In this test, a metal pendulum of specific weight is allowed to strike the
testing sample and after that the energy absorbed by the specimen is measured. This test is done
to measure the material behaviour on exposing high rate of loading, bending, tension or torsion
4. Salt Bath Immersion techniques: This technique is used to check chemical, electrochemical or
metallurgical interaction between the environment and the material
5. Magnetic particle inspection: To detect crack, tears, seams and inclusion
6. Ultrasonic sound Waves: It is used to detect porosity, internal cracks, shrinkage voids and
large non-metallic inclusions
 Element Effect
C (Carbon) Increases hardness & strength, decreases ductility
Mn Improves hardenability & toughness
Si Deoxidizer, improves strength
Cr Increases corrosion resistance (stainless steel)
Ni Improves toughness, corrosion resistance
Mo Increases strength at high temperatures
V Refines grain size, improves strength
Al Deoxidizer, helps control grain growth

Heat Treating of Steel – Detailed Explanation

Heat treatment is a group of industrial and metalworking processes used to alter the physical and sometimes
chemical properties of a material, most commonly steel. The primary purpose of heat treatment is to enhance
properties such as strength, hardness, ductility, toughness, and machinability by changing the material’s
microstructure.

General Stages of Heat Treatment

Heat treatment generally involves three main stages:

1. Heating

• The steel is heated uniformly to a specific temperature below its melting point.
• The heating rate must be controlled to prevent internal stresses or thermal gradients which may cause
cracking or distortion.
• Factors affecting heating:
o Size and shape of the component
o Grade and prior condition of the steel
o Desired microstructural change

2. Soaking (Holding)

• Once the target temperature is reached, the metal is held (soaked) at that temperature for a specific
period.
• This allows the internal structure (e.g., grain size, phase) to homogenize and transform.
• Soaking time depends on:
o Type of steel
o Desired mechanical properties
o Thickness of the material

3. Cooling
 • After soaking, the steel is cooled at a controlled rate.
• Cooling can be:
o Fast (quenching in water, oil, or brine)
o Slow (air or furnace cooling)
• Cooling rate directly affects the final microstructure and properties.
o Fast cooling = High hardness, low ductility (e.g., martensite)
o Slow cooling = Soft, ductile structure (e.g., ferrite + pearlite)

Major Types of Heat Treatment Processes

1. Annealing

• Purpose: Soften the steel, improve ductility, relieve internal stresses, refine grain structure.
• Process:
o Heating above critical temperature
o Soaking, then very slow cooling (usually in the furnace)
• Result: Improves machinability and prepares steel for further processing.

2. Normalizing

• Purpose: Remove internal stresses and refine grain structure.

• Process:
o Heating above critical temperature
o Soaking
o Air cooling (faster than annealing)
• Result: Harder and stronger than annealed steel, but still ductile.
• Applied only to ferrous metals.

3. Hardening

• Purpose: Increase hardness and strength by forming martensite.

• Process:
o Heating to austenitizing temperature
o Soaking
o Rapid cooling (quenching) in water, oil, or brine
• Disadvantage: Creates brittleness and internal stresses.
• Often followed by tempering to reduce brittleness.

4. Tempering

• Purpose: Reduce brittleness and increase toughness after hardening.

• Process:
o Reheating quenched steel to a lower temperature (150–650°C)
o Soaking
o Air cooling
• Adjusts hardness to a safer, usable level.
• Produces tempered martensite—tough yet strong steel.
5. Case Hardening (Surface Hardening)

• Purpose: Harden only the outer surface of the steel while keeping the core ductile and tough.
• Used when surface wear resistance is important but core toughness is also needed.
• Two major methods:
o Carburizing: Heating in a carbon-rich environment to allow carbon diffusion into the surface.
o Nitriding: Introducing nitrogen (via ammonia gas) to form hard nitrides on the surface.

Cooling Media Comparison

Medium Cooling Rate Typical Use
Brine Fastest High-carbon steels
Water Fast Plain carbon steels
Oil Medium Alloy steels
Air Slow Annealing/normalizing

Key Interview Tips on Heat Treatment:

• Understand how microstructure (like pearlite, martensite, bainite) changes with different processes.
• Be ready to relate heat treatment to real applications (e.g., TMT bar manufacturing, surface
hardening of tools).
• Know critical temperatures from the Iron-Carbon diagram (e.g., eutectoid temp 727°C).

Treatment Microstructure Formed Key Feature

Annealing Ferrite + coarse pearlite Soft, ductile
Normalizing Ferrite + fine pearlite Stronger than annealed
Hardening Martensite Hard and brittle
Tempering Tempered martensite Tough and strong
Case hardening Hard martensitic surface + tough core Surface wear resistance

Application Examples in Industry (BSRM Context)

• TMT Bars: Undergo controlled quenching and self-tempering for high strength + ductile core.
• Rebars, tools, gears: Require case hardening or full hardening based on wear needs.
• Steel wires and sheets: Annealed to improve formability.
 Pro Tips for BSRM Interview
• Be clear on critical temperatures:
o A1 (eutectoid): ~727°C
o Ac3 (upper critical for hypo-eutectoid steel): varies with carbon content
• Understand relation between phase diagram and heat treatment.
• Practice drawing or explaining the Iron-Carbon diagram & TTT diagram.
• Be able to explain martensite, bainite, pearlite, ferrite in simple terms.

Here’s a clearly organized and concise Overview of BSRM’s Products & Services, based on their official web
content:

BSRM at a Glance
BSRM Steels Limited is the largest steel manufacturer in Bangladesh, headquartered in Chattogram. With
core operations spanning melting billets, rolling long products, and recently, wire & electrode
manufacturing, BSRM has become a leader in supplying high-grade steel for major national infrastructures
like Padma Bridge, Rooppur Nuclear Plant, and significant flyovers in Dhaka (bsrm.com).

Key Capacities & Reach:

• Annual melting capacity: ~2.0 million MT

• Annual rolling capacity: ~1.6 million MT
• Wire production capacity (through BSRM Wires): ~65,500 MT/year
• Distribution through 26 regions, 19 sales offices, 13 warehouses, and 650+ dealers (bsrm.com, Business
Inspection BD).

Product & Service Portfolio

1. MS Billets & Reinforcing Bars (Rebar)

• Operates induction melting furnaces producing high-quality billets (~250,000 MT/year capacity)
(newnation.io, Business Inspection BD).
• Produces Grade 500 rebar in sizes up to 50 mm diameter with patented DANIELI thermal quenching
& tempering technology, compliant with ISO 6935, BS4449, and BNBC specifications (newnation.io).
• Premiere brands include:
o BSRM Xtreme 500W / B500 DWR — first EMF-tested & fatigue-tested high-strength steel in
Bangladesh with guaranteed tensile/yield ratio ≥ 1.25 (Scribd).
o BSRM Ultima — strain-hardening grade for enhanced ductility and earthquake resistance
(Scribd).
o BSRM Maxima — grade 80 reinforcing rods (ASTM 706), reducing steel consumption by
~20% in construction (Scribd).
o BSRM Strong — channels and angles for structural applications (Grade 50 steel) (Scribd).
o BSRM Cantura — epoxy-coated rebar for corrosion resistance in aggressive environments
(Scribd).
2. BSRM Wires Division

• Located in Mirsharai, Chattogram, with world-class infrastructure and testing labs.

• Produces:
o Galvanized wire
o ACSR core wire
o LRPC (Low-resistance power conductors)
o MIG wires
o Welding electrodes and related consumables (bsrm.com).

3. Supply Chain & Vendor Services

• BSRM operates one of Bangladesh’s most robust steel supply chains—from scrap sourcing, raw
materials, and consumables to logistics and spare parts procurement.
• Emphasizes:
o Quality assurance
o Cost transparency
o Regulatory & environmental compliance
o Innovation and vendor partnerships geared toward reliability (bsrm.com).

Key Highlights & Achievements

• BSRM is the leading steel brand in Bangladesh, supplying material for landmark infrastructure projects
such as Padma Bridge, Hatirjheel, Mayor Hanif Flyover, and Rooppur Nuclear Power Plant (bsrm.com).
• It holds multiple awards, such as the Best Brand Award (No.1 Rod Brand, 2011–2019) and Export
Trophy for contributions to Bangladesh’s export sector (Business Inspection BD).
• Its supply chain strength supports both domestic usage and global distribution efforts.

Summary Table
Category Products / Services Highlights & Standards
Xtreme 500W / B500 DWR, Ultima, Grade 500 high-tensile, ductile, seismic-
Reinforcing Bars
Maxima, Strong, Cantura compliant, anti-corrosive
Billets (Melting Medium-frequency induction furnaces,
MS billets for rebar production
Unit) ISO/BEN standards
Wire & Galvanized wire, ACSR, MIG wire, Manufactured at BSRM Wires plant with in-
Electrodes welding electrodes house testing capabilities
Supply Chain Scrap procurement, logistics, spares, Strong network focused on quality,
Support vendor partnerships compliance, innovation

Would you like detailed specs of a particular product (e.g. Xtreme B500 DWR), insights into their wire-
electrode line, or an organizational process (e.g. supply chain)? Let me know!
In Bangladesh, BSRM (Bangladesh Steel Re-Rolling Mills Ltd.) is the only manufacturer of several
specialty steel products that are not made by any other steel company in the country. Here's a list of BSRM-
exclusive products and technologies:

Products Exclusively Manufactured by BSRM in Bangladesh

1. Xtreme B500DWR / B500CWR

• First and only fatigue-tested rebar in Bangladesh.

• Specially designed for dynamic loads such as bridges, flyovers, and elevated expressways.
• Complies with ISO 6935-2 and BS 4449.
• Only rebar in BD tested for low cyclic fatigue—essential for earthquake resistance and high-stress
infrastructure.
• Unique Property: Guaranteed tensile/yield strength ratio ≥ 1.25.

2. BSRM Maxima (Grade 80 Rebar)

• Only Grade 80 rebar in Bangladesh.

• Used in mega projects to reduce steel usage up to 20%, increasing cost efficiency.
• Suitable for high-rise buildings and heavy-duty structures.
• No other company in BD produces ASTM 706 Grade 80 reinforcement rods.

3. BSRM Cantura (Epoxy Coated Rebar)

• Bangladesh’s first and only manufacturer of corrosion-resistant epoxy-coated rebars.

• Ideal for:
o Marine environments (e.g., coastal bridges)
o Sewage plants
o Chemical exposure zones
• No other steel company in BD currently offers factory epoxy coating on rebars.

4. MIG Welding Wire and Electrodes (via BSRM Wires Division)

• BSRM is the first and only steel group in Bangladesh with its own MIG wire and welding electrode
production line.
• Used in both industrial fabrication and structural welding.
• Ensures consistency in quality and supply for large infrastructure and mechanical projects.

Summary Table
 Product Exclusivity Use/Application
Xtreme B500DWR Only fatigue-tested rebar in BD Bridges, flyovers, earthquake zones
BSRM Maxima (Grade
Only Grade 80 rebar in BD Mega infrastructure, reduced steel consumption
80)
Corrosion-prone environments, coastal
BSRM Cantura Only epoxy-coated rebar in BD
structures
Only local production line in
MIG Wire & Electrodes Welding/fabrication industries
BD

If you mention these in your BSRM interview, it will show that you understand their unique market position
and technological leadership.

Would you like a quick note sheet or flashcard version to revise these before the interview?

Here’s a comprehensive set of notes on Cast Iron based on your uploaded PDF, structured clearly for
interview preparation or exam revision:

CAST IRON – OVERVIEW NOTES

Definition

• Cast iron = Ferrous alloy with >2% carbon (typically 2.5–4%).

• Contains carbon + silicon, and may include Mn, P, S.

General Composition

• Carbon: 1.7–4.5%
 • Silicon: 0.5–3%
• Manganese: 0.5–1%
• Phosphorus: 0.1–0.9%
• Sulfur: 0.07–0.1%

TYPES OF CAST IRON

1. ⚪ White Cast Iron

• Structure: Cementite (Fe₃C) + pearlite

• Properties:
o Very hard and brittle
o Brinell Hardness: 375–600
o Tensile Strength: 20,000–70,000 psi
o Compressive Strength: 200,000–250,000 psi
• Application: Ball mills, cement mixers, extrusion nozzles.

2. ⚫ Malleable Cast Iron

• Formed by annealing white cast iron.

• Structure: Irregular graphite nodules (temper carbon) in ferrite/pearlite.
• Properties:
o Tensile Strength: 58,000–65,000 psi
o Yield: 40,000–45,000 psi
o Ductile (elongation 15–20%)
• Application: Pipe fittings, hoists, rail equipment.

3. Pearlitic Malleable Cast Iron

• Structure: Pearlite + temper carbon.

• May contain Mn or Cu for improved properties.
• Application: Camshafts, crankshafts, small tools (wrenches, clamps).

4. ⚫ Gray Cast Iron

• Most common type.

• Structure: Flake graphite in ferrite/pearlite.
• Graphite flakes give a gray fracture surface.
• Mechanical Properties:
o Tensile Strength: Up to 40,000 psi
o High compressive and torsional strength
o Low ductility (elongation < 4%)
 • Application: Machine bases, pipes, enclosures, furnace doors.

5. ⚪ Chilled Cast Iron

• White iron layer formed on the surface by chilling with a metal mold.
• Core remains gray iron, surface becomes hard white iron.
• Application: Rolls, dies, wheels, sprockets.

6. Nodular Cast Iron (aka Ductile Iron)

• Graphite in spheroidal/nodular form.

• No heat treatment needed.
• Properties: High toughness, ductility, machinability.
• Application: Crankshafts, pulleys, elevator doors.

7. Alloy Cast Iron

• Added elements: Ni, Cr, Mo, V for:

o Heat resistance
o Corrosion resistance
o Abrasion resistance
• Mo: Improves fatigue & strength
• V: Forms carbides, increases hardness
• Ni: Graphitizer, enhances corrosion & structure control
• Application: High-performance and wear-resistant components.

Heat Treatment of Cast Iron

Method Purpose
Sub-Critical Annealing Improves machinability by dissolving pearlite
Full Annealing Promotes ferrite by slow cooling above eutectoid
Solution Annealing Dissolves carbides in stainless castings
Water Quenching Achieves martensite in low-alloy steels
Polymer Quenching Fast cooling with reduced cracking risk
Oil Quenching For medium-carbon steels
Normalized Treatment Converts graphite or carbides to pearlite
Austempering Increases ductility and toughness (e.g., ADI)
Carbon Restoration Ensures full surface hardness post-treatment
 Production Process of Cast Iron
• Made by re-melting pig iron with scrap iron/steel, coke, limestone.
• Melting in electric arc or induction furnaces.
• Adjusting composition (C, Si, Mn) before casting.
• Casting methods: Sand, permanent mold, centrifugal.

Key Properties of Cast Iron

• High compressive strength
• Excellent machinability
• Good wear resistance
• Poor ductility & toughness
• Non-weldable (in general)

Applications of Cast Iron

• Pipes and fittings
• Machine tools & beds
• Automotive parts (cylinder heads, blocks, gear housings)
• Furnace doors & elevator parts
• Dies, molds, and crushing equipment

Would you like this formatted as a PDF handout for printing or interview prep? I can also make a flashcard
version for last-minute revision.

Here’s a detailed explanation of Optical Emission Spectroscopy (OES) — its working mechanism,
components, and why it's important in metallurgy and steel industries like BSRM.

Optical Emission Spectroscopy (OES)

Definition:
OES is an analytical technique used to determine the elemental composition of metallic samples (like steel,
cast iron, aluminum alloys, etc.). It’s widely used in quality control for foundries, steel plants, and metal
recyclers.

Working Principle of OES

OES works based on the principle of atomic emission spectroscopy:

1. Atoms absorb energy and move to an excited state.

2. When these atoms return to a lower energy state, they emit light at specific wavelengths.
3. Each element emits characteristic spectral lines—acting like a “fingerprint” for that element.
4. A spectrometer detects and analyzes these light emissions to determine which elements are present and
in what concentration.

Step-by-Step Working Mechanism

Step 1: Sample Preparation

• The metallic sample (e.g., steel) must be flat and clean, often polished.
• A small disc or block is placed in the spark stand.

Step 2: Spark Generation

• An electrode emits a high-voltage spark or arc onto the metal surface.

• This vaporizes a small amount of the material into a plasma.
• The plasma is made of excited atoms and ions of the elements in the sample.

Step 3: Light Emission

• The excited atoms in the plasma emit light at element-specific wavelengths.

• These emissions are passed into an optical system.

Step 4: Spectral Analysis

• A diffraction grating or prism separates the emitted light into its component wavelengths.
• A detector (usually a photomultiplier or CCD) measures the intensity of light at each wavelength.

Step 5: Element Identification & Quantification

• The system compares detected wavelengths with known values for elements.
• The intensity of the emitted light is proportional to the concentration of that element in the sample.
• The software calculates and displays the chemical composition (e.g., %C, %Mn, %Si, %Cr, %Ni, etc.).

Main Components of OES Instrument

Component Function
Spark Stand Holds the sample and creates electrical spark
Electrode Produces high-energy spark to vaporize sample
Optical System Collects and separates emitted light by wavelength
 Component Function
Spectrometer Detects and analyzes light intensity at various wavelengths
Detector (PMT/CCD) Converts light into electrical signals
Software Interprets data, gives percentage composition, generates reports

Applications of OES in Industry (e.g., BSRM)

Application Purpose
Steel manufacturing (melting) Control %C, %Mn, %Si, %P, %S, etc. in billet/ingot
Quality control Ensure composition meets international standards (e.g., ASTM, ISO)
Incoming raw material check Verify scrap or alloy content before melting
Heat tracking Match heat number with chemical composition in rebar
Failure analysis Identify alloying issues or contamination

✅ Advantages of OES
• Fast and accurate results (within seconds)
• Detects multiple elements simultaneously
• Very low detection limits (ppm levels)
• Works well with solid metallic samples
• Ideal for ferrous and non-ferrous alloys

Limitations
• Sample must be conductive and solid (not for liquids or powders)
• Requires careful calibration
• Surface must be clean and flat for accurate results
• Not ideal for non-metallic materials

Summary Chart
Feature Details
Method Type Emission Spectroscopy
Excitation Source Spark/Arc discharge
Sample Type Solid metals (steel, iron, aluminum, etc.)
Output % Composition of elements (C, Mn, Si, Cr, etc.)
Time per Analysis 5–30 seconds
Sensitivity ppm to wt%