defects atlas for surface defects on cold rolled steel

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  • 8/18/2019 Defects Atlas for Surface Defects on Cold Rolled Steel

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    DEFECTS ATLAS FOR SURFACE DEFECTS ON COLD ROLLED STEELhttp://www.iitk.ac.in/robotics/project!ists/sai!/at!as.ht"!#RUST

    This page is primarily meant to introduce non-experts to some of the types of defects that arise in Cold

    Rolling. The images used in these atlas were taken under varying lighting conditions at the very initial

    phases of the Surface Defect Inspection ro!ect.

    List o$ De$ects

    • "##$"% C&%&R

    • '%"C( "TC)

    • C&I% 'R$"(

    • )&%$

    I#D$#T

    • IR "RTIC%$S

    • %"*I#"TI

    • "R"%%$% '"#D I*R$SSI

    • I#C) *"R(

    • R&%% *"R(

    • R&%%$D I# SC"%$

    • R+T+R$

    • R+ST

    • SC"'

    • SCR"TC)

    • S%I,$R

    • S*II

    • +#D$R IC(%I#

    • /",I#$SS

    ANNEAL COLOR

    De$ect Description:

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    Coloured markings usually found along the coil edges in hood annealed material. The colour can vary fromlight 0rown to deep 0lue.

    %ossib!e Ca&ses:

    • )igh oxygen content in the protective gas for annealing.

    • %eakage in sand sealing 0ase.

    • Sudden drop of protective gas pressure causing sucking in of air.

    Re"e'ia! (eas&res:

    • revent %eakage during hood annealing.

    • $nsure protective gas has low &1 content.

    %ossibi!ities o$ con$&sion with other 'e$ects:

    They could 0e mistaken for prominent oil marks or light grease marks.

    Attribute Value

    Shop name Shearing Line

    Movement and Shape Stationary, Flat

    Type of Lighting SodiumLight Distance infinity

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Left/Do!n

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name Shearing Line

    Movement and Shape Stationary, Flat

    Type of Lighting Sodium

    Light Distance infinity

    Light Angle Centre/Mid

    Camera Distance %Camera Angle Centre/Do!n

    Flash "sed #es

    $ic Type &'(

    Attribute ValueShop name Tandem mill

    Movement and Shape Stationary, Coil

    Type of Lighting $orta)le Flourescent

    Light Distance %

    Light Angle *ight/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed +o$ic Type Color  

     

    Attribute Value

    Shop name Steel Cutter  

    Movement and Shape Stationary, FlatType of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient Lighting

    Camera Distance 5

    Camera Angle Left/Do!n

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name Steel Cutter  

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient Lighting

    Camera Distance 5Camera Angle Centre/Do!n

    Flash "sed #es

    $ic Type Color  

    )LAC* %ATC+

    De$ect Description:

    Dark 0lack stains on the surface distri0uted either as 0ands2clusters. They are generally of irregular shapeand can vary from small to reasona0ly 0ig si3es4 can appear on 0oth sides.

    %ossib!e Ca&ses:

    &il2emulsion residues on the strip surface which get transformed to car0on residue durind hood annealing

    Re"e'ia! (eas&res:

    • $mulsion wiping after Tandem *ill air-!ets.

    • Degreasing of coil surface 0y $lectrolytic cleaning line after Tandem *ill.

    %ossibi!ities o$ con$&sion with other 'e$ects:

    Dark and prominent 0lack patches mistaken for grease marks.

    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance 5Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute ValueShop name Tandem mill

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance -

    Camera Angle Centre/Mid

    Flash "sed #es$ic Type &(

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    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance .

    Camera Angle Centre/Do!n

    Flash "sed #es

    $ic Type Color  

    Attribute ValueShop name Slitting Line

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Do!n

    Flash "sed #es$ic Type Color  

    CO,L )REA*

    De$ect Description:

    Creases2Ridges4 transverse to the rolling direction. enerally covers total width of the strip. It may also 0efound near the edges with regular or irregular spacing. 5ormed during uncoiling of the strip after annealing.

    %ossib!e Ca&ses:

    • )igh yield point elongation particularly with low yield strength values.

    • )igher 0ending stresses induced in strip due to smaller diameter of guide rolls 6S-rolls7 and greater

    strip thickness.

    Re"e'ia! (eas&res:

    Increase speed of uncoiling at S*4 particularly for thicker guages.

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    Attribute Value

    Shop name Shearing Line

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type &'(

    Attribute Value

    Shop name Shearing Line

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type &'(

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    +OLE

    De$ect Description:

    )oles are discontinuities of the material extending from the top to the 0ottom. enerally4 they have locali3edpresence on the strip surface and can 0e present randomly.

    Si3e8 +sually varies from 9 to :; mm4 sometimes even 0igger.

    Shape8 Irregular.

    %ossib!e Ca&ses:

    • Seperation of Rolled in Sca02$xternal *atter.

    • *echanical Damage prior to Colled Rolling leading to locali3ed thinning and su0se

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    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance infinity

    Light Angle Am)ient

    Camera Distance .

    Camera Angle *ight/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, FlatType of Lighting Am)ient

    Light Distance infinity

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    ,NDENT

    De$ect Description:

    Indentation 6depressions7 can 0e distri0uted at definite distances apart or irregularly throughout the lengthand width of the stock.

    %ossib!e Ca&ses:

    These are mainly caused 0y damaged rolls4 0y protur0ences on the rools ar rollers. The distance 0etweenthe periodically appearing defects often provides indications of origin and source.

    Re"e'ia! (eas&res

    • The work rolls should 0e safeguarded againt foreign matter which may roll in.

    • Regular cleaning and inspection of the the work rolls and pinch rolls is re

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    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance infinity

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Do!n/Mid

    Flash "sed +o

    $ic Type &'(

    ,RON %ART,CLESDefect Description8

    They are patches on the rolled surface4 appearing as large num0er of minute iron particles spread over that

    area. They largely occur in 0ands. the particles are strongly adhered to the surface4 and amount to a highly

    rough surface.

    ossi0le Causes8

    The mechanical wear of the sheet material due to friction results in minute iron particles4 which are

    transferred from the work rolls to the rolled surface.

    Remedial *easures

    Regular cleaning of the work rolls4 transfer rolls and stretcher rolls.

    ossi0ilities of confusion8

    rominent iron-particles could 0e mistaken for fine dents.

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    Attribute Value

    Shop name Slitting Line

    Movement and Shape Stationary, Flat

    Type of Lighting Sodium

    Light Distance infinity

    Light Angle Centre/Mid

    Camera Distance 5Camera Angle *ight/Mid

    Flash "sed +o

    $ic Type Color  

    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance infinity

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle *ight/Mid

    Flash "sed #es

    $ic Type &'(

    LA(,NAT,ON

    Attribute Value

    Shop name La)

    Movement and Shape Stationary, FLAT

    Type of Lighting Am)ient

    Light Distance infinity

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    %ARALLEL )AND ,(%RESS,ON

    De$ect Description

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    Two pairs of continuous parallel lines o0served on the strip surface along the rolling direction.ap 0etween the lines8=;mmap 0etween the 0ands8=>;mm6Centre to Centre7.

    %ossib!e Ca&ses:

    Due to the prolonged usage4 the 0ack up rolls Tensioning Device which su0se

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    Attribute Value

    Shop name

    Movement and Shape Stationary, Flat

    Type of Lighting Sodium

    Light Distance infinity

    Light Angle Center/Mid

    Camera Distance 5Camera Angle Left/Do!n

    Flash "sed #es

    $ic Type Color  

    %,NC+ (AR*

    De$ect Description

    %inear markings of single or periodic occurence diagonal to rolling direction

    %ossib!e Ca&ses:

    • Single results from lack of flatness causing pinch folding in the roll gap of S*.

    • eriodic roll marks results from transfer of pinch marks from work rolls of S*

    Re"e'ia! (eas&res:

    Improve strip flatness at CR* Change S* work rolls.

    %ossibi!ities o$ con$&sion with other 'e$ects

    "lthough they are of characteristic identification4 0ut they could 0e mistaken for pitting defects and thosedue to rolled in matter.

    Attribute Value

    Shop name

    Movement and Shape Stationary, Coil

    Type of Lighting Sodium

    Light Distance 5

    Light Angle Left/Do!n

    Camera Distance .

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name

    Movement and Shape Stationary, coil

    Type of Lighting Sodium

    Light Distance 5

    Light Angle Left/Do!n

    Camera Distance .Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name

    Movement and Shape Stationary, Coil

    Type of Lighting Sodium

    Light Distance 5

    Light Angle Left/Do!n

    Camera Distance .

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinityLight Angle Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type &'(

    ROLL (AR*

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    De$ect Description:

    Surface markings4 generally depressions of various shapes attri0uta0le to defective work cell2pinch rollsurface.

    "ppearance8Smooth shinning patches.Shape8Irregular&ccurance8eriodic on strip surface.enerally found on one side of the strip.

    %ossib!e Ca&ses:

    /elding of metallic pieces like detached slivers4 sca0s etc. on work roll2pinch roll surface.

    Re"e'ia! (eas&res:

    • Identify the rolls causing the defect 0y measuring the gap 0etween the marks.

    Clear roll surface.

    • Change rolls

    %ossibi!ities o$ con$&sion with other 'e$ects:

    They could 0e mistaken for minute 0listering and spilliness

    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance infinity

    Light Angle Am)ient

    Camera Distance -

    Camera Angle Left/Mid

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting porta)le Flourescent

    Light Distance 5

    Light Angle Center/Mid

    Camera Distance Camera Angle Camera/Mid

    Flash "sed #es

    $ic Type Color  

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    ROLLED ,N SCALE

    Defect Description8

    &ther types of rolled in defects are marks in the surface caused 0y rolled in metallic or non-metallic foreign

    0odies of varying shape and si3e. %argely4 they could 0e identified as scales on the sheet surface

    &ccurence8

    Rolled in defects are caused 0y foreign 0odies imprinted in the stock during rolling.

    ossi0ilities of Confusion8

    Rolled in types of defects can 0e mistaken for identations when the rolled foreign 0ody has 0een removed

    from the defect area. Similar defects can also 0e caused in the su0se

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    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting porta)le Flourescent

    Light Distance -

    Light Angle Centre/up

    Camera Distance 5

    Camera Angle *ight/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute ValueShop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting porta)le Flourescent

    Light Distance -

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es$ic Type Color  

    Attribute Value

    Shop name *DCS La)

    Movement and Shape Stationary, Flat

    Type of Lighting porta)le Flourescent

    Light Distance 01

    Light Angle Diffused Lighting

    Camera Distance 5

    Camera Angle Centre/Do!n

    Flash "sed #es

    $ic Type +one

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    RU%TURE

    Attribute Value

    Shop name Tandem mill

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance -

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance -

    Light Angle Am)ient

    Camera Distance 5Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    RUST

    De$ect Description:

    atches of rust or randomly distur0ed4 normally of irregular shapes o0served on 0oth surfaces.Colour8 Reddish 0rown to 0lack.

    %ossib!e ca&ses:

    • resence of a

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    SCA)

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance 21

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance 21

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name La)Movement and Shape Stationary, Flat

    Type of Lighting Flourescent

    Light Distance 01

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    SCRATC+

    De$ect Description:

    Scratches are mechanical damages in width4 depth and length at the surface. They are mostly parallel or atright angles to the rolling direction. They may 0e slightly rolled over and seldom contain scale.

    %ossib!e Ca&ses:

    rimarily caused 0y friction 0etween the stock and parts of the e

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    Attribute Value

    Shop name La)

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle   Left/Mid

    Camera Distance 5

    Camera Angle Left/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name La)

    Movement and Shape Stationary, Flat

    Type of Lighting Flourescent

    Light Distance 01

    Light Angle   Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type &'(

    Attribute Value

    Shop name La)

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle   Left/Mid

    Camera Distance 5Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name *DCS La)

    Movement and Shape Stationary, Flat

    Type of Lighting Flourescent

    Light Distance 5

    Light Angle   Left/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type &'(

    Attribute Value

    Shop name La)Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance Am)ient

    Light Angle   Left/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name *DCS La)

    Movement and Shape Stationary, Flat

    Type of Lighting $orta)le Flourescent

    Light Distance -

    Light Angle   Centre/Up

    Camera Distance 2

    Camera Angle Left/Mid

    Flash "sed #es

    $ic Type Color  

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    SL,-ER

    De$ect Description:

    Irregular flaky overlapping material with non-metallic inclusions or scale under it. It is found along the rollingdirection and can appear on 0oth surfaces.Sometimes referred as Shell.

    %ossib!e Ca&ses:

    Slag or non metallic inclusion entrapment.

    Re"e'ia! (eas&re"ents:

    • revent slag carry over during tapping

    • +se clean ingot moulds

    • roper scarfing of sla0s

    Attribute Value

    Shop name La)

    Movement and Shape Stationary, Flat

    Type of Lighting Flourescent

    Light Distance 01Light Angle   Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name La)

    Movement and Shape Stationary, Flat

    Type of Lighting Flourescent

    Light Distance 01

    Light Angle   Centre/Mid

    Camera Distance 5

    Camera Angle Centre/Mid

    Flash "sed #es

    $ic Type Color  

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    S%(,,

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance Am)ient

    Light Angle   Ambient

    Camera Distance 01

    Camera Angle Centre/Do!n

    Flash "sed +o

    $ic Type Color  

    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle   Ambient

    Camera Distance 01

    Camera Angle Left/Do!n

    Flash "sed +o

    $ic Type Color  

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    UNDER %,C*L,N

    De$ect Description:

    This defect is characteri3ed irregular dark patches spread irregularly over the whole surface of the steelsheet. The patches are finger like and angular in the form.

    %ossib!e Ca&ses:

    This defect is caused due to the im0alance 0etween the composition of the acid and the time of reaction inthe ickling *ill.

    Re"e'ia! (eas&res:

    This defect originates prior to the cold rolling mill4 hence it could spoil the final rolled surface4 it is importantto inspect the reaction time and the composition of the acidic vehicle in the rickling *ill.

    Attribute Value

    Shop name Dispatch

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle   Ambient

    Camera Distance -Camera Angle Centre/Do!n

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop name Dispatch

    Movement and Shape Stationary, Coil

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance 5

    Camera Angle Centre/Do!n

    Flash "sed #es

    $ic Type Color  

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    A-,NESS

    De$ect Description:

    Cross ripples2undulations of varying magnitude appear along the long direction either at the edge or middleof the strip2sheet. Centre 0uckles are located at the middle of strip4 while edge waves appear at the edges.'uckle )eight8 *ostly upto ?mm for precision levelled material.

    %ossib!e Ca&ses:

    • *ismatch of roll gap with in-comming strip crown leads to differencial elongation along the rolling

    direction 0oth at )ot @ Cold rolling stage.

    • Incorrect profile or positioning of support rollers.

    • Contact with edge guides.

    Re"e'ia! (eas&res:

    • Reduction of waviness through precision leveller2stretch leveller.

    • Control of waviness at 0oth )S* and CR* 0y work roll 0ending and selective cooling.

    Attribute Value

    Shop name Slitting Line

    Movement and Shape Stationary, Flat

    Type of Lighting Sodium

    Light Distance nfinity

    Light Angle Centre/Mid

    Camera Distance 5

    Camera Angle Left/Mid

    Flash "sed #es

    $ic Type Color  

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    Attribute Value

    Shop name Steel Cutters

    Movement and Shape Stationary, Flat

    Type of Lighting Am)ient

    Light Distance nfinity

    Light Angle Am)ient

    Camera Distance 01Camera Angle *ight/Do!n

    Flash "sed #es

    $ic Type Color  

    Attribute Value

    Shop nameMovement and Shape

    Type of Lighting

    Light Distance

    Light Angle

    Camera Distance

    Camera Angle

    Flash "sed

    $ic Type