The process of producing I-beams
The production of I-beams is one of the fundamental processes in the steel industry, carried out through hot rolling.
The production of I-beams is one of the fundamental processes in the steel industry, carried out through hot rolling. In this process, metal billets are heated to high temperatures and passed through rolling mills to achieve their final shape and size. I-beams, due to their widespread use in construction, play a significant role in determining housing prices. Advanced technologies in various stages of production, including melting, casting, and final processing, help improve the quality and efficiency of these products. In this article, you will become familiar with the steps of I-beam production and the importance of each stage in the construction industry.
How is the I-beams production process?
Hot rolling is the most important stage in the I-beam production process. It should be noted that the size and standard of the I-beam do not affect the overall production process, and the method of production is almost the same for all types of this product. This metal section is so widely used in construction that the price of I-beams can be considered a significant factor in housing prices.
In the hot rolling method, which is used for producing many metal sections and is a very common method for shaping metal products, blooms or billets are used as raw materials. A billet or bloom is considered an intermediate product in the metals industry, with a surface length of less than 230 square centimeters. Steel blooms are used as raw materials in the production of metal sections such as I-beams, rails, channels, and angles.
I-beams Production Process
In the I-beam production process, the billet, whose cross-section is determined according to the type of the final product, is placed into the furnace to be heated to the desired temperature, which is around 1100 degrees Celsius. In the next stage, the heated billets are passed through rolling mills to gradually reduce their cross-sectional area and take the desired shape. The product must pass through three rolling mills: the initial, intermediate, and final, to achieve the desired shape.
In the initial rolling mill, the billet’s cross-sectional area decreases, and its length increases. The intermediate and final mills are responsible for shaping the product into the desired form, after which the I-beam is cut to the required lengths and prepared for packaging.
The I-beam was first produced in 1849. The production process of I-beams is carried out in two methods:
One method involves welding, where several steel plates are placed side by side at the desired width, and two steel bars are placed on the sides, forming an H-shape. The I-beam is then produced by welding the steel pieces together. The second method involves using heating furnaces, where steel plates are heated in the furnace to 1100 degrees. The molten steel is then passed through rollers, which shape the body of the I-beam into a narrow strip, and the edges are formed by side rollers according to standard calculations.
In general, carbon is used to increase the strength of the I-beam and improve thermal conductivity. Carbon I-beams are commonly used in railroads and tracks. Another type of I-beam is stainless steel, where the high chromium content provides resistance to corrosion.
I-beams Production Stages
The I-beam is one of the essential products in the steel industry, widely used in various structures and buildings as a structural alloy. The production of I-beams involves several stages, including melting raw materials, casting, and final processing. Below is a general overview of the I-beam production process:
- Melting Raw Materials: The process begins with melting raw materials such as iron ore, carbon, and other additives. These materials are either powdered or lumped and placed in furnaces for melting. Heat and chemical additives melt the raw materials, turning them into molten iron.
- Casting: After melting the raw materials, the molten iron is cast into molds with the desired shape and size. These molds can be blooms or billets. The molten iron solidifies in these molds during this stage.
- Final Processing: After casting, the semi-finished I-beam pieces undergo final processing operations such as heating, stretching, sheet working, machining, and turning. These operations shape the I-beams into their final dimensions.
Advanced Technologies in I-beam Production
The I-beam production industry, like the steel industry, utilizes advanced technologies to improve performance, increase efficiency, and reduce costs. Some advanced technologies in I-beam production include:
- Advanced Ironmaking Technology: This technology employs various ironmaking processes to enhance the mechanical properties and quality of I-beams. High-quality I-beams with optimal strength and hardness, and free from defects, are produced using these technologies.
- Use of Advanced Raw Materials: High-quality raw materials have a direct impact on the quality and lifespan of I-beams. Advanced technologies for refining and improving the quality of the raw materials used in production can enhance manufacturing performance.
- Advanced Melting Methods: Advanced steel and iron melting methods, such as electric arc, induction melting, and others, can improve the mechanical properties and quality of the produced I-beams by reducing pollutants.
- Advanced Processing and Joining Technologies: These technologies include advanced welding techniques like electron beam, laser, or resistance welding, which can enhance the quality and precision of I-beam joints.
- Smart Control and Automation: Using intelligent control systems and automation in I-beam production can improve manufacturing performance while reducing costs and increasing efficiency. These systems can include production line control, quality control, automatic material handling, and smart systems for predicting and monitoring production performance.
- Energy Management and Environmental Protection: Advanced technologies are also used to manage energy efficiently, reduce pollution, and protect the environment. These technologies may involve recycling systems, smart cooling systems, energy optimization, and sustainable production approaches.
Quality Control Techniques in I-beam Production
Quality control in I-beam production is a critical operation to ensure high standards. Some techniques and methods for quality control include:
- Non-Destructive Testing (NDT): Methods like Magnetic Particle Testing, Ultrasonic Testing, Radiographic Testing, and Penetrant Testing are used to detect potential flaws and weaknesses in the I-beams and check their quality.
- Dimensional Control and Measurement: Precise dimensional measurements of I-beams using tools such as micrometers and calibration instruments ensure conformity to the required technical specifications.
- Physical and Chemical Tests: These include tests for mechanical properties (tensile, impact, and combination tests), chemical analysis, and microscopic examinations to ensure the beams meet the required standards.
A Quick Overview of the I-beam Production Process
Initially, billets are loaded into a furnace at 1100 degrees Celsius with a hydraulic jack, arranged in specified rows. After the billets are heated, they are placed on rollers to move to the roughing stage. At this stage, the diameter of the billets is reduced three times, and their length is increased. In the next stage, rolling mills, consisting of 10 to 18 stands calibrated accordingly, further shape the billets. Finally, the cutting shear is used to cut the products into different lengths.
Production of Honeycomb I-beams
To produce honeycomb I-beams, rolling operations are first carried out, and then the web is marked in a trapezoidal shape. To prevent deformation at various points, welding tacks are applied before placing the beam on a horizontal frame. The beam is then cut along the marked line using a cutting machine, and the teeth of the upper and lower parts are welded together to form the honeycomb structure.
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