KALYANI

DRIVING INNOVATION

THE

GROUP

KALYANI GROUP
INTRODUCTION

Established in mid 1960s, we are an Indian multi-national with advanced technology,

engineering & manufacturing capability across critical sectors such as Engineering Steel,
Automotive, Industrial, Renewable Energy, Urban Infrastructure and Specialty Chemicals.
As a Group, we have an annual turnover of over $ 3 Billion and market capitalization of
our listed entities stand at approximately $ 4 Billion.

KALYANI GROUP
COMPANIES
4

Bharat Forge Ltd

Worlds largest forging unit - Automotive, Defence, Railways, Energy,

Marine.

Bharat Forge Kilsta

Bharat Forge CDP
BF Aluminiumtechnik

Europe based forging units - Heavy Trucks, Tool & Die, Industrial Machinery

Kalyani Steels

Low & Medium Alloy Steels (through Blast Furnace route)

Kalyani Carpenter
Special Steels

Medium & High Alloy Steels (through Electric Arc Furnace route)

Kalyani Technoforge

Automotive Forging

Automotive Axles Ltd

Axles Manufacturer with technology support from Meritor USA

Kenersys GmbH

Wind Energy

Hikal

Speciality Chemicals

Kalyani Global

Urban Infrastructure

Kalyani Lemmerz

Automotive Wheels

KALYANI GROUP
HIGHLIGHTS

Largest Forging Company

Largest Exporter of Forgings

in the world

From India

Today, Kalyani Group is the

market leader in all respective
business segments
Leading Engineering Steel
manufacturer in India

Leader in Axle Aggregates

in India

JV with Meritor
[Automotive Axles Ltd]

JV with Maxion Wheels

[Kalyani Lemmerz]

The Group has Joint Ventures with

World Leaders in respective fields
JV with Alstom
[Alstom Bharat Forge]

JV with Carpenter Technology

[Kalyani Carpenter Special Steels]

KALYANI GROUP
RESEARCH & DEVELOPMENT

Kalyani Centre for Technology and Innovation (KCTI)

Established in Pune with an investment of USD 14 Million.

Recognized by Department of Scientific & Industrial Research (DSIR), Government of
India.
KCTI augments groups employee knowledge and skills through three areas:

Advanced Technical training

Advanced Academic Courses

Research and Development

Activities at KCTI

Modelling and Simulation

Performance Testing and Validation
Investigation and Failure Analysis
Training and Development
Partnership with Premiere Academic Institutes

KALYANI GROUP
INTERNATIONAL PRESENCE

USA

Upcoming Manufacturing
facility for Auto Components

GERMANY
Automotive Components
Aluminium Forgings
Industrial Equipment
Wind Energy
SWEDEN
Automotive Components

INDIA
Engineering Steel
Automotive Components
Energy
Infrastructure
Chemicals

Our Core Objective

KALYANI GROUP
CORE OBJECTIVE

is to be committed to listening and responding to the needs of

our customers, associates and business partners,

and honoring their individual value.

To be committed to an entrepreneurial spirit

that fuels the growth of our companies

and increases shareholder value.

B N Kalyani
Group Chairman
8

KALYANI STEELS

KALYANI STEELS
INTRODUCTION

Kalyani Steels was established in 1973 as a part of Kalyani Group.

Today, we are a prominent Indian manufacturer of Forging and Engineering quality
carbon & alloy steels using the Blast Furnace route, with a sharp focus on Quality
and a strong R&D backup.

With four decades of experience in Alloy Steels, we have acquired for ourselves the
status of preferred supplier for leading national and international OEMs in the space
of Automotive, Engineering, Energy, Aluminium Smelting, Defence and so on.
10

APPLICATIONS

APPLICATIONS
INDUSTRY SEGMENTS

AUTOMOTIVE FORGINGS

CONSTRUCTION EQUIPMENT

BEARINGS

SEAMLESS TUBES

ALUMINIUM SMELTING
12

FORGING

MACHINING

APPLICATIONS
AUTOMOTIVE

STEEL BARS

A preferred supplier of Forging Quality steel for a variety of Automotive Applications

crankshaft, camshaft, connecting rods, gears, transmission shafts, axle beams, steering
knuckles and so on. Our steel finds use in Commercial Vehicles, Passenger Cars as well
Farm and Construction Equipment.
13

APPLICATIONS
AUTOMOTIVE : ENGINE
14

We manufacture a range of grades for

Crankshaft, Camshaft, Connecting Rods, Piston
Pins, Diesel Injection Rails and other critical
components of automotive engines.
Improved Toughness fine grain material
(6+)
Improved Fatigue clean steel
Consistent hardening response and better
distortion control close band Jominy
Use of Micro-Alloyed Steel

Grades
EN18, EN19, SAE4140, 42CrMo4, SCM440, EN19B,
39Cr5, SAE1541, S48C, SAE1548, CMA-1, 40CrMo4H,
2CrMo, C38+N2, 38MnSiVS5, 38MnS6, 46Mn5, 38MnSiVS5,
C70S6, S48CS1

APPLICATIONS
AUTOMOTIVE : TRANSMMISSION
15

Grades

Our case hardening and micro-alloyed grades

find usage in Gears, Input Shaft, Output Shaft
and other transmission components.
Improved Toughness fine grain material
(6+)
Improved Bending Fatigue - reduced internal
oxidation (controlled Si Levels, optimized S
levels)
Improved Fatigue clean steel
Consistent surface hardening response and
low distortion upon quenching close band
Jominy
Shortened Carburizing time high
temperature carburizing (optimized Al:N
ratio)

SAE8620, SAE8625, SAE8627, ETN22, ETN25, ETN27, 16MnCr5,

20MnCr5, SCM 420, SAE4120, EN353, EN354, SAE8822H,
815M17

APPLICATIONS
AUTOMOTIVE : AXLE PARTS
16

Our steel bears the load in the Axles Beams

and Shafts of Light, Medium and Heavy
Commercial Vehicles, as well as that of Farm
and Construction Equipment
Grades

SAE1045M, 709M40, SAES322, 40Cr4C, 41CrS4, S58C, SS4510/HMnTi,

30MnVS6+Ti, EN15A, SAE1041, SAE1541

Our steels that go into Bearings have high stability to withstand fatigue, distortion,
speed and temperature

APPLICATIONS
BEARINGS

We produce Case Carburizing, Through Hardening and Hub Bearing grades

Improved Toughness : Fine Grain Material (6+)
Improved Fatigue clean steel (low O2, Ti, other
tramp elements)
Consistent surface hardening response.
Low distortion upon quenching (close band
Jominy)
Shortened Carburizing time high temperature
carburizing (optimized Al:N ratio)
Low Decarb gas fired reheating (homogenous
heating)
Low Banding and Carbide Segregation
Good roller contact fatigue
Grades
Case Carburizing: SAE8620, 20MnCr5, 5120, 17CrNi3
Through Hardening: SAE52100, 100Cr6, SUJ2, SUJ3
Hub Bearing: S53C, CF53, CF55, C56E2
17

APPLICATIONS
SEAMLESS TUBES

We are a leading producer of round casts for supply to manufacturers of seamless

tubes. These are for usage in Oil & Gas industries and High Pressure Critical Boilers.
Our plant is approved by Indian Boiler Regulation as
Well-known steel maker for supply of boiler grade quality steel.
Creep resistant steel grades like SA213-T11 & SA213-T22, for use at elevated
temperatures.
We offer range of carbon alloy steel as per major international specifications such as
SAE, BS, DIN, JIS and API.
Grades
SA210 Gr.A1, SA210 Gr.C, SA106 Gr.C , SA192, T11, T12, T22, BS3059
Gr.440, SAE1537(V), SAE1010, SAE1018

18

APPLICATIONS
ALUMINIUM SMELTING

We offer Low Electrical Resistivity (LER) steel, developed specifically for primary
aluminium industry to reduce level of electrical resistance within the steel during the
electrolysis process of aluminium smelting.

19

LER Steel was developed after extensive tests with large numbers of steel grades at
the premiere technological & academic institute IIT Mumbai as a product that
offers considerable reduction in electrical resistance under elevated temperatures up
to 800 Celsius, over other grades commonly used for this application.
We can supply machined and drilled cathode bars for direct use as per technical
drawings provided by the customer.

Grades
LER, ASTM-A36, ASTM-A663Gr.60

PRODUCT RANGE

PRODUCT RANGE
GRADE FAMILIES

Carbon Steel

Carbon Manganese
Chrome Steel
Chrome Manganese
Chrome Nickel
Chrome Moly
Chrome Nickel Moly
(Low Carbon)
Chrome Nickel Moly
(Medium Carbon)
Bearing Steel

AISI / SAE

DIN

B.S.

JIS

1010

CK10

EN2A

S10C

1015

CK15

EN32B

S15C

1025

CK25

EN3B

S25C

1035

CK35

EN8, EN8A

S35C

1045

CK45

EN43B

S45C

1055

CK55

EN9

S55C

1065

CK65

EN43D

S58C

1541

28Mn6

EN15

SMn420H

40Mn4

SMn433H

1137, 1141

EN15AM

SMn433H, SUM41

5130

34Cr4

EN18A, EN18C

SCR435

5140

41Cr4

1541

16MnCr5

SCR415, SUM420

20MnCr5

1320

15CrNiM06

EN352

4130

25CrM04

EN19C

SCM440H

4135

34CrM04

SCM435, SCM420

4140

42CrM04

8620

EN353, EN354

SNCM420H

4320

17CrNiM06

EN36C, EN

361, 362, 363

4340

EN24

SNCM431, SNCM439,
SNCM447

SAE52100

100Cr6

EN31

SUJ1, SUJ2 etc

SAE5160

EN45A

SUP6, SUP9, SUP11

SCR440

Above are the Grade Families and some grades that we commonly produce.
In addition, we regularly undertake New Product Development initiatives jointly with
our customers to develop tailor-made / application-specific grades.
21

Categories
Size Range (mm)

PRODUCT RANGE
APPLICATION & SIZE RANGE

Forging Quality

Carbon, High Carbon, C-Mn, C-Mn-Si, C-Mn-Cr, Cr, Cr-Mn, Cr-Mo,

Cr-Mo-B, Cr-V, Cr-W, Mn, Mn-N2, Mo, Ni-Cr, Ni-Cr-Mo, Micro Alloyed

For Seamless Tube

ASTM-A213-T11/T12, SA210Gr.A1/C, SA192, SA106Gr.C, SAE1010, SAE4042, MSLI/IA/II/IV/7/8, BS3059, Gr440, SAE1537(V)

For Bearings

SAE52100, 100Cr6, SUJ2/3, CF53, CF55, C56E2, 20MnCr5, 5120, 17CrNi3

For Cathode Bar

ASTM-A36, ASTM-A663, Gr60, LER, SAE1006/8

Cast Rounds

160 Dia, 200 Dia,

Cast Billets

125 x 125, 160 x 160, 200 x 200, 210 x 230, 240 x 280

Rolled Rounds (DIA)

36, 38, 40, 42, 45, 48, 50, 52, 53, 54, 55, 56, 58, 60, 62, 63, 65, 66, 68, 70, 72, 73,
75, 80, 83, 85, 88, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135

Rolled Squares (RCS)

45, 55, 60, 63, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 122, 125, 130,
140, 160, 180

Rolled Flats

160x70, 180x80, 160x140, 170x130, 170 x 140, 140x100, 150x100, 160x100

220Dia

We can roll smaller sections (down to 5mm dia) in our alternative facilities within Kalyani
Group. We can also develop any intermediate size suited for customers application
based on business volume and potential.
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Soft

ANNEALING

Isothermal

HOT ROLLED BARS

PRODUCT RANGE
VALUE ADDED PRODUCTS

Spheroidized

Annealed
Bright Bars

As Rolled
Bright Bars

PEELING

Heat Treated
Bright Bars

Hard & Temper

HEAT
TREATMENT

Quench &
Temper

Air
Water
Oil

Post Rolling Value Addition

23

Annealed
Black Bars

Heat Treated
Black Bars

Finished Goods

STEELMAKING

STEELMAKING
QUALITY ASPECTS
25

QUALITY POLICY
We are committed to improve Manufacturing Process & Products
on continual basis
through
effective Quality Management Systems
for
achieving Customer Satisfaction

Phosphorus

0.015%

Sulphur

0.010 % in Seamless Tube & CHQ grades

STEELMAKING
QUALITY ASPECTS

Inclusion Level -

Heavy

Thin

Oxides

0.5

1.5

Aluminates

Nil

Nil

Silicates

Nil

0.5

Oxygen Level Case Carburizing Grades

15 ppm max

Through Hardening Grades

15 ppm max

Ball Bearing Grades

10 ppm max

Hydrogen level

< 2.0 ppm

Banding

Within Acceptable Limits

Decarb

0.3mm

Streaks in Blue Facture Test

Nil

Streaks in Step Down Test

Nil

Narrow Range of Chemical Composition

Four Point Range of Hardenability

26

27

Manufacturing Facilities
Testing Facilities

STEELMAKING
FACILITIES

Mini Blast Furnace Energy Optimizing Furnace -

3 Nos (250m3x2 + 350m3x1)

50 MT

Ladle Furnace -

50 MT x 2

Vacuum Degassing Unit -

50 MT x 2

Bloom Caster -

Three Stands

Billet Caster -

Three Stands

Blooming Mill H.V. Mill -

Reversible Type
Six Stands

Electron emission spectrometers

Pneumatic sample carrier.

Oxygen, Nitrogen & Hydrogen Analyzer

Jominy hardenability.

Computerized Brinnel Hardness Tester

C & S Analyzer.

Inverted Metallurgical Microscope.

Forging Hammer.

Digital Rockwell Hardness Tester

XRF

BHN & Rockwell hardness tester.

Image Analyzer

MPI sample testing facilities.

Mobile spectrometer

Ultrasonic testing machine.

Brugger Test Equipment

Universal testing machine.

Auto UST (Phase Array)

Hydrogen Analyzer

Auto MFL inspection line

Automatic UST (Phase Array) Inspection Line

(20 - 130 mm round & 45 130 RCS)
Equipment Type
Ultrasonic Testing Machine (Phase Array)
Make
Olympus NDT , Canada
Size
Test Frequency

STEELMAKING
FACILITIES

Probe size

Round bars 15 mm to 130mm & 45 130 mm RCS

Length - 2.5 meters and more
5 MHz
Each element size - 0.6 to 0.8mm,
Total 128elements in each probe.

Speed

0.5 1.5 meters/sec - for SDH method

0.1 - 0.5 meters/sec - for FBH method

Defect detection Sensitivity

SDH - 0.5 (capability down to 0.3mm)

FBH - 0.7 to 1.5mm

Automatic MFL Inspection Line

(Round Bar, 20 - 130 mm)

Equipment Type
Magnetic Leakage Flux
Make
Pruftechnik NDT GmbH

Size
Speed
Frequency
No. of Testing Channels
Defect detection Sensitivity

20 mm to 130 mm diameter
length up to 6meter
Up to 2.4 m/sec max
7KHz (Typically 6KHz)
8 Channel
Depth 0.30mm - in hot rolled black bar (capability down to
0.15mm)
Depth 0.10mm - in peeled bar

All material inspected through above are Shot blasted and Machine Straightened
with 0.2mm/meter (0.2%) straightness [Capability up to 0.1mm/meter]
28

Sinter

Fluxes

Hot Metal

Blast Furnace Gas

Slag

To Steel Making

Stove

Captive Power Plant

& Billet re-heating

WASTE RECYCLING

Blast Furnace

Cement Plant

29

Ore Fines /
Sludge / Mill Scale

INPUT

Iron Ore

Pre heated Air

IRON MAKING

STEELMAKING
P R O C E S S 1/2

Coke

From Iron Making

Oxygen

Ferro Alloys

Fluxes

Argon/ Nitrogen

EOF

Bloom & billet Reheating

Ladle Refining
Roughing & Rolling Mill
Vacuum Degassing
Continuous casting
UST / Surface Inspection
Bloom & Billet
Marking / Storage

CUSTOMER &
STOCKYARD
30

Storage /Dispatch

Marking / Bundling / Packing

INPUT

Mill Return

BAR ROLLING

Hot Metal

STEEL MAKING

STEELMAKING
P R O C E S S 2/2

Air Separation Plant

STEELMAKING
CERTIFICATIONS
31

ISO 9001 : 2000

ISO 14001 : 2004
ISO/TS 16949 : 2009

OHSAS 18001 : 2007

WHY

KALYANI

WHY KALYANI STEELS

Why Kalyani Steels ?

Because our customers agree we are good at
what we do

Four decades of experience in Forging and Engineering Quality Steels.

Approved by Major International OEMs and Tier-1 ancillaries.

Global Reach through Bharat Forge (group company).
Specialized in Steel for Critical Components Engine, Transmission, Bearings, Boilers.
Specialized in Micro-Alloyed Grades.
Capability to manufacture more than 600 different steel grades.

33

WHY KALYANI STEELS

Why Kalyani Steels ?

Because we can do a lot more for you
Can produce Reliable and Consistent quality of clean steel
Produced from Iron Ore through Blast Furnace route.
Low gas elements, Low tramp elements = Superior Steel.
Advanced Testing Facilities

Can develop Tailor-Made products for special applications

In-house R&D facilities prototyping, simulation, testing.
In-house value addition facilities annealing, heat treatment, peeling.
Cross Functional Teams for new product development.
Can support custom requirements
Small quantities (50MT multiples), staggered deliveries, special packaging.
Adept Logistics partners for overseas deliveries.
Can produce any grade of steel (low/medium alloy, micro-alloyed) that is produced
commercially anywhere in the world.

34

PHILOSOPHY
35

To use our specialized skills and innovative technology to contribute to the

welfare of the society. It is our intention to grow along with our employees and to aid and
encourage them to participate in our Goals in order that they realize their full potential.

Our prosperity is linked to the prosperity of our customers.

CONTACT

US

CORPORATE OFFICE
Pune, Maharashtra
India
T : 0091 020 6621 5000
F : 0091 020 2682 1124
W : www.kalyanisteels.com
MANUFACTURING FACILITY
Hospet, Karnataka
India
NORTH
Ajit Yadav
E : ajit.yadav@kalyanisteels.com
WEST
Arvind Sangamnerkar
E : arvind.sangamnerkar@kalyanisteels.com
SOUTH
Kush Jeevan Deep
E : kush.jeevandeep@kalyanisteels.com
EXPORTS
Vilas Patil
E : vilaspatil@kalyanisteels.com
Saikat Sarkar
E : saikat.sarkar@kalyanisteels.com