svdp bond voor materialenkennis 091029 b-comp · 2009. 11. 20. · selection introducing ultra high...
TRANSCRIPT
OCAS : a joint venture between ArcelorMittal and the Flemish Region
Bond voor Materialenkennis
OCAS, 29 October 2009
Sven Vandeputte
Welcome
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OCAS - Shareholders’ structure
Vlaams Gewest
(Flemish Region)
FINOCAS (FINancing OCAS)
50 %50 %
22,5 %
77,5 %
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OCAS - Missions
�Provide steel and metal-based products, services and solutions, to satisfy and anticipate our customer’s needs
�To realise breakthrough developments
�To set up new industrial spin-off activities
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OCAS - Markets
� Industry includes
• appliances, mechanical construction and engineering, heavy plate, tubes and pipes, HVAC, radiators, drums, furniture, electro-magnetic applications, energy generation, transport and storage systems, off-shore applications etc.
• Covering product mix from 0,2 to 100 mm
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OCAS - Core expertise
�New alloys and coatings
�Surface functionalisation
�Steel solutions
Steel grades forenergy transport
Plates for windmills Improved efficiency electrical steel
Steel grades forfuture hydrogen
economy
Self-cleaningsurfaces
Enhanced esthetics Increased corrosionresistance
Easy manufacturing
Structural design of components
Welding Metal sheet rapidprototyping
FEM simulations
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OCAS - Typical examples of R&D contribution
• optimisation of customers’ processes
• rapid prototyping & production of small series (e.g. back panel refrigerator)
• environmental friendly pre-treated products
• weight reduction thanks to innovative product design and smart materials selection introducing ultra high strength steel (e.g. gas cylinder, agri-tipper)
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OCAS - Spin-offs and partnerships
� Incubation of new industrial activities and spin-offs by leveraging steel related product and solution expertise
• elytra: continuous manufacturing of light weight sandwich panels
• xcelcoat: industrial deployment of advanced functional coatings
• borit: embossed panels
� Leverage effect of R&D through partnerships• Design and forming centre for industry (JV with AM TOP)
• Metal Processing Centre (JV with CRM)
• Flamac, a division of SIM
Elytra NV │ Lammerdries 18 e 2440 Geel │ Tel: 014/28 20 90 │ E-mail: [email protected] │ www.elytra.be
RoestvaststaalKoolstofstaalAluminiumCurv ®Glasvezelversterkte polymeren
Vederlichte oplossingen voor het zware werk!
Composite Panel Solutions
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OCAS Day-to-day
� People year 2008– 132 employees : 72 researchers, 60 technicians
– Mean age : 34– 15 nationalities, 45% researchers of non-Flemish background
– 20 sponsored PhD’s, 3 sponsored post docs– 53 international trainees for a 3-9 month period
� Skills– Metallurgy– Surfaces– Application technologies (forming, welding, numerical simulations, etc.)
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OCAS - History
1989 Creation of OCAS (Shareholders: Sidmar, Arbed, ALZ) 1995 SWB becomes shareholder in OCAS, Arbed↔LDD
1999 Aceralia becomes shareholder in OCAS2001 Merger Arbed-Aceralia-Usinor: Arcelor2003 Restructuring R&D Arcelor “Innovation 2005”
from competence centre towards market oriented research from automotive to industry research centre
2004 Ocas becomes joint venture Arcelor - Flemish Region
2005 Deployment of R&D Business Development Unit (BDU)2006 Merger Arcelor - Mittal2006 Creation of 1st spin-off “Elytra”
2007 Creation of 2nd spin-off “XcelCoat”2008 Creation of “Design and forming centre” a joint venture with AM TOP2008 Creation of “Metal processing centre” a joint venture with CRM
2009 Creation of “Metal structures centre”2009 Creation of “borit nv”
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R&D topics - Substrate & Metallic Coating Development (1)
� Steel grades for mechanical construction
• Pearlitic-bainitic-martensitic multi-phase steels
• Steel grades for high temperature applications
• Weathering & fire resistant steels
� Steel for energy pipes and heavy plates
• Development of ultra high strength product range
• Optimisation of heavy plate metallurgy for wide range of applications
• Improving embrittlement resistance of steels
• Optimising hydrogen induced cracking corrosion (HIC) properties
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R&D topics - Substrate & Metallic Coating Development (2)
� Electrical steel grades
• Fully processed (high permeability, low loss)
• Grain-oriented electrical steel grades
• Electro-magnetic shielding
• Coatings for electrical steels
• Amorphous alloys
� Enamelling steel grades
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R&D topics - Substrate & Metallic Coating Development (3)
� Metallic coatings
• Mg in metallic coatings
� Basic research
• Precipitation
• Phase transformation
• Damage
• Texture control
• Modelling
• Hydrogen
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Example - Substrate & Metallic Coating Development
Material characterisation - Girth welds of line pipe
• Request– Characterization of different welding techniques for girth welds
using a specific line pipe grade, wall thickness up to 30 mm– high tensile strength steel grade tubes
– suitable for very low temperature usage
– showing H2S compatibility
– Interpretation of the results
• Approach– Tests according to API 1104 : tensile test, nick break, side bend,
hardness, Crack Tip Opening Displacement, chemical composition
– Additional characterization of the weld through: Charpy tests at different positions, cylindrical tensile tests on weld material
– Sulphide Stress Corrosion Cracking tests according to EFC/16 to demonstrate H2S compatibility
• Result– Two out of three tested welding processes are suitable
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� Passivation coatings
• Cr-free temporary protection / thin organic coating
• Universal substrate for organic layer deposition
� New functional coatings
• Steel with antibacterial / self cleaning properties
• Aesthetic and reflective surfaces
� Coating process development
• Chemical vapour deposition
• Thin organic / hybrid coatings
roll
sheet
R&D topics – Surface functionalisation (1)
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� Appliance
• Corrosion resistance
• New concept for enamelling
• Material selection for laundry dryers
� Metal processing
• Ready-to-paint
� Construction
roll
sheet
R&D topics – Surface functionalisation (2)
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Example – Longer lasting in-use properties
� Enhanced corrosion resistance for off-shore applications– Reduce cost of corrosion protection by using better suited material
– Check corrosion resistance by accelerated testing– Study corrosion mechanism by means of electrochemical techniques
Atmospheric
zone
Splash zone
Tidal zone
Low water zone
Immersion zone
Soil zone
Corrosion rateO,075 mm/year
LAT
LOW ATTACK
HIGH ATTACK
LOW ATTACK
HIGH ATTACKHAT
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R&D topics – Steel solutions and design (1)
� Concept and solution development using new products
• Problem-solving
• Co-design
• Co-engineering– Feasibility
– Cost calculation– Simulations
– Prototypes
� Applied research– New solution concepts
– Deployment kits
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R&D topics – Steel solutions and design (2)
� Numerical simulation
• AutoForm® (process definition, sensitivity analysis)
• Prediction of gloss loss of pre-painted steel due to forming
• SIMULIA / ABAQUS®– Stiffness, crash / drop test analysis, buckling– Clinching, vibration (modal analysis), etc.
• FE-Fatigue® (nCode)– Fatigue (coupled with work hardening effects after forming)
• COMSOL® Multi-physics (heat transfer)
• Flux® 2D for magnetic modelling
• CAD: NX-4 (I-Deas® / Catia®)
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Examples - Steel solutions and design
Co-engineering – Optimize panel thickness of cabinet
• Request– Thickness optimization of cabinet panels
– Change to more cost effective steel grade
• Approach– Finite element modelling to simulate rigidity of cabinet– Check simulation results with real life tests at customer
• Result– Good correlation between experimental results and simulation
– Change of steel grade validated displacements [mm]
Solution 1 illustrated
250 N
d
upper
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Examples - Steel solutions and design
Co-engineering – Design of new oven cavity
• Request– Design new oven cavity optimising stampability and
thermal behaviour during and after enamelling
• Approach– Forming simulations to assess stampability– Thermal calculations to study enamelling behaviour
• Results– Customer agreed with our recommendations and asked
us for rapid prototyping of final design
– Successful assembly and enamelling of prototyped parts by customer
Stamping simulation
Enamelling simulation
Rapid prototyping final part
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Examples - Steel solutions and design
Co-engineering – Compete composite gas bottles
• Request– Innovative steel answer to composite gas bottles
• Approach– Reduce wall thickness by using high strength grade– Include beneficial effect of work hardening of selected grade
to pass burst test– Check weldability
• Result– Good correlation between experimental strain analysis and
deep drawing simulation– Successful testing at customer (weld, burst and drop test)– Weight of innovative steel gas bottle < composite !
Deep drawing simulation
Burst simulation
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Examples - Steel solutions and design
Co-design – New design steep walled bathtub New design shower
• Request– Deep drawing feasibility study
– Selection of steel grade
• Approach– Deep drawing simulation to determine optimal
– Steel grade– Geometry – Blank geometry– Springback analysis
• Result– Development of softer enamelling grade
– Proposal to modify geometry in critical areas
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R&D topics – Product Safety
� Air analysis • Welding fumes and risk assessment
• Volatile organic substances (VOC)
• Volatiles emission from coated panels (Indoor Air Quality)
• Release of thermal degradation compounds
� Nano-particle analysis (sampling and characterisation)• Real-time particle size distribution and concentration measurement
� Release into soil and water• Leaching test, extraction
• Lixiviation of metals (Cr VI)
� Providing data • REACH compliant
• As input for material data safety sheets (MSDS)
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OCAS - Sites
Site ZwijnaardeTechnologiepark 903BB-9052 ZwijnaardeBELGIUM
Site ZelzatePres. J. F. Kennedylaan 3
B-9060 ZelzateBELGIUM
+ 32 9 345 12 [email protected]
www.ocas.be