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The thyssenkrupp Steel magazine

compact
Issue 02/2018
thyssenkrupp-steel.com

Pull-out
Two-page infographic
on hot and cold forming

A
smart
solution
smartform® is an innovative
process that enables high-strength
steels to be formed reliably and
cost-efficiently
Page 8

Hot forming in the auto Visit to the steel mill: The Volvo
sector: We have the XC40 is packed with high-tech
materials and the expertise steel from Duisburg
Page 14 Page 24
2 3
Contents

Editorial
Looking good
Beautifully
decorated tinplate
cans have become
bestsellers among
design-conscious
“We’re sending a strong
message to our customers:
end consumers.

20

The path is clear to construct a


new hot-dip galvanizing
line at the Dortmund site.”

T
his year, thyssenkrupp has made
a number of important decisi-
ons. Here in the Steel division, we
paved the way for the planned joint
venture with Tata Steel by signing
An all-round the corresponding agreement this
success summer. Next up are the audits to
thyssenkrupp Steel is check compliance with competition law. Moreover,
implementing its patented our parent company, thyssenkrupp AG, decided
concept for a lightweight
steel wheel in China. at the end of September to separate its operations

Photos: cover: thyssenkrupp Steel Europe Photography | Photos: pages 2–3: thyssenkrupp Steel Europe Photography (2), Jonas Friedrich, Getty Images
into two individual stock corporations. So we’re Andreas J. Goss
23 taking decisive steps to secure the future of both CEO thyssenkrupp
Steel Europe AG
the Group and the joint venture.
The Steel division has made some groundbreaking
investments this year: As a result, our new ladle
Focus: Forming furnace in the melt shop will go into operation demonstrating that we’re pursuing innovation and
When it comes to technologies
and materials for cold and hot this fall. We can use it to manufacture high-alloy creating jobs. In the future, we will use this line to
forming, thyssenkrupp Steel steel grades that will provide our customers with serve the growing demand from our automotive
is an innovative partner to the additional opportunities for differentiation; for ex- customers for high-quality, hot-dip galvanized
automotive industry.
ample, in the area of ultra-high-strength structural materials. We’ve also reached a milestone when
08 components for vehicles or industrial applications. it comes to technological development: our new,
We’re also building an additional hot-dip galvaniz- patented smartform® forming technology. Our cus-
ing line at the Dortmund site: In doing so, we’re tomer Volkswagen will soon be using this method
sending a strong message to our customers, to mass-produce ultra-high-strength, cold-formed
components.
We’re also looking ahead to the future of steel
Component production production through our collaborative project
Less material, greater benefits: Carbon2Chem. The goal here is to convert the
The many advantages of the hot-dip A trip to the mill process gasses released during production into
galvanized flat product scalur®+Z. A car made with steel: The chemical products. We’ve already become the first
30 new Volvo XC40 paid a visit
to the Duisburg site. The pace of innovation in the world to manufacture methanol from blast
furnace gases under real conditions, an important
24
is increasing: We step towards sustainable steel production. This
year’s Euroblech in Hanover, Germany, will serve
developed over half as the perfect forum to discuss all these develop-
ments and innovations. The motto is ‘Empowering
of our 2,000+ steel you,’ which echoes our greatest key objective:
advancing our customers.
Credits
Published by:
Editorial staff:
Kilian Rötzer (legally responsible)
Communications
Photographic department, layout,
and production:
C3 – Creative Code and Content GmbH
Printing:
thyssenkrupp Steel Europe
Digital/print media
grades within the last
decade.”
thyssenkrupp Steel Europe Marcus van Marwick Heiligegeistkirchplatz 1 compact is printed
Kaiser-Wilhelm-Strasse 100 Head of Brand & Customer Communications 10178 Berlin, Germany on FSC-certified paper.
47166 Duisburg, Germany —
— Christiane Hoch-Baumann
Tel.: +49 203 520 Please contact us to share your comments and suggestions:
Brand & Customer Communications (Editor in Chief)
Fax: +49 203 522 5102 compact.tkse@thyssenkrupp.com

The thyssenkrupp Steel magazine compact steel 02/2018


4 5
View

View
Gateway to
digitization
An astonishing 2.5 million vehicles pass through the
thyssenkrupp Steel facility annually. Gate 6, located
9.8 km2
is the total area of the mill
on Hoffsche Strasse in Duisburg, is one of the most
important vehicle entry and exit points from a logistics site in Duisburg-Nord. That
standpoint, which is why it was chosen to be the first is roughly twice the size
of seven gates to undergo upgrades. Along with major of Tegel Airport in Berlin.
structural changes, a digital gate control system will
provide for greater transparency and fast handling from
early in the morning to late at night.

5
lanes lead in and out of
gate 6. They can be used
for vehicles entering or
leaving the facility, based
on demand.

Photo: thyssenkrupp Steel Europe photography


1,000 trucks
arrive each day at the facility to collect
steel for delivery. If you add in all of the
other vehicles from suppliers bringing in
materials for the mill and plant, this figure is
roughly twice as high.

The thyssenkrupp Steel magazine compact steel 02/2018


6 7

Knowledge &value
Reports

Reports
Steel finder The industry in brief

Sought and found Italy


Germany 19
21.5 million tons

The thyssenkrupp Steel division has digitized


its product range and compiled its entire Spain 11
portfolio in a dedicated database. The ‘steel France 7.1
finder’ offers several filter options, and the Poland
hit list provides a precise technical descrip-
tion of each product. This allows customers Belgium 3.1
6.5
Steel scrap in the EU
to put together an industry or application United 2.6
The consumption of steel scrap in
Kingdom the European Union (EU-28) amounted
product range that is fully tailored to their
Austria 2.6 to 93 million metric tons in 2017. In
own needs. Better yet, the tool delivers
quick, variable, and reusable results. Luxembourg 2.4 Germany, around 19 million tons were

Precision strip The steel finder can be accessed at used to produce steel. (Source: Eurofer)
Sweden 2.3
Site anniversary www.thyssenkrupp-steel.com/en.

put to best use Close to our


customers:
More than half
With its own Application Technology unit thyssenkrupp of the annual
Precision Steel is delivering even more value to its customers. production
volume in Three questions for... Dates
Hohenlimburg is
delivered within
The declared aim of the new Application Technology unit is
25 unit in Hohenlimburg is to the specimen store. It is vital for
a radius of only
Alexandra Gies, a thyssenkrupp Steel,
provide customers with strategic performing tests – both for in-
a few kilometers.
is in charge of meeting corporate
standards.
architect@work
support in the development house product development Market launch: 7/8 Nov. in Berlin and

1
of new components. This is and for customers. In addition A new grade from 5/6 Dec. in Stuttgart
Anniversary in achieved, above all, by providing to the technical know-how of thyssenkrupp
Precision Steel
The event, which is organized both
nationally and internationally, addresses
southern Spain the material characteristics of the precision strip specialists, is now being

3
urban planners, engineers, private
precision strip grades for cold close proximity to customers and used in airbag
gas generators. What is the abbreviation and municipal property developers,
Not far from Valencia, the forming. Another important direct communication among architects, professors, and designers.
The customer IATF 16949 all about?
thyssenkrupp Galmed galvanizing aspect includes the identification all parties involved also Visitors to the annual event learn about
line produces ultra-high-quality implemented IATF stands for International innovative applications, products, and
of the material characteristics contribute to success. the new product
galvanized sheet, which is mainly Automotive Task Force, an services for various types of buildings.
supplied to automotive manu­ of hot rolled grades, which is at their site
within a few association of major carmakers. thyssenkrupp Steel will be presenting its
facturers in southern Europe and carried out on site by a team of ideas for facade design, among other
their suppliers. After a temporary weeks after IATF 16949 is a revision of
five. In addition to welding and things.
shutdown a few years ago, the Web a successful ISO/TS 16949, the preceding How do you ensure that all
brazing systems, the unit now test run in the #pladur® #steeltechnology4.0
approximately 130 employees standard that has established requirements are being met?
celebrated their 25th anniversary also has a hydraulic press for fine For information on this topic, visit Application
www.thyssenkrupp-steel.com/en Technology unit. itself as a global quality standard This is the task of the multipliers at
this summer. It is in no small part blanking and deep drawing. The and navigate to Precision Steel under in the automotive industry. By all our locations. For a company of
down to them that production
here at the site has returned to
most important element of the Company > Business units.
gaining this certification, we have our size and varied portfolio, this bauma 2019
the highest levels of quality and reached an important milestone is a huge undertaking. Colleagues 8 to 14 April in Munich
output. “We are getting the site that ensures our continued ability must ensure that every employee A must-attend event for everyone
in shape for the future by manu- involved in the construction machin-
facturing zinc-magnesium prod- to make supplies to this industry. in the individual companies
ery industry: The international trade
ucts, which are in strong in high Ultimately, it’s our high-quality knows what to look out for. fair, which is regarded as a global

Photos: thyssenkrupp Steel Europe photography | Illustration/infographic: C3 Visual Lab


demand,” says André Matusczyk, products that make us stand out Every action and activity ­innovation driver, only takes place
CEO of the Automotive business
unit at thyssenkrupp Steel. In- Facts and figures from the competition and remain performed must be verifiable once every three years. It is the key
a supplier over the long term. retroactively – regardless of hub for learning and spreading industry
vestments in coating technology news, so it goes without saying that
and process automation should
further contribute to securing the On the way to a the system or the process step
involved. And this must be
the Heavy Plate business area of

72
2
thyssenkrupp Steel will be present-

sustainable future,
plant’s position in the future. internalized, because if we do ing its innovative grades for yellow
not regularly prove compliance goods here.
individual
grades steel is not the What is the difference between
with these standards, we could
lose orders.
#processoptimizer #steelexperts

of the Precision Steel business


unit are.being given a new name. problem, it can the new and the old standard?
The IATF has rephrased,
CWIEME 2019
The precision strip specialists from

thyssenkrupp Steel –
Hohenlimburg are thus putting their
quality and brand promise into
be a key to the extended, or added many
requirements for suppliers.
21 to 23 May in Berlin
The leading trade fair for coil winding,
insulation, and electrical production
like!
The Steel division’s Facebook
concrete terms. In the future, all
products will be marketed under the
brand name ‘precidur®’. For example,
solution.” This primarily concerns
documentation and risk analysis.
provides a platform for suppliers and
manufacturers from the automotive,
page keeps visitors up to date on energy, electrical, and electronics
what’s new in the world of steel! HSM 380 will be called ‘precidur® Andreas Goss, CEO of thyssenkrupp Steel, on Everything we do must be
HSM 380’ after the change. The the occasion of the launch of the “In4climate. sectors. The Automotive and Electrical
Let’s become friends traceable. And because we can
on https://www.facebook.com/ official launch of the new product NRW” initiative in September 2018. The initiative Steel business units will jointly represent
thyssenkruppSteel. brand will be announced at the sees science and industry partners working do that, we have successfully thyssenkrupp Steel.
Euroblech trade fair in Hanover. together to further reduce greenhouse gases. passed the audit. #mobility_of_the_future #electrified

The thyssenkrupp Steel magazine compact steel 02/2018


8 9

Smarter
Cover

Cover
From start to finish:
René Groß (left) and
Ferry Grumptmann
assess the individual
steps of component
production at the
VW plant in Zwickau.

forming
thyssenkrupp Steel’s innovative and
patented smartform® technology now
allows ultrahigh-strength steels to be
processed reliably by cold forming in a
dimensionally stable way with almost no
springback

smartform®

The individual Step one: The blanks are Step two: The blank Step three: Next, the Step four: Sizing is the Steps five to seven: The final three steps
steps of the cut precisely to make sure is then fed into the preform is created by final step. Compressive in the process complete the component,
smartform® they are optimally shaped cold forming press to forming the blank into stress superposition including final trimming, perforation, and
process: while minimizing cutoff. preshape the base. a ‘U’ shape. This is the reduces springback, and preparing the welding flanges for later
actual start of the two-stage the component already integration into the chassis.
smartform® process. takes on its final shape.

The thyssenkrupp Steel magazine compact steel 02/2018


10 11

9,000
Cover

Cover
longitudinal members pass through
the transfer press each day at the
VW plant in Zwickau. Logistics then
delivers the finished components
to all corporate locations of the
automobile manufacturer.

smartform® means
a high level of
dimensional accuracy
and a reduction in the
amount of material
used.”
Hans-Joachim Sieg, Technical Customer Support,
thyssenkrupp Steel

Text Judy Born | Photos Rainer Kaysers thus opening up new lightweight construction
potential. Cold-rolled, dual-phase steels

O
from thyssenkrupp Steel expand the range
n this late summer day, there of applications in cold forming, display high
are certain points where the resistance to deformation, high absorption
sun streams in and reflects off capacity, and improved cold forming properties.
the shiny white floor. First- However, they also increase the challenges
time visitors are surprised to placed upon the component production process
see such a bright, spacious, chain. “As a part of the InCar® plus project, we
and clean hall, which seems already presented a cold forming process that
more like an oversized laboratory rather Views and insights: in particular compensates for unavoidable
than a production facility for auto parts. A component is stamped out springback problems. It was initially applied
At least by the looks of it. But the constant of steel blanks (left). to the production of longitudinal members,”
A bird’s eye view of the
sound of rhythmic pounding that causes says Hans-Joachim Sieg, a technical customer
transfer press (below).
the air to vibrate makes it clear where you support advisor at thyssenkrupp Steel
are immediately: at the Volkswagen Sachsen
The advantages responsible for working with the Volkswagen
press plant in Zwickau. of smartform® group on issues surrounding materials. “With
at a glance: conventional deep drawing, the required
Distribution throughout the group Consistent component
material comes from the thickness,” says Sieg.
Components for Volkswagen’s modular adds. This enormous production volume quality thanks to almost “The thinner the material gets, the higher the
transverse matrix (MQB, modularer was one of the reasons why the Volkswagen completely springback-­ stresses in it. As a result, it springs back as soon
free forming of ultra-high-
Querbaukasten) are produced here, at the group’s technology planning and development strength steels. as the component is removed from the tool.”
Mosel location just outside the city, and are production processes were moved from Geometric freedom and
then delivered to every European production Wolfsburg to Zwickau two years ago. “The maximum process reli- smartform® for cold forming
ability when cold forming
facility for the group brands Seat, Škoda, and aim was to test the development of sizing high-strength steels.
The smartform® process basically consists of
Audi. Only the parts required to manufacture deep drawing without trimming,” says René Amount of material used
two steps: the production of a preform similar
the Golf and Golf Variant remain in Zwickau Groß, Head of Maintenance at the Zwickau reduced by an average to the finished component, and then control of
itself. “At the moment, we are producing the press plant. “This method was specifically of 15 percent and a im- the dimensional accuracy in the sizing pro-
proved material utilization
longitudinal members for the Golf platform,” developed for forming high-strength steels per coil (depending on cess. In the smartform® process, the material
says Ferry Grumptmann, who is responsible by cold forming.” It was then refined by the component). is compressed during sizing rather than being
for individual parts planning and overall thyssenkrupp Steel into the patented Significant cost drawn and made thinner. “It’s a brilliant idea
optimization and time
planning. If you add up the number of left- and smartform® process, which is suitable for saving in tool design, tool
from thyssenkrupp Steel. Simply put, rather
right-side members, a total of up to 320,000 manufacturing components that require a high construction, and in mass than drawing it, the material is now being com-
components leave the plant each month. “A degree of dimensional accuracy from steels production. pressed,” says René Groß. In the smartform®pro-
true high-volume component,” Grumptmann with strengths beyond 600 megapascals (MPa), cess, the blank is cut to almost the same size ›

The thyssenkrupp Steel magazine compact steel 02/2018


12 13

“smartform® is the
Cover

Cover
Inspection at the
pressing plant:
Ferry Grumptmann

hottest thing that cold (left) and René Groß


inspect the quality
of a longitudinal

forming has to offer.” member.

Eva Maria Kolodziej, Key Account Manager


for Volkswagen at thyssenkrupp Steel,
is impressed by smartform®.

1
How did the
smartform® technology
come about?
Automotive manufacturers these
days are using ever-stronger
materials. These materials
present technical challenges
during processing. Previously,
there was no satisfactory
solution, but thanks to
smartform® this has changed. Eva Maria Kolodziej is
responsible for the entire

2
customer relationship
What are the between the Volkswagen
benefits of using group and thyssenkrupp
smartform®? Steel.
The sheet thickness of the
component can be thinned out
and the blank cutting process

4
can be optimized, meaning less Is this how smartform®
material needs to be used. The was introduced at
result is a weight-optimized Volkswagen?
component with greater dimen- Here again, the cooperation was
sional accuracy at lower cost. In outstanding. Volkswagen very
other words, ­smartform® is the quickly saw the potential in the
hottest thing that cold forming process and worked with us to Experts
currently has to offer. become the first customer to
implement it. We still had a lot › as its final geometry before it is formed, As regards smartform®, this process has al- Ferry Grumptmann forming process must demonstrate its reliability

3
How important is it to learn as the technology is so reducing the number of trimming operations in ready proven that it generally works in the way is a trained tool maker and and suitability for mass production. There
graduated from Zwickau Uni-
to work together new, but together we managed the process chain, and, naturally, the amount required by VW. versity of Applied Sciences is already a wealth of experience with the
with customers? to get the process ready for mass of material used. According to Hans-Joachim with a degree in mechanical process on hand thanks to several thousand
engineering. He first worked
The highly complex materials production in just over two Sieg, this saves an average of 15 percent in The road to mass production as a designer at Audi in
components having already been produced.
we produce as a premier years. comparison to conventional types of forming, A test tool was initially designed and then Ingolstadt before moving on “It’s still too soon to say whether all of our
manufacturer make it extremely depending on the size and complexity of the a prototype was created together with to become a team coordina- expectations will be fulfilled in the long term

5
tor. He has worked for VW
important for us to involve our How important component. “We have a lower working weight, ­thyssenkrupp Systems Engineering on the basis in Zwickau as a press plant as well,” says Ferry Grumptmann, who is
customers in the development are dialogue and less waste, and lower disposal costs,” adds Groß. of the geometries of the longitudinal members planner since 2010. also responsible for cost control and meeting
process. The earlier we do that, consultation for the This will also reduce energy consumption and to be produced. “It was impressive to see how René Groß
delivery deadlines. Of course, Grumptmann
the sooner we can understand cooperation? investment costs of mass production over the good the component was that came out of has qualifications as a
is also setting his sights in the future on a
one another, allowing us to Consultation is a tradition at long term. “That’s exactly what we are testing at the press even in the first forming test,” says master metalworker, as high level of dimensional accuracy, higher
advise them on which product thyssenkrupp Steel. It is incred- the Zwickau plant right now.” Grumptmann. “We succeeded in reducing the an engineering technician, quantities, lower maintenance costs, and a
and as a technical business
is most suited for which ibly important for a long and smartform® is suitable for various vehicle amount of final trimming needed on the blanks manager. He heads the reduction in the amount of material used.
component. Or it might be that successful customer relation- structure components, meaning it’s also in two critical places as part of this cooperation, maintenance department “However, if the process works as well as it
we need to adjust something on ship. We have been working in suitable for U-shaped profiles such as the enabling us to then develop a method for mass at VW in Zwickau and also suggests it will, I have no concerns.”
supports the development
our side, a grade or a process, partnership with Volkswagen longitudinal members. “We’re not just the ideal production.” At this point, it also became process for new tools.
for example. Both sides get for decades, and recommending partner because of the component’s shape and clear that smartform® should be factored in
something out of it – we learn the right high-tech materials application, but also because we need a lot of at the design stage of the component in order
from the customer and they get or a production process as early them here and we have experience with high- to make use of all of the process advantages
an optimized product. as the pre-development phase strength materials,” says Groß. There is also the it offers. “The aim in the future should be
for components is a part of our prospect that thyssenkrupp Steel can supply that all component geometries that allow the Contact
everyday work. even stronger grades of steel in the future. use of smartform® are actually produced by Eva Maria Kolodziej, Automotive business unit,
“This is no doubt a highly attractive proposal.” smartform®,” says Groß. In the next step, the +49 203 524 0464, eva-maria.kolodziej@thyssenkrupp.com

The thyssenkrupp Steel magazine compact steel 02/2018


14 15
Focus

Focus
Hot forming is the go-to process for manufacturing
lightweight, impact-resistant components for the automotive
industry. During a factory tour in Kassel, we got a glimpse
behind the scenes of our customer Volkswagen’s operations.

compound is. Once we’ve passed through the


multi-story Nordrandbau with its numerous
offices and crossed countless small roads within
Text Judy Born | Photos Rainer Kaysers the complex, we find ourselves in front of Shop
2. “Welcome to the most versatile manufactur-

N
ing facility in this complex,” says Ilda Hujdur
ordrandbau is the name of the by way of an introduction. “We make just about
imposing brick building complex everything here.” She leads us past exhaust
where ten five-meter-high letters system manufacturing, the electrocoating unit,
on the roof spell out the name and the press plant. Hujdur is a VW production
of the company that operates engineer in hot forming production, where she
here: Volkswagen. Since the is responsible for quality and dies. “Kassel was
190-meter-­long lettering was originally focused entirely on transmissions;
mounted on the roof of the kilometer-long the location opened in 1958 to prepare engines
building in 1964, it has become a landmark of and transmissions for the Beetle.” 60 years
business history in the town of Baunatal, south later, more than half of all vehicles produced by
of Kassel, Germany. the Volkswagen Group include a transmission
After its main plant in Wolfsburg, the made in Baunatal.

Some like
VW location in Baunatal is the automotive
company’s second-largest production site – Pioneer in the automotive industry
except that rather than entire vehicles, this Volkswagen is considered one of the pioneers of
site manufactures components for all of the steel vehicle construction. There are numerous
group’s other plants. The site in Kassel covers reasons in favor of the material: First and fore-
approximately 2.9 square kilometers. “It takes most is its potential as a cost-effective material
just over half an hour to walk from here to the for lightweight construction. Steel’s long history

it hot
southern end,” we’re told at the gate, illustrating and fail-safe processes are also important,
once again just how impressively expansive the allowing for solid, reliable processing – and
ultimately, steel can be recycled without loss
of quality. The automobile manufacturer has
been using hot-formed steels since 2004; these
materials’ extreme strength also makes them
eminently suitable for use in lightweight con-
struction and even for the most complex compo-
nent geometries, depending on the process.
Hot-formed steels made a significant contribu-
tion to breaking from the trend of increasing ›

Sleek shells: Placed on top Speed and precision: Ilda Hujdur (VW Kassel)
of one another, the two and Dr. Jürgen Schramm (thyssenkrupp Steel)
components will later serve know why stable processes for hot forming are
as the cross beam for the so important.
footwell.

The thyssenkrupp Steel magazine compact steel 02/2018


16 17
Focus

Focus
“Steel manufacturers need
to know our processes.”
Ilda Hujdur is a production engineer in hot
64
thousand components
are produced in
forming at Volkswagen and explains the the forming dies at
Volkswagen in Kassel
most important aspects of the technology. every day. Depending
on the system and
the component, up to
four blanks per stroke

1
can be hot formed
Why do you use hot simultaneously.
forming in Kassel?
Hot forming provides
both impact resistance and
lightweight construction. To
that end, we employ steel from
the MBW® family produced by
thyssenkrupp; it receives its
high strength when formed, al-
lowing hot-formed components
to be designed with thinner Ilda Hujdur has worked at
VW in Kassel for four years.
dimensions and consequently The production engineer is
reducing the weight of the responsible for quality
chassis. and dies.

2
What happens during
the hot forming

4
process? In your view, what
First, the steel blanks are heated constitutes a good
to temperatures of 880 to 950°C starting material?
in a roller hearth furnace. They To achieve the best results,
are subsequently formed in steel manufacturers need to
the press and simultaneously be intimately familiar with the
cooled while the die is closed. customer’s hot forming process
This rapid cooling changes the and know the specific require-
steel’s microstructure, making it ments for any given component.
particularly strong. VW strives for the optimum in
terms of time and quality, so we

3
Which components determine – in advance – the
is hot forming best precise properties that any steel
suited to? to be used must have. We then
Hot forming is best for highly search the existing portfolio for › weight in vehicle construction. “Above all, Because thyssenkrupp Steel’s precise goal is
complex structural components suitable materials and figure they are still indispensable for the structural to provide products with exactly the properties
How long has
in vehicles that are relevant out how best to combine the components that are key to vehicle safety,” needed to meet the specific requirements of cus-
to impact resistance, such different types of steel in the Hujdur says. tomers’ intended applications. “Lower weights
hot forming
as B-pillars. The high final chassis. Lighter vehicles mean lower fuel consump- and optimized costs and processes are the key existed?
strength of the material allows tion, which, in turn, means lower CO2 emissions. considerations here,” Schramm says. The development of hot

5
for the construction of pillars Do you feel like you The best example is the VW Golf 7; its chassis In order to fully tap the potential for forming for automotive
manufacturing began in
that are comparably thin and, receive good advice alone is 23 kilograms lighter than its predeces- lightweight construction, the material must be 1984. That was the first
consequently, very light, but and support from sor’s. Components made of hot-formed steel suitable for martensitic microstructure trans-
Photos: thyssenkrupp Steel Europe Photography

time a side impact beam


still impact-resistant. What’s thyssenkrupp? from thyssenkrupp played an important part in formation. That is the only way to achieve the was manufactured using
this technology. Coated Under pressure: The
more, they are cost-effective in Oh yes, they provide an ex- weight reductions of this nature. “MBW® 1500 high level of strength required to reduce materi- manganese-boron steel dies in Shop 2 press
comparison to other materials. tremely high level of expertise, is standard for these applications today; als and weight while maintaining the same level was used for the first time multiple components
We can also create different and here at our location, we it was one of the decisive developments in of stability. And naturally, the steel needs to be in 1999. per minute. To achieve
strength zones in our B-pillars really value their willingness the area of cost-effective lightweight steel readily formable. “This is made possible by the Incidentally: The patent this, they need to be
dates back to 1974. The overhauled regularly.
in certain dies, allowing them to to maintain a candid, trusting construction,” says Dr. Jürgen Schramm, high temperatures in the process; MBW® allows technology was originally
meet various needs – different partnership. Head of Product Management for Coated and for the manufacturing of highly complex compo- used in the production of
wear-resistant compo-
resistance to deformation in High-Strength Steels at thyssenkrupp Steel in nents,” Schramm says. “If we consider the grow- nents (such as spades)
different areas. Duisburg. And development continues, with ing prevalence of hybrid and electric vehicles, for agriculture.
steels of even higher strengths being created: we can expect demand in this area to rise.” ›

The thyssenkrupp Steel magazine compact steel 02/2018


18 19
Focus

Column
imately 64,000 components are produced
here every day, some using just one die,
while others require three dies at the same
time. Currently, Ilda Hujdur doesn’t see an
alternative to hot forming: “At least not if we
want to work cost-effectively.”
In the expansive Shop 2, growing num-
bers of work units have relocated around
hot forming. As we tour the facility, we pass
cutting and laser tools. “In terms of work-
flows, this all makes sense,” Hujdur says.
“First, we cut the blanks, then we form them
and use a laser to finish the contouring.” The
continuous nature of the process is impres-
sive to behold. The pressed components roll
out of hot forming and into laser automa-
tion constantly and without interruption;
afterwards, they are packed up. A driverless
transportation system picks up the package
Contract work: The
(currently) 11 systems from there and drives it to the shipping faci-
in Kassel produce lity. As of recently, parts can also be welded
hot-formed components on site and shipped out as complete compo-
for all Volkswagen plants nents, such as finished side members.
in Europe.

Reliable manufacturing
Efficient production processes and
intelligent use of resources make all the
difference – on both a large and small scale.
For thyssenkrupp Steel, this means getting
customers involved in the development
process for new products and technologies
› Thanks to their very high resistance to as early as possible and understanding their
deformation, hot-formed components are production processes.
ideal for the stringent safety requirements “As a manufacturer, we would like to

Steel is the surrounding batteries. And in terms of


electric vehicles, Volkswagen already has
have the largest possible process window in
the future,” says Hujdur, referring to more

dominant a platform for mass production with its


Modular Electrification Toolkit (MEB). Hot
durable materials, efficient processes, and
an optimum use of materials. Corrosion

material in forming also has a role to play here: Starting


from the end of the year, a whole series of
protection also plays a major role, partic-
ularly in battery housings. thyssenkrupp

automotive structural components for the MEB will be


produced in Kassel. “We want to expand on
Steel is already working on new solutions in
that area. “We are constantly refining our

manufacturing, that, because the MEB will contain twice as


many hot-formed components as standard
portfolio,” says Dr. Jürgen Schramm. “Steel
is the dominant material in automotive

and it will stay toolkits,” Hujdur says. That’s good news for
Duisburg, because when it comes to electric
manufacturing, and it will stay that way.”

that way.” vehicles, thyssenkrupp is well-positioned.


“Steel is in high demand not just as a
lightweight material for chassis, but also
Dr. Jürgen Schramm, Head of
as electrical steel, an indispensable basic
Product Management for Coated
and High-Strength Steels, material for electric motors,” Schramm says.
thyssenkrupp Steel Hot forming may still have been consid-
ered a niche technology in 2004, but the VW
plant in Kassel developed the technology
for mass production at a very early stage.
Currently, there are 11 hot forming lines in Contact
operation, with two more planned, making it Dr. Jürgen Schramm, thyssenkrupp Steel,
the group’s largest hot forming site. Approx- +49 203 524 0221, juergen.schramm@thyssenkrupp.com

The thyssenkrupp Steel magazine


20 21
Market & design

Market & design


Pinhais, sardines in
tomato sauce, Portugal

Since 1920, the company


L’Estornell, olive oil, based just outside of
Spain Porto has been supplying
the whole country with
Did you know that canned fish. The fisherman
the acidity of an olive mending a net represents
increases as soon as courage and the strength
it is picked? Therefore, to face the forces of nature
the organically grown day after day in order to
fruits of this low-acid catch the best fish.
oil from Catalonia are
ground within 24 hours
of harvesting.

Ortiz, white tuna in oil, Spain

This specialty from the Basque


region is still traditionally caught
by hand with a fishing rod, which
protects the environment and
marine reserves.

Leatherwood honey,
Tasmania, Australia

D
Situated in the Indian Ocean, o you know Peter Durand? He’s
this Australian state shares the
42nd parallel with the southern tip
the one you should thank the

Stylish
of Chile and New Zealand, among next time you open a tin can.
others. When the Tasmanian elm More than 200 years ago, the
flowers for almost two months, Brit came up with the idea of
bees collect the nectar for this
spicy and savory honey. preserving food in tin cans and
had this invention patented in

steel
1810. Only three years later, the world’s first
can factory commenced production in London.
In the 19th century, the world was in upheaval
and the navy and army were the main buyers
of food preserved in sheet metal. The idea was
to prevent soldiers from going hungry in the
Visuals are important. The cans shown field. However, because the can opener was not
here – tinplate in its most pleasing invented until around 50 years later, opening
the cans initially presented the brave men
form – prove just how beautifully liquid with great difficulties. They resorted to using
hammer and chisel or their rifles’ bayonet.
and solid food can be packaged. Today, a slight pull on the tear tab is usually
all it takes to get to the food.
Tinplate cans have become an indispensable
part of our everyday lives. Around 90 percent
of the tinplate produced in Germany, including
that of thyssenkrupp Packaging Steel, is used
to manufacture packaging. Packaging steel is
efficient, highly optimized, and sustainable.
Moreover, thanks to being easy to fill, airtight,
stackable, and safe to transport, tins are also
highly practical. They can be produced in many
sizes and shapes and are ideal for increasing
product sales – provided the steel quality ›

The thyssenkrupp Steel magazine compact steel 02/2018


22 23

Rim redux

Development
Market & design

Through the use of hot forming, thyssenkrupp Steel has succeeded


Colman’s Mustard, mustard
powder, United Kingdom
in reinventing the wheel. The new product is to be put on the road in
Since 1814 Colman’s, based
collaboration with Chinese steel wheel manufacturer Jingu.
in eastern England, has been
producing its world-famous

A
mustard in the well-known
bright yellow packaging. The wheel is a wheel is a wheel. for steel wheels as a partner for volume
powder is ideal for seasoning The creative possibilities for production of the new technology: Jingu
delicate dishes. manufacturing a car wheel, Wheels based in Hangzhou. Ansteel, which
on which the tire is later
pulled, are limited. And yet, In the future, is already cooperating with thyssenkrupp
in the Tagal joint venture, will supply
as part of the InCar®plus
research project, engineers we can produce steel products. In addition to the clever,
patented concept, expertise in hot forming
of the Duisburg-based steel group have
developed a concept for designer wheels innovative and lightweight construction is also of key
importance for the innovative joint project.
made of steel that will break new ground
both technologically and visually. “We have designer wheels
applied the hot forming process, which
is the standard in body construction and made of steel.”
allows for significant weight savings, to the
David Pieronek,
wheel,” says David Pieronek, who is respon- Application Concepts
sible for wheel research and development at
thyssenkrupp Steel. “In the forming stage,
more complex geometries than usual can
be produced through hot forming while still
Gallo, tuna in oil, Spain
achieving high strengths at the end of the
Steamed and preserved in olive › and appearance are right. As is always process.”
oil and salt, the fish in this can the case in the world of commerce, only things This is of critical importance as the
comes from the Bay of Biscay, or, with a pleasing look and feel will sell well. At wheel has to be strong enough to withstand
more precisely, the Cantabrian
Sea. The animal insignia, which best, steel cans are treated as collector’s items, high loads and is constantly in motion. The
represents the brand Gallo as is often the case with oil and fish preserves use of hot forming also has another major
(‘rooster’), is the visually most from southern Europe. If you think of canned advantage: The material’s lightweight
striking feature on the packaging. fish here in Germany, herring is the first thing design allows thinner materials to be used.
that comes to mind. In Portugal, on the other Looking at the entire process chain, it has
hand, it’s the sardine. The fishing association been possible to generate lightweighting
therefore considers this fish to be the ‘true potential of 20 to 30 percent compared to
ambassador’ of the country. As consumers are conventional steel wheels. “Nowadays,
becoming increasingly conscientious about wheels are mainly designed from a function-
where their daily food comes from and how al perspective, but they also need to be cost
it is produced, local products are making a effective and perform well,” says Pieronek.
comeback. This also includes the fish in steel That’s why they only weigh as much as is
packaging, which is canned without coloring absolutely necessary. “When it comes to alu-
or preservatives in top-quality olive oil, ready minum wheels, looks are all important - the
to be served at the dinner table. According wider, more bombastic and more flamboyant
to manufacturers, the can guarantees the the better.” But this also means more weight.
preservation of the healthy fatty acids of the
fish and stores important minerals. The modular design wheel
Photos: Jonas Friedrich | Rendering: C3 Visual Lab

In addition to preserving foodstuff, cans are thyssenkrupp Steel uses a modular design
also a highly sustainable means of packaging. to get the lightweight steel wheel looking
Thanks to their magnetic properties, tinplate good. It is constructed from a uniform
cans can be recycled quickly, nearly fully, and base carrier comprising the rim and an
at little cost. But given the many beautiful additional design shell. The wide spoke
designs, wouldn’t you rather keep it? rim of the outer shell raises the appearance
of the steel wheel to a whole new level.
Dr. Yu Sun, head of Regional Business Contact
Contact Development at thyssenkrupp Steel, and David Pieronek,
Application Concepts
Carmen Tschage, Packaging Steel business unit, project manager Matthias Hein were able +49 203 524 5526,
+49 2632 3097-2764, carmen.tschage@thyssenkrupp.com to win no less than China’s market leader david.pieronek@thyssenkrupp.com

The thyssenkrupp Steel magazine compact steel 02/2018


24 25
Behind the scenes

Behind the scenes


How our
major portion of the Volvo SUV on display here.
And not only the Volvo: Steel, in its many vari-
eties and shapes, forms the material backbone
of the entire automotive industry. The ques-
tion of whether and why this will remain so

high-tech steel
in the future was also raised by ‘Die Autozei-
tung’ magazine, which was producing an ar-
ticle on the new Volvo XC40 on the premises of
thyssenkrupp Steel in Duisburg. They picked
the ideal backdrop since the business ties be-
tween the Duisburg-based steel group and the

gets on the
Swedish car brand go back several decades.
Thanks to this close relationship, the ve-
hicle is allowed to go places that are normal-
ly strictly off limits to non-employees. “We ba-
sically supply Volvo with everything we have
in our portfolio,” says Sebastian Deumlich,

road
a member of the Volvo key account team at Hooked: Where coils aver-
thyssenkrupp Steel. “From galvanized deep- aging 25 tons are moved on
a daily basis, a car of about
drawn steels and bake-hardening steel through 1.8 tons is practically a
to micro-alloyed and multiphase steels. But featherweight.
the list also includes uncoated materials and
materials coated with zinc-magnesium.”

Swedish carmaker Volvo sends its new SUV XC40 on a Steel – a recycling marvel
The blast furnace is suddenly very busy.
journey to its roots in the steel mill of thyssenkrupp. A fresh batch of red-hot molten iron is ready
‘Die Autozeitung’ magazine accompanied it. for further processing. Every four to six hours,
a tapping takes place, which makes things ex-
tremely hot for the smelters at the furnace ing lines. As impressive and spectacular as
door. Directly at the outlet, temperatures can steel production is, the true magic of many
Text Judy Born | Photos Daniela Loof and Rainer Schroeer reach up to 800 degrees. Those who are not grades and qualities happens much lat-
absolutely essential keep their distance. er in the production process – when the slabs
The XC40 doesn’t seem to mind the tempera- are hot-rolled and cold-rolled into carbon
ture. Is it because the car senses the kinship steel flat products on the processing lines.

A
shared with this place? Not very likely.
brand-new car parked right in And neither does it suspect that parts of it will Its versatility is what makes steel so special
front of the blast furnace is a return to this plant after it has served its term: thyssenkrupp’s range with more than 2,000
rare sight indeed. Frankly speak- In addition to iron ore and coke, pig iron also steel grades differ in their strength, elastici-
ing, it shouldn’t be there in the contains a large share of ‘old iron,’ i.e., steel ty, and corrosion resistance, in the way they
first place, but it sure makes for scrap. During production, up to 30 percent of can be formed, which coating they receive, and
a spectacular shot! Inside the this is fed into the BOF melt shop alone. It is much more. The full potential of steel can only
blast furnace, coke and iron used for cooling during the blowing process. be exploited when knowledge of material prop-
ore are melting at temperatures of up to The reason for this is that before pig iron erties is combined with expertise in processing.
2,000° Celsius to form the liquid gold of can become steel, it must be cleansed of un- The core component that ensures the con-
the Ruhr region: pig iron. Each day, more wanted by-products such as carbon, phos- tinuous development of the company’s steel
than 30,000 metric tons are produced at phorus, silicon, and sulfur. This is done in portfolio is the in-house application technolo-
thyssenkrupp Steel in Duisburg alone. the converter by blowing in oxygen. As a re- gy center. It allows the steel maker to simula-
Before the melting process is completed, sult, the substances oxidize and then form te and compare a wide variety of production
New Swede on the block: The the photographer directs the vehicle to the per- so-called slag puddles on the surface of the techniques, check and optimize steel grades,
XC40 is Volvo’s smallest and fect spot. An important detail in the final pic- molten metal, which are then removed. The and optimize products in close cooperation with
most compact SUV.
ture is the tapping process in the background process generates an enormous amount of customers and in line with their requirements.
with red, glowing pig iron flowing out of the fur- heat, which is reduced by adding steel scrap. Duisburg’s high-tech materials are
nace. In the basic oxygen furnace (BOF) melt Next, the purified molten steel is formed found both in the interior and exterior
shop, the iron is then turned into steel, which, and cut into solid steel blocks, called slabs, of the Volvo XC40, including the side
in turn, is the base material that makes up a on the casting-rolling and continuous cast- panel, doors and dashboard, tailgate, cov- ›

The thyssenkrupp Steel magazine compact steel 02/2018


26 27
Behind the scenes

Behind the scenes


The XC40
doesn’t seem
to mind the
temperature.
Is it because the
car senses the
kinship shared
with this place?
Not very likely. And neither does it
suspect that parts of it will return to
this plant after it has served its term:
In addition to iron ore and coke, pig
iron also contains a large portion of
‘old iron,’ i.e., steel scrap.

The thyssenkrupp Steel magazine compact steel 02/2018


28 29
Behind the scenes

Behind the scenes


Steel in the car:
Four reasons
for using
material from
thyssenkrupp

Versatility
Finding solutions for
the various demanding
automotive applications
is a matter of course
for the researchers
and developers at
thyssenkrupp Steel.

Given Volvo’s high safety There is still much to


discover about steel,
one of the most innova-
standards, we consider it tive materials around.

an honor that our material Standard


is built into their models.” Certified and regularly
inspected, thyssenkrupp
Steel meets the high
Sebastian Deumlich, Volvo Key Account team, thyssenkrupp Steel service and quality stan-
dards of the automotive
industry.

Safety
Steel from
thyssenkrupp bolsters
safety concepts
(not just from Volvo),
especially when it
comes to crash-relevant
› ers, cowl, as well as cross and longitudinal components, and has
been a reliable partner
members. “A colorful mix, although we are ad- for carbon steel and
mittedly particularly proud of the parts used top performance for
in the outer paneling,” says Deumlich. “These from Duisburg to the rest of the world, includ- decades.

are the premium components in every car.” ing the Swedish production sites in Gothen-
burg and Olofström. A few production steps lat-
Safety made in Duisburg er, the individual components are assembled E-mobility
Crash-relevant parts also play a very im- in Ghent, Belgium, where they roll off the as- Electrical steel from
portant role. “Volvo is renowned across the sembly line as the Volvo XC40. It is a long jour- thyssenkrupp Steel
can be used for any
world for its high safety standards. It is there- ney from iron ore to high-quality steel grades, drive system, from seat
fore an honor for us whenever materials from such as those produced by thyssenkrupp adjustment motors
through to motors for
us find their way into a Volvo, either direct- Steel. That’s also what the ‘Autozeitung’ team e-mobility. The portfolio
ly from us or via suppliers.” In the case of takes home after having spent a day driving also includes cold-
the XC40, these are first and foremost high- nearly 50 kilometers across the approximate- and hot-forming high-
strength steels used
strength, hot-dip galvanized dual-phase (DP) ly 9.8-square-kilometer factory site in Duis- for the battery housing.
steel and hot-formed, hot-dip aluminized burg to gather information for their article.
steel. The DP steels are used, for example, in The whole process involves many production
the cross and longitudinal members, while the steps and a high degree of expert knowledge.
hot-formed grades are used for the B-pillar. And something else, too, becomes clear
The new Volvo XC40 is built on the Com- on this day: Steel, even though it was invent-
pact Modular Architecture, or (CMA) platform, ed thousands of years ago, is and will re-
and is the smallest SUV in the Swedish vehi- main one of the most versatile and modern
cle fleet. It is also the youngest generation in materials of our time, thanks to properties
the Volvo family and has already been named such as low cost, ease of processing, light
Car of the Year 2018, even though it has been weight, high crash safety, and the fact
In the spotlight: Autozeitung pho-
on the market for less than a year. The newcom- tographer Daniela Loof positions that it is almost 100 percent recyclable.
er is so successful that the original planned pro- the XC40 for some beautiful shots
duction figures have already been increased. (above). Together with author
“That’s good for us, too,” says a pleased Deum­ Markus Schönfeld and Mark Stagge
(on the right, thyssenkrupp Steel),
lich, “because it means that we will also be she examines the motif and takes Contact
able to increase our delivery volume.” center stage herself. Sebastian Deumlich, Automotive business unit,
The material is wound into coils and shipped +49 203 524 0797, sebastian.deumlich@thyssenkrupp.com

The thyssenkrupp Steel magazine compact steel 02/2018


30 31

Interview
Product

Interview
New hot-dip
Less is more galvanizing line for Dortmund

scalur ®+Z stands for maximum efficiency in


component production. The hot-dip galvanized flat

3
product offers the very close thickness tolerances
while also providing a number of advantages. Tekin Nasikkol
is General Works
Council Chairman at
thyssenkrupp Steel.

1
Multi-talented
The key property of scalur®+Z
is its extremely close thickness
tolerances down to +/- 0.06 mm
over the entire length and width of
The ultra-flat
profile of scalur®+Z
provides a number
of advantages
during slitting.”
Roger Hannig,
Technical Customer Support,
thyssenkrupp Steel
2
A product with many uses
The hot-dip coated flat product
scalur®+Z is ideal for applications
that demand stricter tolerances.
Due to its low camber, scalur®+Z
is used in the construction sector
for example in the profiling of
facade elements. The structural
steels scalur®+Z S390GD, S420GD,
and S450GD, for example. These
structural steels were certified in
Germany for use in construction
“Mr. Nasikkol,
what does the
“Mr. Fischer, what
are the reasons
Heribert Fischer
is Head of Production
at thyssenkrupp Steel.

the strip - much lower than with Savings on many levels launch of the for building
following approval by the Materials
conventional hot-dipped galvanized Opting for scalur®+Z allows customers
flat products. Thanks to its ultra-flat to achieve savings on several fronts.
Testing Institute. Components new line mean a new line in
such as runners help ensure that
profile, scalur®+Z offers significant First off, they save on materials.
drawer units move smoothly. The for employees? Dortmund?”
advantages when it comes to That’s because, based on the steel
logistics sector is another key area
further processing. The slit grade and coil weight, they receive
of application for the product, It means a lot: employees have There is growing demand for
strip is ideal for use in the up to 110 additional meters of coil
primarily in the construction of been living under a shroud of high-quality hot-dip galvanized
production of profiles by ordering thinner coil compared to
containers; container bottoms uncertainty for some time. That products in the automotive sector.
due to its very straight conventional hot-dip galvanized flat
made from scalur®+Z are up to 20 is now lifted. The construction We see this as an opportunity
longitudinal edge products. The result is a reduction
kilograms lighter. Factoring in the of a new line is an investment to continue to improve on our
(camber). in set-up times as well as downtimes
average number of containers on a in the future of our company. It position in this market segment.
during production, since the coils need
cargo ship, that saves a considerable is a sign that, the forthcoming Our company was the world’s
to be replaced less frequently. The
amount of weight. scalur®+Z also joint venture is about more than first steel producer able to offer
customer thus saves materials and
has many applications in lightweight just cutting costs and jobs. With all standard surface coatings in
time. scalur®+Z also offers significant
automotive construction, such as the new line, we will not only use in the automotive industry
lightweighting potential due to the up
in electric motor housings or in be able to maintain our current for exposed panels highly popular
Photo: Gettyimages, thyssenkrupp Steel Europe photography

to 20 percent reduction in component


longitudinal members and shock workforce, but will also likely be zinc-magnesium products are also
weight and through the use of higher
mounts. adding more than 100 new jobs. to be produced on the new line,
strength scalur®+Z grades.
That’s a positive signal, one that which is being built alongside
was needed. The fact that the the existing FBA 8 line. Another
hot-dip galvanizing line is being factor that worked in favor of
built in Dortmund demonstrates Dortmund was the fact that one
Less weight, same
load - bearing a clear commitment to the steel of our research centers is located
capacity: scalur ®+Z industry here in the Ruhr. The at the Westfalen­hütte facili-
makes cargo lighter region is developing into Europe’s ty – and innovative technologies
and reduces the Contact biggest center of excellence for are essential to maintaining the
empty weight of Roger Hannig, Industry business unit
containers by up +49 203 52 41154, roger.hannig@thyssenkrupp.com
hot-dip galvanized products – and international competitiveness of
to 20 kilograms. Günter Topp, Industry business unit, this investment is making a key our industry.
+49 203 52 40440, guenter.topp@thyssenkrupp.com contribution.

The thyssenkrupp Steel magazine compact steel 02/2018


Steel

Because your standards


are exacting: scalur ®+Z Experience
scalur ® +Z:

EuroBLECH
October 23– 26, 2018
Hall 17 | Booth E33

A hot-dip galvanized flat product of unprecedented precision – that’s scalur ® +Z. Depending on the
sheet thickness ordered, we achieve very close thickness tolerances as low as ± 0.06 mm. That is lower
than with comparable conventional hot-dip galvanized sheet and offers you considerable advantages.
It increases your output by minimizing material input and reduces set-up times, resulting in fewer
manufacturing downtimes and faster production. So if you have to set more stringent tolerance requi-
rements, for instance for stampings, profiles or telescopic rails, what’s the best material for you to use?
Precisely: scalur ® +Z. Further details at www.thyssenkrupp-steel.com /en /scalurz