A new breed of steel that meets the engineering challenges ... · A new breed of steel that meets...
Transcript of A new breed of steel that meets the engineering challenges ... · A new breed of steel that meets...
Hybrid Steel®A new breed of steel that meets the engineering challenges of tomorrow.
Our vision:
Innovative steel for a betterengineered future
What if… …you could get the
properties of re-melted steel, in large
quantities to a cost effective price?
What if…
…you could reduce production steps by
up to 50%?
What if…
…there was a steel that challenged
established ideas of what engineering steel
can do?
We work closely with our customers to develop a high quality innovative steel.
This way, we create a common foundation for a better future.
We are proud of what our steel enables the end user and are convinced that our steel can create conditions for further reducing CO2 emissions.
When you’re designing demanding steel components, it often involves a tradeoff between needs and affordability.Strength vs. heat, corrosion vs. strength, quality vs. cost.
Not any more.
Thanks to an innovative breakthrough from the engineering steel specialists at Ovako, Hybrid Steel resolves these “dualities”, enabling you to embrace tomorrow’s design challenges.
Today.
REIMAGINE
The development of our innovative Hybrid Steel started
with a vision.
We wanted to develop a steel that could solve many of the
challenges that our customers, and end customers struggle with.
Our innovative Hybrid Steelenables component manufacturers
to achieve exceptional performance, especially in
demanding elevated-temperature applications.
It also offers major possibilities to reduce production cost.
Rethink. Reimagine. Redesign.
Hybrid Steel - a new family of steel for tomorrows engineering challenges.
Rethink the traditional steps
of parts manufacturing
Rethink the boundaries of
traditional metallurgy
Rethinkthe norms
RETHINK…
REIMAGINE
What if you could reduce parts production steps
by up to 50%?
What if you could combine two
hardening mechanisms?
What if there was a steel that
challenged established ideas
of what engineering steel
can do?
REIMAGINE
What if you could use a steel as a facilitator for new designs and also save cost?
What if you could retain
fatigue strength at elevated
operational temperatures?
What if you could get the
properties of re-melted steel, in large quantities,
more cost effectively?
REDESIGN
Redesign to increase efficiency
Redesign to save time
Redesign to increase
margins
REDESIGN
Redesign to boost
productivity
Redesign to increase efficiency
Redesign to be part of
the future
Our ambition is to help the industry
get desired material properties,
such as corrosion resistance
and high strength at elevated temperatures.
We aim to do this at a lower price,
but without compromising quality.
This is possible through providing a Hybrid Steel,
that is available in very large volumes.
We are currently working closely with Bodycote and ten other companies
in various industries in order to develop and prototype new applications.
“The idea is to get the same technical material
properties that they have today, but at a far
better price.”
Area Sales Manager, Ovako
A material created to solve our customers’ challenges
FEATURES
Hybrid Steel is one of the most significant developments in steel metallurgy for decades
Low segregation
High strength at elevated temperatures
High volume, cost effective
Low distortion after heat treatment
Attractive nitriding properties
High corrosion resistance
High steel cleanliness
Segregation per element
Low segregation. The Hybrid Steel has as low segregation as a re-melted tool steel, but without having to go through the expensive re-melting process
02468
10121416
0 0,0002 0,0004 0,0006 0,0008 0,001 0,0012 0,0014
Weight [%]
Distance [mm]
Tool steel 50 per. Mov. Avg. (V)
50 per. Mov. Avg. (Cr)
50 per. Mov. Avg. (Mo)
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0 0,0002 0,0004 0,0006 0,0008 0,001 0,0012 0,0014
Weight [%]
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Hybrid Steel 50 per. Mov. Avg. (V)50 per. Mov. Avg. (Mo)50 per. Mov. Avg. (Cr)50 per. Mov. Avg. (Ni)50 per. Mov. Avg. (Al)
C Si Mn S* Cr Ni Mo V Al O* N*
Hybrid Steel 60 0.3 0.1 0.3 3 5 6 0.7 0.5 2 3 13
High steel cleanliness. Hybrid Steel is our cleanest steel ever produced, resulting in excellent fatigue properties that prolong lifetime and performance of components
S + O + N = 19 𝑃𝑃𝑃𝑃𝑃𝑃
Hybrid Steel composition
High volume, cost effective. Hybrid Steel can be produced in large batches, enabling a cost effective price
Large batches of Hybrid Steel
Ovako production site
High strength at elevated temperatures. Three times the yield and tensile strength of conventional steel at 500°C enables reduced material use and energy consumption
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Temperature [C]
Rp02 [MPa] Tool steelEngineering steelHybrid Steel
Yield strength vs Temperature
Low distortion after heat treatment. The low distortion enables reduced manufacturing costs by up to 20%
Production process cost reduction per process step in relation to total costTypical steel production cost structure
0%0%
+6%+6%
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Reducing production
cost by ≈20%
Bearing steelΔ Hybrid Steel
Grinding generally stands for 30% of the total cost. Thanks to the low distortion after heat treatment this cost can be reduced vastly.
Attractive nitriding properties. Maintained high core hardness after plasma nitriding and possibility to reduce material use and nitriding process time which cut costs
HARDNESS AND RESIDUAL STRESS AFTER NITRIDING
Plasma nitriding of Hybrid Steel520°C, 20h
ISO 15158 Corrosion of metals and alloys10mV/min 0.01M NaCl
High corrosion resistance. The high corrosion resistance compared to engineering steels prolongs lifetime of components in corrosive environments
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Potential mV [S.C.E]
Bearingsteel
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13%Crstainless
Acid proofstainless
HybridSteel
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MinAverage
The Hybrid Steel reaches values comparable to stainless steel and is more corrosion resistant than bearing steel and tool steel
APPLICATION AREAS
The unique Hybrid Steel features opens up for the use of steel components in highly stressed applications
Bearings and gears
Engine components
Nitrided components
Machining tools
Fuel injection components
Mining tools
Importance of Hybrid Steel features
Bearings and gears
Lower cost and improve performance of bearing and gear applications
“The idea is that this material could be used for a
variety of bearing applications, so that you do
not need six materials for six different applications.”
Jan-Erik AnderssonSenior Technical Specialist,
Ovako
Low segregation
High steel cleanliness
High volume, cost effective
Low distortion after heat treatment
High strength at elevated temp.
Attractive nitriding properties
High corrosion resistance
Very importantUnimportant
High temperatures and corrosion pose big challenges to bearings. To face them,
we have developed a Hybrid Steel that meets these requirements and also:
• Enables significant reductions in scrap in late manufacturing steps,
thanks to very low distortion
• Creates logistic advantages, since the one steel grade can be used for
both small and large bearing dimensions
• Has excellent nitriding characteristics for very demanding applications
thanks to its high core hardness
Nitrided Hybrid Steel is ideal for strengthening and extending the lifetime of
hydraulic and transmission components thanks to features like:
• High wear and corrosion resistance
• Low distortion after nitriding
• High strength
The features opens up the possibility to cut process steps and allows for
more efficient material use.
Read about our collaboration with the nitriding and hydraulics industry.
Nitrided components
Improved performance thanks to the unique combination of high surface and core hardness
“We have only scratched the surface. If we can create a steel
family where we can adjust the material to
the needs of a specific application, the
potential is huge”
Technical Manager, Bodycote
Importance of Hybrid Steel featuresVery importantUnimportant
Low segregation
High steel cleanliness
High volume, cost effective
Low distortion after heat treatment
High strength at elevated temp.
Attractive nitriding properties
High corrosion resistance
To face the automobile industry’s ambition to improve the quality of diesel
combustion, a steel that could manage high pressure at elevated temperature
was needed. That is why we developed the Hybrid Steel.
Compared to conventional steels, Hybrid Steel performs up to:
- 3 times the strength at high temperatures
- 10 times the pressure resistance
We are currently testing with major manufacturers of diesel injection applications.
Fuel injection components
Reducing emissions requires a steel that manages high pressure at elevated temperatures
“We saw that our customers were in need of
a material that could handle higher temperatures, and decided to do something
about it.”
Patrik ÖlundHead of R&D, Ovako
Importance of Hybrid Steel featuresVery importantUnimportant
Low segregation
High steel cleanliness
High volume, cost effective
Low distortion after heat treatment
High strength at elevated temp.
Attractive nitriding properties
High corrosion resistance
Lower CO2 emissions and total costs with a lighter engine We aim to help system providers support OEM:s in improving engine
components. Our Hybrid Steel enables a lighter engine with lower material use:
• Thinner engine walls
• Smaller pistons
This enables lowered emissions and lower total costs,
and is possible thanks to the steel’s high strength at elevated temperatures
and high corrosion resistance.
We are currently testing how Hybrid Steel can improve engine performance.
Engine components
“The Hybrid Steel opens up for new design solutions in regards to
wanted temperatures and increased efficiency.”
Area sales manager, Ovako
Importance of Hybrid Steel featuresVery importantUnimportant
Low segregation
High steel cleanliness
High volume, cost effective
Low distortion after heat treatment
High strength at elevated temp.
Attractive nitriding properties
High corrosion resistance
For machining tool producers, a steel with high strength and
fatigue resistance is key.
Our Hybrid Steel pro-longs product lifetime by improving critical components
which means:
• Fewer product replacements
• Reduced total cost
We are currently testing in corporation with European leading tool producers.
Machining tools
“The materials they [the clients] use today
meet the technical requirements, but are
expensive.”
Area sales manager, Ovako
Importance of Hybrid Steel featuresVery importantUnimportant
Increased machining tool performance through improvement of critical components
Low segregation
High steel cleanliness
High volume, cost effective
Low distortion after heat treatment
High strength at elevated temp.
Attractive nitriding properties
High corrosion resistance
We aim to help the mining industry increase drilling productivity
with our Hybrid Steel, that has outstanding properties for demanding:
• Corrosion environments
• Temperatures
• Wear requirements
This is a game changer for several components in the drill string, and we are
currently testing various mining applications. Moreover, Hybrid Steel is available
in large volumes at a cost effective price.
Mining tools
Increased drilling efficiency at a cost effective price
“The idea is to get the same technical material properties that they [the customers] have today, but to a far better price.”
Area Sales Manager, Ovako
Importance of Hybrid Steel featuresVery importantUnimportant
Low segregation
High steel cleanliness
High volume, cost effective
Low distortion after heat treatment
High strength at elevated temp.
Attractive nitriding properties
High corrosion resistance
BENEFITS
Benefits with Hybrid Steel
Hybrid Steel provides benefits across the entire value chain
Reduced manufacturing cost and complexitySince the steel develops its hardness after tempering, it can be machined in a softer condition and hardened without risk of distortion. This means that a conventional process can reach a significant reduction in complexity and cost.
Prolong product lifetimeHigh cleanliness, wear and corrosion resistance, along with the high strength at elevated temperatures, enables a high performing product over time, with reduced breakdowns and increased lifetime.
Efficient material use• Low distortion after treatment enables reduced scrap in production• High strength enables a component design with lower material use
Reduced environmental impact Our Hybrid Steel was initially designed for meeting the challenges of fuel combustion efficiency, by performing in high temperatures. The resulting steel can reduce emissions of CO2, and also provides an alternative to the use of harmful chemicals.
Benefits with Hybrid Steel
Hybrid Steel enables reduced CO2 emissions due to increased engine efficiency
High strength reduces material usageThe high strength of the Hybrid Steel enables the products, for example an engine, to be:• Smaller• Thinner• Lighter
This reduces the environmental impact, for example by reducing the amount of CO2 emissions.
High corrosion resistance improves engine efficiencyDiesel injection engines requires material that has high strength at elevated temperatures to manage the high pressure. Legal regulations will increase the demand of more efficient engines, and thus lower CO2 emissions. Materials with good corrosion properties will be necessary to cope with this development.
Benefits with Hybrid Steel
Bypass the need for surface treatment and reduce the use of harmful chemicals
Many applications are surface treated with chromiumMany steel components, like hydraulic applications, are coated with chromium in order to manage its tough requirements on performance.
The chroming process requires harmful chemicalsOne of them is hexavalent chromium, a chemical with usage restrictions by the EU, that are likely to be even firmer in the years to come.
We need to find another wayAs environmental regulations and customer requirements on the usage of hexavalent chromium are getting tougher, we need to find effective alternatives.
Hybrid Steel provides a unique opportunityHybrid Steel has the potential to replace chromed products with untreated material due to its strength, high corrosion resistance and friction qualities.
Eliminating production steps entirely will reduce complexity and manufacturing costs
Benefits with Hybrid Steel
Process the Hybrid Steel in new conditionsIt is possible for production engineers to machine components in a softer condition and then harden it without any risk of distortion. This means that a conventional manufacturing process can be reduced to fewer stages.
Properties of the Hybrid Steel enables simplified production routesThe Hybrid Steel develops its full properties only after heat treatment, meaning that manufacturers will be able to adopt new, efficient processes, that eliminate a number of stages.
To exemplify, a component might be forged and machined to its final dimensions when it is in a soft and easy to machine condition, and then heat treated to achieve its full strength. This route offers a significant reduction in manufacturing cost and complexity.
CUSTOMERS ONNITRIDED
HYBRID STEEL
What our customers say
Our customers see a clear value with the performance increase enabled by nitrided Hybrid Steel
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Nitriding layer stress
Surface hardness
Core hardness
Corrosion resistance
AVG VALUE of improvement0=low to 5=high
Note: Responses from nitriding customers only. Other customers may have other views.
What our customers say
Our customers see a clear value with the opportunities enabled with nitrided Hybrid Steel
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Lower material use -production
Fewer process steps
Lower distortion after heat treatment
AVG VALUE of improvement0=low to 5=high
Note: Responses from nitriding customers only. Other customers may have other views.
Ovako is prototyping hydraulic components with several customers. One premium brand customer is currently prototyping its quick release with Ovako’s Hybrid Steel, a part that requires high performance.
Customer in hydraulics sector
We search for a material that can help us meet the increasing requirements and stay ahead of our competition
Why are you working with Hybrid Steel? We have a premium image, which is important for us to maintain. This means that product life time and quality is our highest priority.
We manage current requirements well, but the coming years brings tougher requirements, and as a supplier of high performing premium products we need to stay ahead of our competition.
We simply need to be even better in the future!
Today’s requirements on pressure resistance
will increase, while room for the
component remains limited.
Our hope is that Ovako’s Hybrid Steel
will help us face those challenges.
Customer in hydraulics sector
Ovako is prototyping hydraulic components with several customers. One premium brand customer is currently prototyping its quick release with Ovako’s Hybrid Steel, a part that requires high performance.
Customer in hydraulics sector
Ovako’s Hybrid Steel can help us to maintain our image as a premium brand
Increase pressure resistance Within a few years, we will have to increase the pressure resistance of our components from 350 to +420 bar.
Smarter designRedesign the component for lowered material use with maintained or increased performance.
Eliminate the need for surface treatmentWe are testing if Ovako’s Hybrid Steel can help us eliminate the need for surface treatment with maintained corrosion resistance.
This would be a major advantage for us, since our current process is:• Complicated• Time consuming• Costly
Surface treatment makes up 5% of total product cost
Many opportunities
Why are you working with Hybrid Steel? We see a value in being able to recommend better materials, that in combination with professional heat treatment solves our customers’ problems.
In order to do that, we need to be in the frontline and constantly learn about new techniques, which is exactly what we are doing with the Hybrid Steel.
Bodycote
Bodycote and Ovako are working jointly in the journey of discovering new opportunities with Hybrid Steel.
We have only scratched the surface of discovering the potential with Ovako’s Hybrid Steel
Bodycote
A cost effective way to high performanceThe main reason for using the material is to increase performance in a cost effective way. Hybrid Steel is an extremely stable material with very low distortion, which is critical for heat treatments.
Opportunity for significant savingsThe low distortion makes it ideal for applications with narrow tolerances, and also opens up for the possibility to cut processing steps and thereby significant savings.
Tool steel performance in a conventional steelIn combination with nitriding, Hybrid Steel can reach almost the same characteristics as a tool steel. However it is not close to as expensive to produce. It is expensive to machine hard materials, and customers who can avoid it can produce to a lower cost.
Bodycote and Ovako are working jointly in the journey of discovering new opportunities with Hybrid Steel.
We have only scratched the surface of discovering the potential with Ovako’s Hybrid Steel
A family of Hybrid SteelsIn the near future, we hope to see a Hybrid Steel family, with steel types optimized for each application it will be used for.
This would open up for many new interesting areas.
Bodycote
We have only scratched the surface of discovering the potential with Ovako’s Hybrid Steel
Bodycote and Ovako are working jointly in the journey of discovering new opportunities with Hybrid Steel.
Customer testimonials
It is valuable for us to be able to recommend a better material that
solves the customers’ problem.
Mikael Fällström Vice President Bodycote,
NEE AGI Sweden and Finland
We believe that Ovako’s Hybrid Steel will help us maintain our image as a
premium brand.
Customer in hydraulics industry
It is valuable for us to be able to recommend a better material that solves the
customers’ problem.
Mikael FällströmVice President Bodycote,
NEE AGI Sweden and Finland
Hybrid SteelCustomer testimonial
We believe that Ovako’sHybrid Steel will help us maintain our image as a premium brand.
Customer in hydraulics industry
Hybrid SteelCustomer testimonial
Increased performance -reduced weight.
This is a possibility for us to increase margins!
Anonymous customer
The low distortion of Ovako’s Hybrid Steel enables
more precise production, which lowers our scrap.
Anonymous customer
With Hybrid Steel, we see potential to decrease
lead time, lower production cost and to get a better finish.
Anonymous customer
Hybrid SteelCustomer testimonial
OVAKO QUOTES
We saw that our customers were in need of a material that could handle higher temperatures, and decided
to do something about it.
Patrik ÖlundHead of R&D at Ovako
Hybrid Steel is one of the most
significant advances in the steel industry.
Marcus HedblomPresident and CEO, Ovako
Hybrid Steel
The many advantages of Hybrid Steel means that it will have a wide variety
of potential in highly stressed applications.
Jan-Erik AnderssonSenior GroupTechnical SpecialistInventor of Hybrid steel, Ovako