compact steel, Issue 01/2019 - The thyssenkrupp Steel magazine · 2020-07-19 · 2 compact steel...

Extra insert!Two-page infographic on our e-mobility initiative selectrify®

Two-page infographic on our e-mobility initiative selectrify®

Extra insert!

The thyssenkrupp Steel magazine Issue 01/2019 thyssenkrupp-steel.com

compact

selectrify®.. he electromobility initiative proves how innovative steel can be8

0 he ne line for remi m s rfaces � t for outer panelingPage 16

Our path to

climate neutral steel production

thyssenkrupp Steel’s climate strategy steps up activities to reduce emissionsPage 8

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2 compact steel — Das Stahl-Magazin von thyssenkrupp 01/2018

Power supplyRWTH Aachen and the Electrical Steel business unit loo to � e i le electricit grids to provide renewable energy.

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Cladding as an art formpladur® Relief Icecrystal facades give the Black Forest’s Öschberghof golf resort that special sparkle.

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Helpers around the homei ing room, itchen, athroom

� nd o t here inno ati e steel products are moving into your home.

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The futurologistsFor 50 years, thyssenkrupp Steel’s Application Technology Center has been pushing the envelope of what steel can be and do.

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A packaging wonderThe new tinplate grade is sturdy yet � e i le, ma ing rod cts s ch as spray cans lighter and safer than ever before.

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Women of steelFind out how Grit Reiman (left), Manuela Ruthenberg, and their teams leave hydrogen with nowhere to hide.

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Published by: thyssenkrupp Steel EuropeKaiser-Wilhelm-Strasse 10047166 Duisburg, Germany—Tel.: +49 203 520a 0 0

Credits Editorial staff: Kilian Rötzer (legally responsible)Communications—Marcus van MarwickHead of Brand & Customer Communications—Christiane Hoch-BaumannBrand & Customer Communications (Editor in Chief)

Photographic department, layout, and production:

reati e ode and ontent mHeiligegeistkirchplatz 110178 Berlin, Germany

Printing: thyssenkrupp Steel Europe Digital/print mediacompact is printed on

certifi ed a er.

Please contact us to share your comments and suggestions: [email protected]

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The thyssenkrupp Steel magazine

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An one reading the � nancial papers over the last few months could be forgiven for believing thyssenkrupp is in the middle of the per-fect storm. You shouldn’t believe everything you

read, but at the same time there’s no deny-ing that 2019 was a turbulent and challeng-ing year for us. In spring, the joint venture we were planning to enter into with Tata Steel was blocked by the European Com-mission. As a result, steel will now remain an integral part of the thyssenkrupp Group. At the same time, we are working hard on a new steel strategy, and by the end of the year we will have a new structure in place that will enable our business to grow and enjoy sustained success in the long term.

The world around us is no less turbulent. Trade disputes are damaging our relation-ships with our international customers.

“We will combine our high technological

and quality standards with an active climate

strategy.”

The new thyssenkrupp Steel Executive Board from left r rnd fl er remal esai r abine aa en ernhard sbur

In the same connection we are seeing a further rise in imports to Europe. This, too, is a challenge that requires us to work with the policymakers in order to keep jobs and production in Europe. A weakening econo-my coupled with highly volatile raw material prices also make 2019 a challenging year.

There can be no doubt that challenges are great. But we on the new Executive Board have a clear vision for the future of steel. We have already made one fundamental decision: we are launching a gradual trans-formation process that will eventually make our steel production completely climate ne tral. o � nd o t ho e intend to do this, check out our cover story on page 8.

We look forward to following the path ahead together with our customers.

remal esaiCEO

ernhard sburCCO

Dr. Sabine MaaßenCHRO

r rnd fl erCTO

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compact steel 01/2019

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Das Stahl-Magazin von thyssenkrupp

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Innovative half-shell technology for an organic and aerodynamic shape

ighl � e i le seat t e for a comforta le, non-tiring ride

eight com ara le ith al min m than s to d ra le thyssenkrupp DP600 steel

ighl rigid ottom rac et for o tim m

power transmission

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Information onlineo can fi nd o t all

about steelworks at www.steelworks.bike or by following us on Facebook: www.facebook.com/steelworks.bicycles.

Automated laser welding for consistently high-end quality

A steel bicycle frame? Surely that’s much too heavy compared ith al min m or car on ot at all or at least not hen

thyssenkrupp Steel’s engineers are on the case. To demonstrate what steel can do today, they designed steelworks, an unbreak-able racing bike that’s as light as a feather (well, almost). The steelworks frame combines: performance and comfort thanks to an e tremel rigid ottom rac et and a highl fl e i le seat t e. Add in the material’s intrinsic shock absorption and you’ve got a ride that won’t tire you out. The half-shell production technology and 3D laser-welding technique used for the steelworks frame guarantee an aerodynamic shape and high-precision construc-tion with almost invisible welds.

Top performance with steel

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&Knowledge value

400 years in Hohenlimburg It all began with Wessel Lappenberg’s old wire drawing operation in the town now known as Hohenlimburg on the banks of the Lenne river. It was exactly 400 years ago that o erations there ere fi rst recorded. At that time, the Lenne valley was a hub for metalworkers. With the advent of the 19th century, wire draw-ing was experiencing a robust boom, thanks primarily to the fact that visionary entrepreneur Gottfried Böing had recognized the industry’s potential and invested in new technologies such as wire rod rolling. After emerging from a tumultuous period involving mergers, name changes, and a move to the city’s Oege district, today’s thyssenkrupp Hohenlimburg GmbH is carrying on its historic tradition of wire drawing. At this plant, the company produces high-quality precision strips un-der the precidur trade mark.

Anniversary

20.6million metric tons of steel prod-ucts were exported by the Euro-pean Union in 2018. Primary im-porters included other European countries, Turkey, Russia, and the Commonwealth of Independent States with total imports of around 7.5 million metric tons. The Europe-an Union imported almost double that amount, or 15.2 million metric tons, from this group of countries, which constitutes its most import-ant steel trade partners.

.. fi g res

Duisburg plant testselectric company carsthyssenkrupp Steel is strength-ening its commitment to envi-ronmentally friendly mobility, and for the past few months the company has been testing an eGolf for its com any eet. nvironmental and Climate Protection has erected a charging station at the site to power the new vehicle with sustainable energy from the plant’s own roduction rocesses. e in the nvironmental rotection department want to lead the way for the company by gathering ex-

erience in this critical fi eld, says de artment head ndreas heuer.

According to Theuer, the eGolf was popular in the team and many employees even used it in place of their private vehicles on business tri s. f e mo ility roves to e a successful venture, thyssenkrupp Steel plans to successively expand its eet. here are also lans to extend the charging infrastructure in Duisburg and at other locations to allow employees to charge their own e vehicles at the lant.

The electricity that powers the electric vehicles at the charging station will be sustainably pro-duced using blast furnace gases generated by the steel production processes at the Duisburg location.

The vehicle has a range of aro nd 200 kilometers. That’s perfect for most siness trips. The charging process takes around four hours.

r rnd fl er CTO of thyssenkrupp Steel Europe

With our climate strategy, our vision for climate ne tral steel production is gradually becoming a realit .

thyssenkrupp teel follow us! Connect with us on Facebook or follow us on LinkedIn and Instagram. thyssenkrupp Steel shares posts about current topics on all of its social media channels.

WebFor information on the topic of e-mobility: thyssenkrupp-steel.com

in

r rnd fl er CTO of thyssenkrupp Steel Europe

steel production is gradually becoming a realit .

Knowledge value&Knowledge value&Knowledge value

Duisburg plant tests

The electricity that powers the electric vehicles

Our roots in HohenlimburgFor 400 years

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®

&Knowledge value …Electrical Steel is the best?thyssenkrupp Electrical Steel GmbH was awarded the Ludwig Erhard Prize for comprehensive management services. The jury was impressed by the company’s international production network, its customer focus, and the successful change process which began in 2017. Electrical Steel employs around 1,700 people at its locations in Gelsenkirchen, Isbergues (France), and Nashik (India), and supplies its customers with grain-oriented electrical steel. Electrical steel is used as a component in transformers and generators.

Did you know that… The industry in brief

Upakovka 202028 to 31 January in MoscowAt Moscow’s Upakovka, the interna-tional specialist trade fair for packaging machinery and the production of packag-ing s lies, aro nd 0 e hi itors ill e presenting innovative technologies and materials. The Packaging Steel business unit will be making one of its regular ap-earances ith its rasselstein® products.

#packagingsteel

Tube 202030 March to 3 April in Düsseldorf

Around 2,600 companies will be bring-ing their products to Essen for Tube, the world’s leading trade fair for the tube ind str . hi its ill incl de machines and systems for tube manufacturing and tube processing as well as raw materials, tubes and accessories, tools used in processing, and measurement, control, regulation, and testing equip-ment. Steel Europe will be represented at Tube 2020 along with its sister company, Materials Services.

#tubeproduction

Coiltech1 to 2 April in Ulm

The leading trade fair for coil manufac-turing, electric motors, and transform-ers, which originated in Pordenone, Italy, will now be held in the Swabian city of Ulm. Companies will present visitors with products made using elec-trical steel from magnetic cores and transformer coils to winding equipment. The Steel Europe business unit will be e hi iting its range of high tech non-oriented electrical steels.

#electricalsteel

Dates

Steel use in the EUThe construction sector is the largest steel consumer in the European Union, followed by the automotive industry. Taken together, these industries consumed over half of all steel produced in 2018.

Source: Eurofer

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Lena Kremer Advanced Product Development Specialist at KIRCHHOFF Automotive Deutschland GmbH

In a joint project with thyssenkrupp Steel, you are currently conducting customer-side tests of our MBW-K® 1900 for hot forming. Can you tell us more about your work? In this project we worked together with thyssenkrupp Steel to test the use of new hot forming materials in crash management systems. Our goal was to produce a product that combined economic, lightweight construction with optimized crash performance. One advantage of hot forming is that it allows us to produce complex geometries. Thanks to an innovative design that took advantage of the strength of the material, we were able to eliminate a locking plate from the cross beam of our crash management system. What sets our cross beam concept apart is that the direction in which the rofi le opens changes across the length of the beam. That allows us to create a part that is highly rigid in the center while increasing the e ective crash box length at the edges, which helps to dis erse energy more effi ciently.

Three questions for…

Are you pleased with the results? Very. By using 1900 we were able to reduce the weight of the product

y around ercentcompared with the ref-erence design while lowering costs by 8 percent.

What are the next steps for this pro e t? We still haven’t carried out a real crash test, so that will be the next phase of the project. We already presented the hardware prototype at the International Motor Show Germany in September. The design and validation has only been con-ducted virtually thus far. The next step will be to carry out towing tests as well as a quasistatic three-point bending test.

Construction 34%

20%Automotive

15%Machine engineering


Metal products 14%

Pipes 11%

Household appliances 2%

Transportation 2%

Other 2%

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…Electrical Steel is the best?thyssenkruppLudwig Erhard Prize for comprehensive management services. The jury was impressed by the company’s international production network, its customer focus, and the successful change process which began in 2017. Electrical Steel employs around 1,700 people at its locations in Gelsenkirchen, Isbergues (France), and Nashik (India), and supplies its customers with grain-oriented electrical steel. Electrical steel is used as a component in transformers and generators.

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MBW-K®

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Climate neutral by the

transformation

million metric tons of steel

are recycled annually, saving around one billion metric

tons of raw materials. If more CO

2 can be saved in future

production processes, its advantages will carry even

more weight.

500

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Text Frank Gilges

The target is clear: By 2050, steel production at thyssenkrupp must be climate neutral. With its climate strategy, the company is accelerating its initiatives to reduce emissions, promoting corporate social responsibility, and pledging its support for the Paris Climate Agreement of 2015.


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Steel reimagined: hydrogen instead of carbon“Soon we’ll be replacing carbon with hydrogen as a reducing agent in the blast furnace,” ex-

lains r. rnd er, Chief echnology ffi cer at thyssen ru teel. his ste will ta e lace in the fall. Chemical reduction using car on releases carbon dioxide while reduction carried out with hydrogen sim ly roduces water va or. n the fi rst ste of this new develo ment, hydrogen will be injected into conventional

It has been four years since 195 countries agreed to work together to slow glo al warming. he inding international accord passed at the

aris Climate Convention in ecem er 2015 was lauded around the world as a historic milestone. he long term

target of limiting the rise in average glo al tem eratures to well elow two degrees Celsius com ared with reindustrial levels is a tas for the entire international community and can only be achieved through carefully coordinated measures. he steel industry has many crucial roles to lay here. n the fi rst lace, steel is and will remain an indis ensa le material after all, without it, neither the energy transition nor e mo ility would e ossi le. econdly, y ena ling economic, lightweight construction, steel can help to reduce the carbon footprints of other industries rimarily the automotive sector.

ut steel roduction must fi rst turn a critical eye on itself, and new technological advance-ments will e necessary for the industry to reach climate targets. last furnace technology has

een res onsi le for ma or advances, and as a result, Germany has cut its car on emissions

y more than half in the roduction of ig iron. onetheless, more radical measures are needed. he state of the art today is close to its theoreti

cal o timum.

Two technological paths, one goals art of its com rehensive climate strategy,

thyssen ru G has committed to ecoming a car on neutral com any y , in line with the goals of the aris greement. y , the com any lans to lower its emissions from

roduction and energy consum tion y ercent com ared to the reference year of . o this end, thyssen ru is investing in a

technological transformation and ta ing ractical research ste s to achieve its aims. Climate neutral steel roduction means rethin ing the entire plant structure. thyssenkrupp faces an industrial uantum lea .

his transformation will see thyssenkrupp em loy two e ually im ortant technological methods. he fi rst involves avoiding car on dioxide during the steel production process by using hydrogen instead of ulveri ed coal C

car on direct avoidance . he second ta es car on dio ide from the roduction rocess and transforms it into valua le raw materials CC carbon capture and usage), in a process referred to at thyssenkrupp as Car on Chem®.

We want to produce climate neutral steel by 2050.”Premal Desai, CEO of thyssenkrupp Steel

In the Carbon2Chem® technology center, process gases from steel production are transformed into base chemicals for the chemical industry, replacing petrochemicals.

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blast furnaces. The transition will begin with just one furnace and expand to include all four blast furnaces in the Duisburg location by 2022, dramatically reducing the use of fossil reducing agents in the process.

Beginning in the middle of the next decade, thyssenkrupp teel lans to uild its fi rst largescale direct reduction (DR) plants. These plants will lay the foundation for the future of steel production. The sponge iron produced here will still initially have to e rocessed in the conventional manner, but it will already have reduced emissions considerably.

Starting in the 2030s, the sponge iron will undergo processing into crude steel in modern electric arc furnaces owered using renewable energy. By 2050, thyssenkrupp Steel will gradually transition all of its facilities to the new climate neutral steel production process. The necessary ste s will need to e ta en in the olitical arena in order to facilitate the creation of

RecyclingAlready sustainable: With its high recycling quota, steel is already saving enormous amounts of energy and raw materials.

Energy transitionNo energy transition without steel. Steel is as vital to generators as it is for wind turbines and high-volt-age power lines. The energy transition is simply not possible without steel.

Social changeClimate protection and environ-mental consciousness are issues aff ecting all of societ . teel already serves as the basis for many products that are funda-mental to a sustainable lifestyle.

Mobility transformationSteel is indispensable for sustain-able mobility, both as a basic ma-terial for e cient electric motors as well is in economic, lightweight construction concepts.

the infrastructure needed for such an undertaing. That includes ensuring the availability of suffi cient sustaina ly roduced electricity and hydrogen, as these are critical elements in the operation of the electric arc furnaces and direct reduction plants.

Hydrogen’s Duisburg debut To turn this 2050 vision into a reality, thyssenkrupp has teamed up with partners Air Liquide and research institute BFI to conduct a special experiment at the Duisburg location in the fall of this year. t will e the fi rst such test of its kind the world has ever seen. In one of the 28 tuyeres of blast furnace 9, the partners will be replacing the current reducing agent, pulverized coal, with hydrogen. They plan to expand the method for use in all tuyeres y . heoretically, replacing pulverized coal with hydrogen at this stage of the production process has the potential to reduce carbon emissions by

How steel helps others to protect the climate

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Political environmentThe economic viability of

ro ean steel rod ction and climate-friendly steel

rod ction is highl reliant on future political and reg lator olicies.

Carbon2Chem®

From pollutant to raw materials: Any CO

2 generated d ring steel

production can be isolated and repurposed as a raw material for the synthesis of base chemicals, for example for f els, lastics, and fertili ers. That releases the chemical industry from their reliance on etrochemicals.

Hydrogen methodSteel production of the future: n the f t re, the s onge iron rod ced red cing the iron

ore will be processed into crude steel in electric arc f rnaces.

Renewable energy and H

2The key to climate neutral steel

rod ction reen energ ill e sed to rod ce green h drogen

for direct red ction. t ill e necessary to simultaneously work to develop the fundamental infrastructure for production and logistics.

u to ercent, e lains r. rnd er. his fi rst test hase will e su orted y the state

government of orth hine est halia, and is e ected to yield im ortant discoveries for the future of steel roduction.

Brand new infrastructure requiredver the ne t few years we will y laying the

foundation for the transformation of the steel industry, fi rst y conducting research, then

y ra idly im lementing large scale industrial solutions, re orts remal esai, C of thyssen ru teel. ecause of the lengthy investment cycles in the industry, we have already egun to carry out the transformation

rocess. e a eals to arameters to give their fi rm and sustained su ort to this im ortant tas his ind of transformation is un recedented in the history of the steel industry.

e will need relia le olitical and regulatory arameters that ena le fair com etition in all

dimensions. ransforming roduction towards climate neutrality will re uire considera le investment, which will have to e fi nanced in the long term.

Using steel mill gases as raw materialshe second method thyssen ru is ursuing in

its goal to ecome climate neutral y is its Car on Chem® ro ect. his initiative focuses on ca turing gases roduced during the steel

roduction rocess and rocessing them for later use. he German federal government has

rovided the ro ect with a grant for over million euros. he steel roduction rocess yields steel mill gases with com onents that contain car on. ith Car on Chem®, we are a le to generate ase chemicals for use in the chemical industry, there y eliminating the need for synthetic gas made from im orted fossil fuels such as oil or natural gas, says r. ar us les, head of Car on Chem®, descri ing the ro ect s central aim. hese ase chemicals can then e used to ma e fertili ers, lastics, or fuels, for e am le.

ince e tem er , thyssen ru has een wor ing on this technology at the Car on Chem technology center in uis urg,

and has for the very fi rst time anywhere in the world roduced ammonia and methanol from steel mill gases. he industrial ilot hase, which aims to roduce methanol from steel mill gases from steel roduction, ic s o in .

he com any lans to esta lish an industrial scale lant y . oth of these methods Car on Chem® and the use of hydrogen as a reducing agent will allow thyssen ru to considera ly reduce the emissions of its e isting

last furnaces, and Car on Chem technology can e em loyed in other industries as well.

Steel is key to the circular economyteel has esta lished itself as a climate friendly

material. arge uantities of this dura le metal have een circulating for decades, as steel is u to ercent recycla le. round million metric tons of steel are recycled each year, saving one illion metric tons of raw materials. teel

roduction is and will remain energy intensive, summari es r. er. ut many steel ased a lications and roducts save more energy and car on emissions over their life cycles than

How steel can become climate neutral

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DecarbonizationTwo paths to a climate neutral future: thyssenkrupp explores t o diff erent methods for decar oni ing steel rod ction

re enting the formation of O2

in rod ction and tili ing an CO

2 emissions generated.

he th ssen r teel maga ine

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Climate neutral steel from thyssenkrupp Steel will be just as excellent and innovative as today’s steel. The change may not be visible but it will make all the differen e

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are required for their production. Trying to do without them is like trying to stop the clock in order to save time.” Life cycle assessment (LCA) is becoming an ever more popular evaluation tool, particularly in the automotive industry. It works like a kind of ecological and economic balance sheet covering every phase of a product’s life cycle from roduction and use all the way to recycling. Today, steel performs better than other materials in LCA comparisons. If more carbon dioxide can be saved during the steel production process in the future, its advantages will carry even more weight. Even during the production phase, alternative materials perform much worse when it comes to climate-based metrics.

No energy transition without steelA climate neutral society is unimaginable with-out steel. Many products and industries are reli-ant on steel to unlock technical innovation and reduce their climate impact. There is real evi-dence for the claim that the energy transition would not be possible without steel: Wind tur-bines, for example, are up to 80 percent steel,

Prevent the formation of greenhouse gasesUp to now, iron ore has been reduced using carbon, resulting in CO

2 emissions. Over

the past few decades, thyssenkrupp Steel has made great strides in increasing the energy e cienc of its e isting blast furnace processes and reducing emissions. In the future, sustain-ably produced hydrogen is set to replace carbon as a reducing agent. The additional processing needed to transform iron pellets into crude steel will soon be conducted in electric arc furnaces, rendering the process climate neutral.

and electrical steel serves as a basic compo-nent in efficient electric motors, generators, and smart power grids. Of course the other side of the story is that climate neutral steel production is not possible without clean energy. That recog-nition makes abundantly clear the importance of viewing climate protection in a holistic sense, and emphasizes the close link between industry and the energy transition.

Steel is indispensable in achieving the world’s ambitious climate targets. And to make sure we can keep producing steel as a climate neutral company, production processes must be revolutionized over the next three decades. thyssenkrupp has ta en the first ste s on that path.

ContactMark Stagge, Press Officer at thyssenkrupp Steel (+49 203) 5225159, mark.stagge@ thyssenkrupp.com


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CO 2 | CO | N 2

CO 2

Process gas

CO 2

Process gas

BF

BF

H 2

H 2

H 2

H 2

H 2

Using CO 2

Using CO 2

Using CO (Carbon2Chem® )

Avoiding CO 2

Avoiding CO 2

Avoiding CO (hydrogen method)

thyssenkrupp is embarking on two parallel and equally important technological paths in order to produce climate neutral steel by 2050: avoiding of CO

2 through the use

of hydrogen and utilizing CO2 through

Carbon2Chem® technology.

Starting in 2019

The test thyssenkrupp will grad-ually replace pulverized coal in one blast furnace (BF) with hydrogen (H

2).

BF

Starting in 2022

The introductory phaseStep by step, all three blast furnaces (BF) will be transitioned to H

2 injection.

2018

he orld fi rstThe concept: CO

2 becomes

raw materials. In September 2018, thyssenkrupp produced ammonia from steel mill gases for the fi rst time at its Carbon2Chem® technical center in Duisburg.

Starting in 2020

IndustrializationThe pilot system at the Duisburg steel plant will use steel mill gases to produce base chemicals.

Two technological paths, one goal


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CO 2

Process gas

BF

DR

DR

H 2

H 2

EAF

2030-30% CO2

2050CLIMATE NEUTRAL

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BF

Starting in 2024

The milestoneUsing large-scale direct reduction plants (DR) which will be operated using green H

2, thyssenkrupp will produce

sponge iron which will then proceed to the blast furnaces (BF) for processing, allowing a further reduction in emissions.

EAF

2025 to 2050

Transformation to climate neutral steel productionUsing electric arc furnaces (EAF), thyssenkrupp will process sponge iron into climate neutral crude steel using electricity from renewable energy sources.

Starting in 2025

The breakthroughCO

2 will be used as a raw material

in an industrial-scale plant. The Carbon2Chem® technology is also useful in other industries, for example the cement industry.


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It’s what’s on

How can we make the production of premium surfaces that are suitable for outer paneling in the automotive industry more e cient and en ironmentall s staina le That’s easy: with a pioneering production plant equipped with the latest technology and innovative process techniques! With its new FBA 10 hot-dip galvanizing line in Dortmund, thyssenkrupp Steel can expand its production capacity and cater to the increasing demand for high-quality, thin, hot-dip galvanized steel sheets.

the surfacethat counts

Surfaces coated with ZM Ecoprotect® generate less abrasion debris, which in turn reduces adhesive tool wear. Tools don’t require cleaning as often, and there are fewer interruptions to production. As such, ZM Ecoprotect® makes stamping plants more e ient.

Top application performance

With ZM Ecoprotect® in primetex® quality, the surface meets the highest of standards in terms of the paint appearance. With a higher peak count and reduced long waviness it has everything the outer paneling of a car needs.

No more orange peel

ZM Ecoprotect® o�ers better processability and higher corrosion protection compared with conventional zinc coatings.

High performance

The combination of zinc and magnesium improves corro-sion behavior with si nifi antly reduced coating thickness.

An innovative remedy for corrosion

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thyssenkrupp Steel is the first manufa turer in Europe to achieve series production of zinc-magnesium-coated surfaces that are suitable for use in outer paneling.

The ne line in ortmund will be able to coat deep-drawing steels, IF and bake-hardening steels, and high-strength DP grades with zinc and zinc-mag-nesium.

o matter hat o ers the cars of the f t re or hether e ill e en e dri ing them o rsel es the ill al a s need o ter aneling that prote ts both the ehi le and the people inside and ro ides for an attracti e finish.

Compared with con-ventional zinc coatings

co rotect a�ects neither paintability nor phosphatability. It also provides et and dry paint adhesion and a high resistance to rust creep after stone chipping.

zinc + magnesium = ZM Ecoprotect®

offers hi h strip

idths

he future of outer panelin

t s all in the oatin

The link to zinc:www.thyssenkrupp-steel.com/ en/ZM-Ecoprotect

Contactr ol er mu ala

Product Manager, ZM Ecoprotect®, +49 203 52 44349, [email protected]

hat s the e�ect that sing co rotect® has on a mid-sized car, as coating weight can be reduced by 30% thinner without

a�ecting the corrosion rotection.This makes for outstandin

en ironmental sustainability, as ZM Ecoprotect® reduces zinc use by 30%.

li hter …

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E-mobility based on steel thyssenkrupp Steel’s selectrify® e-mobility initiative demonstrates the company’s capacity for innovation.

How might our cars look if they were all fully electric? Engi-neers, designers, technicians, and even material suppliers need to head back to the draw-ing board, since innovative technologies will change the

look and design of vehicles in equal measure. thyssenkrupp Steel development team has

also een wor ing to fi nd answers to these questions of the future for some time, coming together under the name selectrify® to combine their materials and applications expertise in the fi eld of electromo ility.

“Steel is the most important lightweight ma-terial for the automotive industry today,” says André Matusczyk, CEO of thyssenkrupp Steel’s Automotive business unit. “With the help of our selectrify® initiative, we want to show our cus-tomers that the material also brings a superior

ro erty rofi le to electric vehicles. his egins with an unrivaled price/performance ratio for the lightweight construction of the vehicle structure and protection of the sensitive battery, and extends all the way to steels with special magnetic properties without which no electric motor could function.”

he worldwide availa ility, esta lished processing methods, and outstanding repair-ability and recyclability of steel make it easy for automotive manufacturers to integrate new steel solutions and concepts quickly into marketable electric cars. “Steel makes elec-tromobility safe and easy, and contributes to getting electric vehicles out of the small-series model niche and ma ing them a orda le for the masses,” says Matusczyk. selectrify® is also on hand for thyssenkrupp Steel when its customers

Text Christiane Hoch-Baumann | Graphics/layout C3 VisualLab

need support in quickly implementing techno-logically demanding requirements in their mass production processes.

The selectrify® reference structure based on a compact-class electric car As a long-standing partner to the automotive industry, thyssenkrupp Steel is once again able to demonstrate its expertise with the selectri-fy® reference structure. efore we were a le to implement our idea of a manufacturer-neutral electric car structure, we defi ned a variety of relevant criteria for the target vehicle from the dimensions to the range, says ro ect

ngineer ndreas reiden ach, who ta es on an interdisci linary role wor ing with colleagues from a wide range of departments.

he result is the virtual structure of an electric vehicle in the high-unit-volume compact class, which is designed for a practicable 500-kilome-ter range, and features seating for a total of

The reference structureAndré Matusczyk (left) CEO of the Automotive business unit and selectrify®, and Project Manager Patrick

lau a present aff ordable steel solutions for weight-optimized and safe electric vehicles in the form of a holistic and highly scalable stand-alone structure.


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fi ve occu ants with trun s ace. com rehensive simulation rogram

ensures the technical feasi ility of the new develo ment and guarantees that the

reference structure meets the re uirements set y all standard crash tests. ools and methods

match those used y automotive develo ers so that the results can e com ared immediately and solutions can e uic ly ut into series

roduction. he selectrify® reference structure is also

ased on a e i le latform that is scala le lengthways. urther derivatives and vehicle classes, such as s or cou s, can e e tra

olated from this asic structure. hat also increases the effi ciency of our solutions.

New steel concepts for new bodies he elimination of conventional com ustion

engines with au iliary units and transmissions also fundamentally changes the design of new

ly develo ed electric cars. Generally s ea ing, the front end loo s neater, meaning the need for geometrically com le dee drawn arts dro s while the use of sim ler structural com onents and rofi les increases. owever, current atteries are still very heavy and the resulting high overall weight of the vehicle continues to lace great demand on the strength of the materials used.

ow, roviding the vehicle s occu ants with com lete rotection starts with rotecting the sensitive attery in the event of a side im act collision. he acce ta le level of intrusion in the attery area reduces to virtually ero.

hat increases strength and design outlay for roc ers, illars, and the surrounding environment. he most stri ing changes are the e ternal ones when it to comes to ur osedesign electric vehicles, that is, vehicles that are develo ed from the ground u e clusively for fully electric o eration e re tal ing a out longer wheel ases and short overhangs here, says reiden ach. e have made sure our ortfolio of materials matches the new re uirements of electric vehicles, so our strength in steel means that we are currently well ositioned for electromo ility and have the right materials in our ortfolio to meet any and all re uirements.

ut develo ment isn t standing still. n the long run, it s conceiva le that the traditional develo ment focus, es ecially in terms of coldformed steels, will shift from fi rm and e i le towards higher strength and more economical alloy conce ts, says ro ect anager atric

lau a. ew ty es of forming technologies such as thyssen ru smartform® and hy rid materials are roviding new ideas in terms of costs and the erformance of steel construction.

he increasing trend towards higher strengths will continue since they are es ecially suita le for weight o timi ed and safe vehicles. trengths have increased signifi cantly in recent years. t s an enormous growth that no ody had dared ho e for, says lau a. ne glance at thyssen ru teel s road roduct

ortfolio ma es it clear how much otential there is in the develo ment of steels. he s ectrum of dual hase steels alone ranges from strengths of a to , a. hen it comes to steels for hot forming such as ®,

ress hardening can achieve strengths of u to , a. ›



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class can meet crash performance requirements while being nearly as light as a traditional battery housing made from aluminum and only costing half the price to build. “Simply put, we’re talking here about cost savings amount-ing to hundreds of euros without compromising on safety. hat is a ma or di erence in the area of car development, where costs are calculated in cents.” In addition to this, steel also gains

oints in terms of fire rotection and electro-magnetic compatibility. Just like the reference structure, the battery concept is also scalable and can e e i ly ada ted to the various di er-ent OEM platforms.

The selectrify® drive system with powercore® electrical steelAnother product from the selectrify® portfolio is used in drive systems: its trade mark power-core® electrical steel. lectrified drive systems

The battery housingThe steel variant weighs almost the same as its aluminum equivalent, but is 50 percent cheaper and more environmentally sustainable. The concept developed by Dr. Daniel

ierhoff ri ht and his team slots perfectly into the reference structure drawn up by Andreas

reidenba h left and his team. Together, the two components meet the highest requirements in terms of crash safety, weight, and overall costs.

The selectrify® battery housing: li hter safer and more e ientThe battery is a recent addition to electric vehicles, and a key component at that. The re-chargeable lithium-ion batteries available today have an e tremely high level of erformance, but they are also immensely sensitive. Any sort of damage runs the ris of devastating fires, which can ut assengers and first res onders in harm’s way following an accident. That’s why comprehensive protection for the battery against crash im acts is first and foremost protection for passengers, and why automotive developers treat this issue with the utmost importance. “Safely housing the battery is the top priority when it comes to providing vehicle occupants with the best possible protection,” says r. aniel ierho from the selectrify®

ro ect team. atteries housed in steel o er sev-eral advantages. A steel solution in the 70-kWh



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demand a lot from steel as a material,” says Volker Kamen, who is responsible for sales of the non-oriented electrical steel produced at the thyssenkrupp Steel location in Bochum. In principle, it is built into each and every electric motor. “Our powercore® NO grades meet the demands of high erforming and efficient drive systems. They are very thin, have homoge-neous mechanical properties, low core losses, and a high polarization. We are also developing functional coatings for an economically efficient packet structure for automotive manufacturers as well as sandwich materials with a great deal of potential for improving productivity in the stamping process and better noise generation management in the drive.”

powercore® ele tri al steel in har in stations Electromobility is one way of lowering CO2 emissions in the long term. However, simply

Find out more onlinewww.thyssenkrupp-steel.com/en/ industries/automotivetrucks/e-mobilityThe drive system

Powercore® ele tri al steels uarantee ultra e ient

and hi h performan e ele tri al dri e systems

lorian er et left and ol er amen are in har e

of de elopment and sales for the pro e t

developing and building electrically driven vehicles doesn’t mean the job is done. In order for Germany to actually achieve its energy transition in the future, the country’s electrici-ty es ecially that used in electric cars must come from renewable sources. This electricity must be distributed intelligently and storage capacity must be created to utilize it. Ultimate-ly, the number of charging stations along with the entire charging infrastructure needs to be expanded on a massive scale.



ith ro, thyssenkrupp Steel is the � rst steel man fact rer to la nch a ne , game changing coating for hot forming ltrahigh strength ® steels

orld ide to ens re maximum automobile omponent reliability.

ext a ine ollmeier | hotos e ler and eifert

he next

eneration of hot formin

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As a pioneer in hot forming, thyssenkrupp Steel does more than simply deliver the right ma-terials; it also develops solutions that o er the customer the est availa le enefits. his means the latest innovation, ro,

guarantees highly relia le com onents and ro-cesses in automotive manufacturing. he new coating ensures significantly lower rocess re-lated hydrogen a sor tion during the annealing

rocess in hot forming, and also ma es the manufacturing rocess more economical.

“As partners of the automotive industry, we see ourselves as drivers of innovation who

now the challenges involved in hot forming and su ort our customers with solutions, says

ndr atusc y , C of the utomotive usi-ness unit at thyssenkrupp teel. han s to our

ro coated hot formed steels, we can now ut an end to energy intensive, time consuming

extra measures that are normally needed in the hot forming rocess.

New alloying concept for hot formingro is roduced in thyssen ru teel s

modern hot di galvani ing lines ust li e a standard aluminum silicon coating. nli e the standard coating, a inch of magnesium is added to the aluminum and silicon in the melt

ool, which is then distri uted homogeneously oth in the melt and in the coating.

his little twea in the chemistry ma es a considera le di erence in the hot forming

rocess, says Georg arma, roduct anager for Hot Forming at thyssenkrupp teel. his is

ecause ro ensures that significantly less di usi le hydrogen is roduced during the annealing rocess, which can force its way into the material. his minimi es the ris of hydro-gen induced crac s forming, which can occur in the event of a worst case scenario com ination of strength and stress when the content level of hydrogen is critical.

Demonstrably less hydrogen in the material

he results roduced with ro are im res-sive, says arma. ests conducted in series

roduction lants rove that the hydrogen con-tent in a com onent after hot forming is reduced

y ercent or more. ydrogen a sor tion

ro the oatin of the future: It ensures high reliability for safety-relevant structural body components.

can even e reduced y u to ercent in a e i ly rolled material. han s to our new

coating for hot forming ultra high strength materials, cost intensive countermeasures to reduce hydrogen will no longer e needed in the future.

he rocessing ro erties of ro are also com ara le with the standard roduct. oining

rocesses such as laser welding and resistance s ot welding can e used as usual, while the a rasion ro erties remain com letely unaf-fected and the com onent is still easy to aint.

aterials coated with ro are availa le to our customers worldwide, says arma. he failure ris goes down, rocess relia ility goes u , and the energy and manufacturing costs are o timi ed long term. nd that s all without any

rocess ad ustments or changes to rocessing ro erties.

In short: MBW® manganese oron steels from thyssenkrupp teel in com ination with

ro are an automotive manufacturing milestone when it comes to the hot forming of weight o timi ed structural com onents whose

ehavior is critical in the event of a crash.

Experience that makes complex processes simpler As a pioneer of hot forming, thyssenkrupp Steel knows the chal-lenges involved in the hot forming process and supports its automotive customers as a partner that always thinks one step ahead.

With MBW® ro, the steel experts are optimizing process reliability during hot forming, maximizing the reliability of compo-nents, and reducing the energy and manu-facturing costs along their customers’ entire process chains.

New products such as MBW® ro ill t the hot forming process on a completely new footing. This shows that steel is the basis for sustainable and economical component production, both now and in the f t re

ot forming e cellence for you.

ot formin ex ellen e ro is the ne oatin for hot-formed steels from the MBW® family.

More onlineearn more a o t ro at

www.thyssenkrupp-steel.com/en/as-pro

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Anyone who knows anything about hot forming is familiar with this challenge: During the heat treatment of alumi-num-silicon-coated (AS) steels, hydrogen can force its way into the material. In the worst-case

scenario, this can then lead to the hydrogen-in-duced failure of the part. The current solution strategies to minimize these failure risks only focus on the process, but these are energy- and cost-intensive.

Of course thyssenkrupp Steel, as a pioneer of hot forming and partner to the automotive industry always loo ing for ways to solve ro -lems hel s conduct research for its customers.

his commitment was instrumental in ro-ducing a technical solution that significantly increases process stability, even under the most critical of conditions. ts name ro.

The new product is manufactured in the steel producer’s modern hot-dip galvanizing line cycle just like a standard AS coating. “The only di erence is that we add a inch of magnesium to the aluminum and silicon in the melt pool, which is then distributed homogeneously both in the melt and in the coating,” says Grit

eimann, roduction ngineer for ot i Galvanizing Lines for thyssenkrupp Steel in Duisburg, Germany. “The new alloying concept ensures that the amount of hydrogen absorbed by the material during the hot forming process is significantly reduced.

It all starts with annealing“The tendency of hydrogen to embed itself in the steel during the annealing process on the cus-tomers’ premises is dependent on the process,” explains Manuela Ruthenberg. She is a Tech-nical ro ect anager in roduct evelo ment

for Steel Coatings at thyssenkrupp Steel, and is res onsi le for the ro ro ect. his is e-cause the high temperatures in the atmosphere of the furnace lead to the surface reacting with the steam.”

With standard AS, oxygen reacts with the aluminum and primarily produces aluminum o ide. ith ro, e cessive magnesium o ide is roduced due to the high o ygen affinity of magnesium. “A thin coating of oxygen forms on the surface in oth cases. he crucial di er-ence ignificantly less hydrogen is roduced with ro coated ® steels than with standard AS-coated hot-formed steels while this reaction is taking place. Consequently, less di usi le hydrogen is availa le to force its way into the material.”

Once hydrogen has forced its way into the material, it will eventually need to leave again.

How do you develop a new, groundbreaking surface for hot forming? You do what thyssenkrupp Steel did with MBW® AS Pro.

Text Judy Born | Photos Rainer Kaysers

Maximum process reliability

Maximum automobile component reliability, than s to ro rit Reimann (left) and Manuela Ruthenberg check critical points on a component.

A guarantee for fla less surfa es checking the material for imperfections.

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Grit Reimann holds a Dipl.-Ing. Diploma in Me-chanical Engineering and Forming Technology and works as a pro-duction engineer at a hot-dip gal-vanizing plant. She played a major role in implementing the plant tech-nolog side of the ro ro ect.

Manuela Ruthenberg was the echnical ro ect anager in charge of the development of

ro. he materials technician has long been conducting research on the topics of hot-dip aluminizing and the optimization of surfaces.

Experts This is because exceeding a critical amount of hydrogen combined with high stresses and high strengths can cause failures. Up to now, the moisture in the furnace atmosphere is reduced using complex dew point control. Another

ossi ility is hydrogen e usion annealing of the finished com onent. his re uires minutes in a furnace at around C.

“This releases the hydrogen that has embed-ded itself in the microstructure,” say Reimann.

oth o tions, dew oint control and e usion an-nealing, are energy- and cost-intensive. With our new ro coating, our customers will e a le to dispense with both methods in the future.”

Reducing process costs while maximizing component reliabilityThis is a groundbreaking development in hot forming. articularly in automotive manufac-turing, hot-formed steels in combination with

ro re resent a milestone in the roduction of weight-optimized structural components whose behavior is critical in the event of a crash. “If, in the future, the critical phase in the annealing process can be eliminated, the failure rate will fall, says uthen erg. rocess reliability for the manufacturers will increase, and lasting energy savings can be made. “The process windows will also grow for the process-ing com anies an advantage that should not be underestimated.”

onfirmation in series produ tion plantshe new ro conce t was tested in the ech-

nology and Innovation division at thyssenkrupp Steel during the course of many operational tests and checks. In addition, the hot forming processes were recreated on the customers’

remises including those that re uired long periods in the furnace. “We took all the unpre-dictable factors into account, and can now say, following our comprehensive investigations, that our new ro coating ee s its rom-ise, even in series production plants,” says Ruthenberg.

The same goes for further processing. “Our new coating o ers at least com ara le rocess-ing ualities to surfaces treated with the stan-dard AS. Whether this is laser or resistance spot welding, or painting, none of these processing ste s re uire any ad ustments to the rocess-es taking place on the customers’ premises.

ro coated steels are also corrosion resis-tant, ust li e our standard coating.

ot formed steels with an ro coating are availa le worldwide. hey o er customers tan-gi le enefits im roved com onent and rocess reliability and proven energy and cost savings.

ContactsGeorg Parma, rod ct anagement, oated rod cts,

0 , georg. arma th ssen r .com

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The name says it all: as thyssenkrupp Steel’s innovation lab, the Application Technology Center aims to do more than simply develop and manufacture new steel materials and technolo-gies it also strives to ensure that

the company’s customers get the most out of these developments. This is achieved through analysis, design, experimentation, simulation, forming, joining, revision, correction, and industrialization.

“As the technological backbone of every-thing our customers do, we can never stop ques-tioning ourselves,” explains Dr. Lutz Keßler, Head of Application Technology. In keeping with this principle, employees in the Application Technology Center use their decades of process-ing experience to keep revising and improving the company’s products to incorporate the latest technological possibilities and ensure that they meet the standards required of the materials.

“Our expertise smooths the way for our custom-ers, helping them with the practical use of our material in a way o ered y no other steel manufacturer.” This process includes both in-depth, individual consulting and a holistic approach to the technological and fi nancial conce t for customers in any industry.

System partner to the automotive industry The large-scale concept studies published at the start of the millennium, such as the NSB® New-SteelBody report, were superseded by the InCar® Group-wide innovation package, which in turn gave way to its successor, InCar® plus, one car generation later. Crucially, none of these con-ce ts is limited to a s ecifi c manufacturer, and the sample applications, proposed solutions, and processing recommendations they contain for innovative steel grades always o er sco e for customization and scaling. One example of this is the selectrify® initiative, the company’s latest automotive electromobility concept. “The au-

Flow formingThe idea: A testing facility that can be used to process ultra-high-strength steels and work in combination with other forming and heating technologies.

The innovation: The new � o forming machine rod ces rotationally symmetrical parts that are up to 50 percent lighter than previous models.

E-Mobility Center DrivesThe idea: To develop high-strength electrical steel with as little energy loss as possible in order to make electric motors e en more e cient and o erf l.

The innovation: An in-house test ench for the de eloment of high tech electric dri e s stems that has alread c t core losses to almost 0 ercent elow those of standard grades.

InCar® plusThe idea: To make the vehicles of the future safer, lighter, more comforta le, more e cient and more environmentally friendly.

The innovation: Around 0 se arate sol tions for the

car body, chassis & steering, and powertrain, which are tested and validated along the entire al e chain to ens re their eff ecti eness.

NSB® NewSteelBodyThe idea: To present thyssenkrupp Steel’s new light-weight materials and production methods in a compact reference concept.

The innovation: The study, which was conducted using a concrete production vehicle, shows how intelligent, lightweight steels and tubular design can cut body-in-white weight by up to 24 percent.

The Research and Development department of thyssenkrupp Steel’s Application Technology Center has had its fi nger on the lse for 0 ears, hel ing and ad ising its c stomers on how to get the most out of steel.

Shaping our o n future

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smartform®

The idea: A reliable production process for making components with a high level of dimensional accuracy using ultra-high-strength steel grades and cold forming techniques.

The innovation: A process that has provided a solution to the springback problem and can be used to produce highly complex shapes with a high degree of dimensional accuracy using ultra-high-strength materials.

Tailored temperingThe idea: An automotive pro-duction technique that combines safety with lightweight construc-tion. The components need to be strong and ductile in order to absorb impact energy in a controlled way.

The innovation: iff erent cooling rates in diff erent areas of a forming die. recisel defi ned ones

ith diff erent le els of strength and ductility can be produced in one operation.

tribond®

The idea: To combine a variety of sometimes contradictory steel properties in a single product and o timi e them for diff erent applications.

The innovation: A triple-layered composite material with a ductile steel outer and a high-strength core.

Virtual engineeringThe idea: Development pro-cesses that are not tied to one location, instead being performed in digital, three-dimensional spaces.

The innovation: The selectrify® initiative is a virtual reality e erience the fi rst ste to ard a virtual reality environment you can work in from any location.

ContactDr. Lutz Keßler, Head of Application Technology,

0 0, l t . essler th ssen r .com

tomotive industry s in uence on technological develo ment is unrivalled y any other sector,

e ler e lains. han s to our technological e ertise and consulting s ills, we have acted as a develo ment artner to this sector for years e wor ed with orsche on the fi rst fully galvani ed car ody ac in , and were early ro onents of ress hardening for structural com onents.

ever stand still and never sto thin ing a out tomorrow or even the day after hat s the lication echnology motto. ou can t change everything overnight es ecially not with roduction cycles that run for several years at a time. thyssen ru teel rovides its customers with new ideas and wor s with them closely to develo these conce ts.

Process-optimized innovationver the last years, the steel com any has

also continued to actively evolve in terms of its own rocesses and roducts. he automotive industry is often the driving force ehind innovations, though the energy, construction and

ac aging sectors have also roven in uential. s the decades have assed, the com any has

grown to ecome a technological e ert that oth roduces and coats steel, as well as show

ing its customers the est way to use and wor the high tech, e i le material. o this end, each of the Grou s usiness units has its own on site esearch and evelo ment de artment. thyssen ru s steel e erts can simulate entire rocess chains, such as the roduction

rocess used for hot forming at automotive stam ing lants. i erent customers in

di erent industries can e hel ed y thyssenru teel s a lications e erts, whether

in uis urg, ortmund or Gelsen irchen, in ochum, ohenlim urg or ndernach. he

com any has long since grown eyond its role as a roducer of materials, and now also acts as a rovider of solutions and services for its customers rocess and roduct develo ment structures right u to the series roduction stage. ee moving, ee uestioning yourself, and ee evolving that is the ey to long term success. he est way to re are for the future is to sha e it yourself.

One shape, many variants: The amazing properties of steel coils are hidden behind an unassuming exterior.

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Cooperative net or s for flexible

grids: In an interview, Prof. Rik De Doncker

abo e and r ndreas ansen

explain ho s ien e and industry ill ha e to or to ether for a su essful transition

to green energy.

Prof. Rik De Doncker has been with RWTH Aachen University since 1996, where he currently heads the Insti-

tute for Power Electronics and Electrical Drives, as well as the E.ON Energy Research Center

and the FEN research campus.

r ndreas ansen has headed Quality

Assurance and Product Development in the Elec-

trical Steel business unit at thyssenkrupp Steel since

0 . n this role, ansen who holds a degree in chem-

istr is res onsi le for the Gelsenkirchen, Isbergues,

and Nashik locations.

Experts

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Prof. De Doncker, you are in charge of the FEN research campus at RWTH Aachen University. What is this project all about?De Doncker: Our electrical supply system will continue to shift towards environmentally friendly, decentralized energy sources. How-ever, this requires new grid infrastructure to transport, distribute, and store this energy in a more efficient and e i le way. ut these types of electrical grids cannot be developed and implemented without a high degree of transdisciplinary research and interdisciplinary cooperation.

What does that mean in practice?De Doncker: Here at RWTH Aachen Univer-sity, we have set up a local medium-voltage and DC grid for demonstration purposes. This five megawatt C grid is o erated within the university’s infrastructure and couples the Center for Wind Drives with the E.ON Energy

esearch Center s five megawatt la oratory for medium-voltage converters. This enables us to develop new DC voltage components such as DC converters for modern substations, wind turbines, or fast-charging stations.

Who is involved in the FEN project? De Doncker: The research campus is funded by the German Ministry for Education and esearch undesministerium f r ildung und orschung . t is an association ›

Sustainably distributing green energy

Text Judy Born | Photo Rainer Kaysers, Rainer Schroeer

If the transition to green energy is to succeed, generating electricity from renewable sources will not be enough; that electricity also needs to be dis-tributed sustainably. Although green energy generated from wind turbines and solar power systems is good for

the environment, we can only be certain that this energy is distributed reliably if it can be fed into the transmission networks at a consistent frequency and voltage. A growing number of consumers now produce their own electricity, for e am le, using solar anels installed on their roofs. This leads to a steady increase in the number of decentralized, regenerative energy sources.

hat s why the le i le lectrical etwor s research cam us at achen niver-

sity took it upon itself to research and develop a e i le ower grid. mong other things, the aim

is to develop new technologies that allow this energy to e distri uted efficiently, securely, and a orda ly in the future. he consortium consists of re resentatives from the fields of science and business.

n this interview, rofessor i e onc er, Managing Director of the FEN research campus, and Dr. Andreas Jansen, Head of Quality and R&D in the Electrical Steel business unit at thyssenkrupp Steel, discuss the use of renew-able energies and what role grain-oriented electrical steel has to play in this process.

We need flexible ele tri al rids to supply energy generated from renewable sources. The FEN research campus has made it its mission to develop them.

Cooperative net or s for flexible

grids: In an interview, Prof. Rik De Doncker

(above) and r ndreas ansen

explain how science and industry will have to work together for a successful transition

to green energy.

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of institutes at RWTH Aachen University as well as a consortium of artners from di erent sectors. ne of those is thyssen ru teel s ecifi cally, its lectrical teel usiness unit.

Dr. Jansen, why is the Electrical Steel business unit involved in the FEN project? Jansen: e thin it s e citing and hugely im ortant that alternative conce ts for the trans ortation and distri ution of electricity are not only eing develo ed here, ut are actually

eing im lemented ecause if we want to ta e the transition to green energy seriously, we have to fi nd new technical solutions to tac le it and

roduce evidence that these solutions wor . t is im ortant for us to now what ower grids will loo li e in the future when it comes to the issue of trans orting energy. f the grids change, then the associated trans ortation e ui ment will also change.

Which is where Electrical Steel comes in?Jansen: actly, ecause you need transformers to trans ort electricity, and grain oriented electrical steel is at the heart of every transformer.

or us, it is a out o timi ing our materials at an early stage so that they can fulfi ll any future re uirements.

What sort of requirements do you mean?De Doncker: f we want to feed in more renewa le energies or even e clusively renewa le energies in the future, we also need to create a storage system for that ur ose. nd we need e i le grids that are ca a le of distri uting

energy in the location in which it was generated.

Why can’t we do that now? De Doncker: f you have a hotovoltaic system on your roof right now, you can t transfer any e cess energy directly to your neigh or. s it stands, this electricity is normally fed ac into the high voltage grids, meaning that its voltage level is increased again efore it is trans orted via the overhead medium and high voltage grid and redistri uted.

What is your solution?De Doncker: he ey to this is C technology, which ena les distri ution grids to e cou led with one another at the same voltage, creating a direct ow of energy etween the generator and consumer. ulti le customers in the same grid can e connected with one another via these decentrali ed solutions and e change energy locally. his turns consumers into rosumers who do not ust use energy, ut also roduce it.

What role does grain-oriented electrical steel play here?Jansen: lectrical com onents and systems such as C transformers are re uired to set u and o erate this ty e of C networ . he core of a device li e this consists of magnetically soft electrical steel, which is designed to erform with the utmost effi ciency. or the ro ect, we are using the thinnest material availa le to us right now to fi rst set u a three hase solid state transformer.

What is so important about the material? Jansen: irst and foremost, the magnetic

ower loss must e reduced to a minimum. ut thermal sta ility and strength are also im ortant. his ty e of transformer is constantly in o eration. he transformer and its grain oriented electrical steel core have to erform hours a day, days a year. f it fails, it can lead to ma or economic losses or create a safety ha ard.

Would the transition to green energy be possible without grain-oriented electrical steel?Jansen: o, without our owercore® electrical steel, there can e no transition to green energy.

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Without our powercore® electrical steel, there can be no transition

to green energy.”Dr. Andreas Jansen, Head of Quality Assurance and

Product Development, Electrical Steel business unit

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ContactDr. Andreas Jansen, Head of Quality and R&D, +49 209 407 50363, [email protected]

It doesn’t matter if we are talking about wind turbines or photovoltaic plants; they all require a transformer to feed power into the grids. Elec-tromobility also doesn’t work without grain-ori-ented electrical steels, since every charging station has a transformer in it.

he e ien y of ele tri al steel has impro ed by up to per ent in re ent years s there still room for impro ement? Jansen: I’m absolutely certain there is, and that’s what drives us to keep innovating. So-phisticated heat treatment processes are needed to manufacture electrical steel with the lowest levels of loss possible. We are always investing in the latest technologies in research, develop-ment, and production. That is precisely why we are also involved in the FEN project: so that we can identify trends early and prepare our mate-rials for the future. De Doncker: Besides, all of our studies have shown that the grain-oriented electrical steel from thyssenkrupp Steel gives us the highest

DC technology turns customers from consumers into prosumers.”

rof i e on er Managing Director of the FEN research campus, RWTH Aachen University

f it has po er there s po er ore® inside

ne of the many ele tri al boxes on the resear h ampus at a hen ni ersity

degree of effi ciency. Given the current state of power electronics, both the thermal and electromagnetic properties achieve outstanding results.

hat ma es the transformer for a fl exible po er rid diff erent from a transformer for our urrent rid?Jansen: It’s a lot smaller and lighter, and it’s fi tted with a lot more electronics. Currently, this new type of transformer can only be manufac-tured using our extremely thin and low-loss powercore®. The best thing about it is that the transformer isn’t just an idea; it is actually being built here in Europe by one of our customers on the FEN research campus, meaning it can be reproduced and could go into series production immediately.

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We call it #tksteel inside: an iron-carbon alloy that shapes our homes. Without thyssenkrupp Steel’s innovative products, ‘home sweet home’ wouldn’t be half as sweet!

Rails and ships, cars and planes, bridges, pipelines and gas tan s without steel our world would grind to a halt. ut it s also im ortant for the little things, and is actually ust as integral to everyday life in our

own homes. esearchers and develo ers are constantly ushing the oundaries of what steel can do, and this is re ected erfectly in thyssen ru teel s roducts and a li-cations. hin ing the future of steel is our motto and we a ly it to all inds of domestic a liances and white goods, from ovens and refrigerators to washing machines, dishwash-ers and driers.

he outstanding forma ility and corrosion resistance of innovative materials and sur-faces ma es them the erfect raw materials for these roducts. ne e am le of this is the galfan® coating, which is used in all inds of a lications that re uire o timum corrosion

rotection and ma imum forma ility, such as the front and side anels of uilt in a liances. n addition to this, the steel com any also o ers

a range of cold rolled steel sheets for customers to form and enamel themselves.

Appearances are everythinghe organic coated car on steels in the ladur®

range ring a touch of class to the loo and feel of any surface, and have een meeting the high-est standards of aesthetics, uality, forma ility, color variety and cost efficiency for years.

ne of the most im ortant factors for domestic

How steel helps out around the house

Text Judy Born | Illustration C3 Visual Lab

60 years of pladur®: design meets functionOrganic coated carbon flat steel from thyssenkrupp Steel is functional and colorful prepainted steel for premium manufacturers. Our range includes over 8,000 different colors and a huge range of textures in different coatings and steel grades.In the construction sector pladur® is used for facades, interior finishing and roofs. Other uses include domestic appliances, garage doors and trailers.

Jahre pladur ®

Design trifft Funktion

60 years of pladur®

design meets function

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appliances is the range of surfaces available, an aspect that covers both coated products and steel products with decorative overlays. Steel products are also found in many kitchen appli-ances, for example: powercore® electrical steel in motors as well as inenamel cookware and

a ing trays, and even in the design of co ee makers.

Steel for your home and interior designModern tubular steel and modular furniture first con uered our living rooms and offices many decades ago, to the extent that many such designs are now regarded as iconic. Here too, manufacturers often choose material from Duis-burg when making their designs a reality.

However, steel also has many less obvi-ous applications, such as in curtain rails and window rofiles. f you want to see the di er-

ence erfect, high uality steel can ma e, ust compare the runners of your soft-close drawers to those of a conventional drawer: the soft-close design uses scalur® , a hot di galvani ed at product commonly found in telescopic runners in shelves and other furniture. This product o ers thic ness tolerances as tight as . millimeters on oth stri length and width.

So as you can see, it’s not all heavy ma-chinery steel also has a lot to o er on a small-er scale, and plenty of its potential around the home remains untapped.

ContactIndustry business unit, T: +49 203 52 - 41048, [email protected]

The house practically looks after itself… Well, not quite, but at least the steel products make things much easier!

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Biomassse-Heizkraftwerk

A fresh facade: The texture of pladur® Relief Icecrystal lends the building an ele ant loo

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After 40 years, it was time for the ‘Der Öschberghof’ hotel complex to get a facelift and expansion. The result is a 5-star exclusive resort with an exterior that, thanks to its pladur®-coated steel facade, blends perfectly into the surrounding landscape.

Stylish living in steel

More than just a facade (from left): Marcel Glapski (Arnold AG), Klaus Kottkamp (thyssenkrupp Steel), Daniel Burkhard (Öschberghof project coordinator), Mirko Bartl (Öschberghof management).

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Text Judy Born | Photos Rainer Schroeer

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Contact:Klaus Kottkamp, Industry business unit, +49 203 5225211, [email protected]

Axel Pohl, Industry business unit, +49 2732 599 4578, [email protected]

More than meets the eye: You can hardly see it from the outside some elements of the facade allow you to look through walls.

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the new facade. Arnold AG is headquartered in Friedrichs dorf, near Frankfurt, Germany.

medium si ed firm, it is one of the country s leading metalworking and metal processing com anies. t was our o to find the right ma-terial, plan the design, and ensure that produc-tion was completed smoothly.”

High-quality pladur® effe tThe right material turned out to be coil-coated steel product pladur® Relief Icecrystal from thyssen ru teel. t s an e cellent material for facade paneling; it has all the right technical properties, and it opens up an incredible range of design opportunities that impressed the client and architects ali e, Gla s i says. laus

ott am , customer consultant in the ndustry business unit at thyssenkrupp Steel, can only agree he s ecial feature here is the very high quality coating, which ensures that the material stays durable and colorfast and also lends it an attractive tactile uality.

Additionally, the steel products score points for sustainability, as they can be recycled at any time. he material also oasts e ce tional corrosion ro erties and ease of rocessing it stands u to even the most com le forming processes. “We conducted initial tests and made our own rofiles with the sheet metal sam les

r. ott am rovided to us, Gla s i says. “Then, we worked together to determine to what e tent we could end the metal during forming. t went e tremely well it s e actly the ind of

collaboration I always hope for.” he material stress test even went a ste

further, as the Öschberghof hotel is located in a region that is prone to hailstorms. “And what

etter way to test the resistance of a golf resort s facade than y firing golf alls at it says Daniel Burkhard. “So we built a model of the building, with pladur® paneling, and we used that to test whether the roofs and facades could withstand a massive hailstorm. s it turns out, they could viously, a ro ect li e sch er-ghof doesn t have a ma or im act on our order

oo s, volume wise, ott am says. ut it s an im ressive demonstration of how versatile pladur® is and all the di erent o tions this

remium roduct has to o er.

How do you e and a hotel com le without changing its overall loo ow do you incorporate the surrounding environment without ma ing the buildings stick out against the landsca e nd how

do you convert a historic location into a mod-ern resort without completely breaking with tradition

This was the task set by the owners of the Öschberghof hotel in Donaueschingen, in the Black Forest region of Germany. Around five years ago, they held a com etition to find the right architects for the job. The design by unich ased architecture firm llmann, Sattler, Wappner came out on top. Their concept was essentially based on an archetypal farm-stead, consisting of little clusters of individual gable-roofed houses. Originally, the roofs and facades of the new building were supposed to have co er aneling. ut we had to dro that idea again pretty quickly,” says Daniel Bur-khard, the project coordinator for the Öschber-ghof hotel renovation. he resort is focused on sustainability, so we collect rainwater to water the green spaces and parts of the golf course, for e am le. ut water ioni ed with co er would

ill o the grass over the long term. The designers realized they needed to look

for a di erent material one that could e used to create oth the dra ing e ect that the archi-tects had originally intended for the facade, and the shining, shimmering e ect of the original material. nd they needed to find someone who could manufacture and imple-ment it. hat s how we got involved, says Marcel Glapski, a project manager at Arnold AG who was ultimately put in charge of designing

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As far as the eye can see: The various folds and edges in the trape oidal profiles reate a drapin effe t

The visible structure in the paint coating is what makes the laddin so interestin

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An innovative materialThe thyssenkrupp Packaging Steel business unit has developed a steel grade in rasselstein® olid e that will transport conventional steel packaging into the future. he new material is e tremely strong, yet also oasts very good forming ro erties, thus ena ling the use of lower material thic nesses without reducing sta ility. his ro erty is articularly im ortant in the production of food cans that are opened using a pull tab. The ‘rivet’ is what is essential here. his com onent connects the lid to the pull tab and should not detach as soon as you pull it.

t the same time, the ac aging steel has to be soft and ductile enough for the rivet to e formed from the sheet metal and for the lid to e e ortlessly

ulled from the can. his means that the material has to e oth solid and e i le or in other words,

olid e

1 2A safe material

longside the aforementioned cans for foodstu s with easy o en ends, rasselstein® olid e is articularly suita le for manufacturing aerosol cans. he s ecially designed ottoms and lids of spray cans are ideal applications for this material.

rom deodorant and hairs ray, to s ray ottles for erfume and room scents, right through to s ray foam for ovens and acrylic paint for furniture and cars tin late ac aging is an essential art of everyday life. owever, manufacturers may only ring aerosol cans on to the mar et under s ecial conditions according to law. e ending on the roduct that is eing sold, it sti ulates the e act ressure the s ray can has to ensure before it ‘fails.’

his deformation ressure is desira le, as it serves as a warning for the consumer. t can e seen from the lid and ottom of the can slowly ulging

outward. his means that you don t have to worry a out cans e loding, as the consumer s safety ta es to

priority.

rasselstein® olidfle s ra

cans light, st rd and sustainable.

Only works under pressure – the perfect spray can is light,

safe and easy to use.

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el

Solid and extremely flexiblehe ne material grade for cans from th ssen r ’s ac aging teel siness nit o�ers a range of

ad antages. e call it rasselstein® olidflex.

Prod

uct

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3A sustainable materialrasselstein® olid e is considera ly stronger than the material that has

een used for s ray cans u to this oint. ts ductility is also di erent

from conventional material. ts higher strength ma es com onents more sta le and means that they can

e roduced from thinner material. his allows more cans to e roduced

using the same uantity of tin late. ost im ortantly, s ray cans

made from rasselstein® olid e are lighter than conventional aerosol cans. his results in a weight reduction of u to ercent com ared to standard s ray cans.

Using rasselstein® olid e doesn t ust hel customers reduce their material costs it also ena les them to minimize their CO2 foot rint

er can. aired with the high recycla ility of ercent for tin late

ac aging, cans made from rasselstein® olid e are environmentally friendly and good for the climate.

ContactAndreas Tschage, Packaging Steel business unit+49 2632 3097 4723, [email protected]

Solid and extremely fl exible

Im G

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ntralogistics is very im ortant to us, so we are een to discover the e tent to which we can incor orate drone trans ort into our rocesses. he tests we re running here haven t een done

efore we re ioneers in this field right now. asically, we can o timi e the utili ation of our la s y ust sending off a few raw material sam les at a time. t the moment, we wait until we have enough to fill a delivery car. sing drones can also save us time, as they can ma e the tri in ust si minutes or so. hat s a s eed that cars sim ly can t match after all, our site is a out five times the si e of onaco rones also offer a way of cutting the traffic on our site, which is also im ortant in terms of occu ational safety we have a lot of level crossings here. f they erform well in routine

o erations, we want to increase our trans ort drone num ers in the medium term.

n the hands of rofessionals, drones can e of great enefit to our society. a e the maintenance of railway trac s or high voltage lines, for e am le a drone is much uieter, more fle i le, and less e ensive than a helico ter, which is what we often use for these inds of wor today. hey can also e very hel ful to the olice and fire

rigade, for trans orting medical goods, and in develo ment aid.

owever, we need to ma e sure that there are strict restrictions in lace for the use of drones in ur an areas when it comes to safety, noise emissions, and data

rivacy. t s also im ortant to note that the ca a ility for flight with no visual contact and even to com ine drones with automated flight is essential to how almost every innovative usiness model wor s. s such, m glad that the new uro ean ermit regulations are so rogressive while still maintaining high safety standards, of course.

“Mr. Lostak, how does your company benefi t from the use of drones?”

“Mr. Jarzombek, what potential do you think drone technology can off er us in the future?”

Thomas Jarzombek is the Federal German government’s German Aerospace Coordinator.

Dr. Thomas Lostak is project manager

for drone logistics at thyssenkrupp Steel.

Interview

“Mr. Lostak, how “Mr. Jarzombek, what

Interview

thyssenkrupp Steel uses drones for transport

InterviewInterview


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The next generation of hot forming in automotive engineering has arrived: AS Pro, a new coating that allows you to minimize process-related hydrogen absorption and maximize the safety of crash-relevant components. In addition, with AS Pro you save energy sustainably – for more cost-efficient production. As hot forming pioneers, we know the challenges involved in the hot forming process and support you as a partner who thinks ahead. For more information on AS Pro, visit www.thyssenkrupp-steel.com/en/as-pro

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bHSteel

Maximum part reliability

ith fi e letters

TKS_AZ_HOT-AS_Pro_DIN-A4_EN_rz.indd 1 26.09.19 09:45TKSE-1901-EN-40-Anzeige [MA-INT].indd 40 25.10.19 08:52

compact steel, Issue 01/2019 - The thyssenkrupp Steel magazine · 2020-07-19 · 2 compact steel...

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Transcript of compact steel, Issue 01/2019 - The thyssenkrupp Steel magazine · 2020-07-19 · 2 compact steel...