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)

02468

10121416

0 0,0002 0,0004 0,0006 0,0008 0,001 0,0012 0,0014

Weight [%]

Distance [mm]

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

0

200

400

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250200150 4504000 300 500350 550

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%

-24%-24%

-2%-2%

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

-200

-100

0

100

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900

Potential mV [S.C.E]

Bearingsteel

Toolsteel

13%Crstainless

Acid proofstainless

HybridSteel

Max

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 strength at elevated temp.



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







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


Low segregation







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


Low segregation







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


Increased machining tool performance through improvement of critical components

Low segregation







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


Low segregation







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.


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.


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


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

4

4

3

2

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

4

4

3

2Lower material use -end product

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.


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.


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.



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



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


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


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

a new breed of steel that meets the engineering challenges ... · a new breed of steel that meets...

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