Tribodays 2016
Gestamp HardTech
©2013 GESTAMP 2
Corporación Gestamp
Corporación Gestamp is a Private European Industrial Group
Steel Service Centers Auto Components Renewable Energy
130 industrial plants
Present in 25 countries
More than 33.000 employees
Turnover 2015 7.000 milj. €
©2016 GESTAMP 3
2.32.0
3.2
4.8
5.8 5.96.3
7.0
2008 2009 2010 2011 2012 2013 2014 2015
Evolution into a leading global Tier 1 automotive supplier
Revenues (€bn) EBITDA (€m)
Key company milestones
1997 1999 – 2001 2002 2006 – 2009 20112004 2010 2013
Formal
foundation of
Gestamp
Automoción
Establishment of
market presence in
Latin America, France
and Germany
Acquisition of
HardTech Group
Entrance into
US market
Acquisition
of EDSCHA
Group
Acquisition of
Thyssen-
Krupp Metal
Forming
Mitsui JV in
the Americas
First phase internationalization
Becoming a multi-technology partner
Focus on products
Expansion into emerging markets
China,
Turkey, India,
Russia, Korea
2016
Acek stake
increase to
100%
Focus on Asia
Strong track record of profitable growth
(restated) (restated)
270223
390
547
620 609657
760
2008 2009 2010 2011 2012 2013 2014 2015
©2016 GESTAMP 4
Gestamp business overview
©2016 GESTAMP 5
Global footprint – plant locations
11+
2
11+
1
Gestamp plants Plants under development
15
45+
1
13+2
Luleå
Plant expansions
Production facilities R&D sites
Western Europe 45+1 8
Eastern Europe 15 -
North America 11+2 1
South America 11+1 1
Asia 13+2 2
TOTAL 95+6 12
Gestamp has a global manufacturing and management footprint, with 95 plants (plus 6 under development) in 20 countries covering four continents
Further customer-driven opportunities to open 6 new plants, particularly in North America and Asia
Strategically located industrial footprint in close proximity to OEMs to enable just-in-time and just-in-sequence supply
The company now employs over 1,300 employees in R&D across 12 facilities around the globe
R&D expertise and innovation leveraged across global footprint
FOOT PRINT
©2013 GESTAMP 6
Evolution in terms of material and technology Gestamp
74 852016 2017
Gestamp PH lines footprint and production capacity
2016/17
DEVELOPMENT CENTER
PRESSHARDENING
o Production facility
o Tool development & manufacturing
o Process development
o R&D
o 500 employees
GESTAMP HARDTECH
Serial toolHardening line 6
©2013 GESTAMP 8
Customers, Volvo, Audi, JLR, VW, Volvo Trucks, Scania
The All-New Volvo XC90
23 parts
GESTAMP R&D LULEÅ, 2016
Research, TRL 0-3
All technologies
Process, Material,
Simulation, Testing
Manager Daniel Palo
5 Phd
2 Ind. docktoral students
7 Msc
1 Msc tooling
1 Msc process technology
2 Test engineers
2 PHD LTU
collaboration projects
Product development
Bumpers
Manager Daniel Palo
14 Msc
Product development
Side impact beams
BIW-codevelopment
Manager Hans Bodin
6 Msc
Tech Center
Built to print products
Production remarks, process
& tool development
Manager Per-Emil Back
22 Msc
Total staff: 65
CAD/ CAE
CAD
UG-NX ,I-DEAS, Catia V5
CAE- Preprocessing
Hypermesh, Ansa
Fec Finite element Converter
CAE- Crash
LS-Dyna, Abaqus, Pamcrash, Radioss
CAE-Forming
LS-Dyna, FastForm
CAE-Flow
Ansys-Fluent
CAE cluster Linux
449 CPU
Drop Tower(2017)
• 50 km/h
Material test equipment
• Tensile testing
• Sample preparatrion
• Microscope
• Hardness testing
• SEM (2017)
• X-Ray ( LTU,Metlab)
• GDOES (LTU, Metlab)
PH Research Lab
Field test corrosion
R&D BIW LULEÅ LAB EQUIPMENTS
Low Speed Crash Test Facility
• 20 km/h
• Bumper test standards
Static beam test rig
• 100 kN
PRESSHARDENING, Innovation 1974
Blanking
Austenizing
Forming & Quenching
Shotblasting
o Formability as mild steel
o UHSS materialdata after hardening
o Yield strength/density same as extruded alu
o Tight tolerances
o Good weldability
Research in collaboration with
Luleå University of Technology
1974-1979
o Process
o Tool
o Material, uncoated boron steel
o Joining
©2013 GESTAMP 13
Wear resistance
• Cutting knives
• Stone cutting discs
• Lawn mower knives
• Shovel blades
FIRST HARDENING LINE FIRST PRODUCTS
1 part/ stroke 25 s cycletime
©2013 GESTAMP 14
Automotive components
• BIW crash reinforcements
• Bumper systems
Material
• Uncoated boron steel
• AluSi coated boron steel
• Zinccoated boron steel
HARDENING LINE 2016
2 parts/ stroke 8-12 s cycletime
Crash Trigging & kinematic control
Increased ductility
Multimaterial joining
TAILORED PROPERTIES
Materialdata
SZ in die technology
Reduced cooling speed
HT400, HT 550
0
200
400
600
800
1000
1200
1400
0 2 4 6 8 10 12 14 16
Reference
HT 400
HT 550
HT 700
Mpa
%
©2013 GESTAMP 16
Tool wear, tool and furnace roller alu cladding
Uncoated boron steel
Damages in drawing radious
Alusi coated boron steel
Cladding on tool surface
Alusi coated boron steel
Cladding on furnace rolls
©2013 GESTAMP AUTOMOCIÓN