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TOPOCROM® – Texturing: Technology and Advantages
Thomas Routschek Salzgitter Flachstahl GmbH, Salzgitter (Germany)
Karl Müll TOPOCROM Systems AG, Weinfelden (Switzerland)
BAOSTEEL BAC 2013, Shanghai (China)
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Ø TOPOCROM® - Electroplating Technology ◄◄◄
Ø Demands of the automotive industry on the surface structure of cold rolled sheet metal
Ø Requirements of the steelmaking industry for texturing technology of working rolls for skin passing mills
Ø PRETEX Surface Structure: Prospects
Structure of Presentation
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TOPOCROM® - Electroplating Technology
TOPOCROM® is a patented Process Technology for Electroplating
of Hard Chromium Coatings with a typical hemispherical Surface Structure
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+ +
Texturing of Working Rolls: Comparison of Technologies
TOPOCROM – Technology
+ +
_
SBT + HCr
EDT + HCr
EBT + HCr
SBT EDT EBT
TOPOCROM
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TOPOCROM plating reactor
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Layout of TOPOCROM - 2 reactor plant (schematically)
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TOPOCROM Facility for Steel Works
POSCO, Gwangyang/South Korea
Startup in 2009
Salzgitter Flachstahl, Salzgitter/Germany
Startup in 1996
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Difference between conventional texturing technologies and TOPOCROM Texturing
SBT
EDT
EBT
TOPOCROM Idea:
Structure for Texturing will be build up on the top of the ground Roll Body by the special TOPOCROM Hard Chromium Electroplating Process
à Convex Texture
Roll Body
Roll Body
Roll Body
Roll Body
Conventional Texturing Technology:
Structure will be build mechanically or physically
into the surface of the Roll Body
à Concave Texture
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Important Features of TOPOCROM® - Texturing
Important Features of TOPOCROM Coatings
Ø Hemispherical Surface Structure with perfect stochastic Distribution Ø Adjustable Roughness and Pc Values: Ra ≥ 0,5 µm to Ra ≤ 12 µm
Ø High Peak Account Values also together with high roughness values
Ø Adjustable Topography: open to closed Structure Ø Hardness comparable with normal Hard Chromium Coatings
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Variability of TOPOCROM® - Topography:
Open to closed structure
Closed TOPOCROM – Structure
Open TOPOCROM - Structure
Adjustable surface topography with TOPOCROM® - Texturing
open closed
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TOPOCROM Texturing: Ra/Pc - values
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Adjustable calotte - density of PRETEX surface structure
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High amount of lubricant pockets with ideal stochastic distribution
Closed voids
Open voids Material face
Sheet Forming tool
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Advantages of PRETEX surface structure
The PRETEX – structure of Salzgitter AG provides unique advantages with all surfaces: Ø Adjustable density of calottes Ø Precisely distributed hydrostatic lubrication pockets for improved formability Ø Ideal stochastic distribution of the lubrication pockets Ø Customized of roughness and peak account Ø Unique solution for combining low roughness with high peak accounts
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Structure of Presentation
Ø TOPOCROM® - Electroplating Technology
Ø Demands of the automotive industry on the surface structure ◄◄◄ of cold rolled sheet metal
Ø Requirements of the steelmaking industry for texturing technology of working rolls for skin passing mills
Ø PRETEX Surface Structure: Prospects
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Increasing demands of the automotive industry on the sheet metal surface structure
Actual and future demands of the automotive industry on the sheet metal surface structure
Ø Improved appearance of painted metal sheet surfaces
Ø Cost saving with paint systems without filler Ø Improved formability
Ø Very low abrasion in the forming tool
Ø Stable surface characteristics along the entire strip width and length
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Demands of the automotive industry on the surface structure of cold - rolled sheet metal
Requirements for the
forming process • High mean roughness values
• High number of lubrication pockets
• Even distribution of lubrication pockets
• Homogeneous friction conditions
Requirements for painting • Low mean roughness values
• High number of peak account values
• Homogenous peak distribution
• Absolutely stochastic roughness distribution (Avoidance of Moirè-effects)
• Less short- and longwave structures (Avoidance of Orange peel)
• Paint adhesion and spreading characteristics
The fine surface structure is applied to the sheet metal surface by skin passing
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Actual and future requirements of automotive industry for surface structure of sheet metal:
Appearance of painted metal sheet surfaces
Requirements for paint appearance Ø Avoiding of Moire΄ – effects Ø Avoiding of orange peel
Short and Long – Wave Comparison of PRETEX with alternative texturing on galvanized steel sheets
Advantages of PRETEX Ø Fine surface structure with high peak accounts and low roughness Ø Absolutely stochastic distribution Ø Low wave-scan values
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Actual and future surface – requirements of automotive industry for painting applications: Cost saving with paint systems without filler
Important factor for surface structure of sheet metall à low waviness • Filler and base coat are leveling the substrate, but are superposing the cathodic dip coat with a new waviness profile • Cathodic dip coat is filtering the roughness characteristic, but waviness will be transferred à The capability for leveling the waviness will be reduced by saving the filler
Challenge for Painting Process • Reduction of production costs, energy demand and CO2 – emission • Reduction of painting and drying steps à Saving the filler
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Actual and future surface – requirements of automotive industry for painting applications: Cost saving with paint systems without filler
Painting Process 2010: Paint System without filler
Standard VW – Group TL 218 (May 2012)
PRETEX is the ideal sheet surface structure for paint systems without filler
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FEA -‐ Simula+on of different fric+on condi+ons
Conclusions: l PRETEX leads to a be/er formability
l PRETEX leads to a safer forming process
Lower stresses and more
reserve to FLC with PRETEX
good draw-‐in
with Pretex
PRETEX ( µ =0,088 ) EDT ( µ =0,109)
draw -‐ in
25.8 mm
draw -‐ in
26.7 mm
Actual and future requirements of automotive industry for surface structure of sheet metal: Improved formability
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Actual and future requirements of automotive industry for surface structure of sheet metal: Improved formability
Ø Previously used: DC06 + ZE 75/75 with EDT – Texturing
Ø Replaced by: DC05 (mod.) + ZE 75/75 BPO with PRETEX – Texturing and Prephosphating
Ø Cost benefit by changing from DC06 to DC05
Ø Reduction of cold welding due to the lower friction coefficient of PRETEX + Phosphating
Car Wing
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Actual and future requirements of automotive industry for surface structure of sheet metal: Less abrasion in the forming tool
Ø Previously used: DC05 with SBT – Texturing
Ø Replaced by: DC05 with PRETEX – Texturing
Ø Cost neutral in steel price
Ø 30% reducing of lubrication volume
Ø Reduced cleaning work before cathodic dip coating
Body-contoured seat
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Structure of Presentation
Ø TOPOCROM® - Electroplating Technology
Ø Demands of the automotive industry on the surface structure of cold rolled sheet metal
Ø Requirements of the steelmaking industry for texturing technology ◄◄◄ of working rolls for skin passing mills
Ø PRETEX Surface Structure: Prospects
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Actual challenge for the texturing technology
Requirements of the steelmaking industry for texturing technology of working rolls for skin passing mills
Ø Characteristic and properties of roll texture
Ø Cost-efficient process for texturing of working rolls Ø Lifetime of textured working rolls in production Ø Schedule free rolling
Production of sheet metal surface structure
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Very low Roughness Wear and therefore long Life Time à due to Hemispherical Surface Structure, Multilayer Design and due to the Hardness of Hard Chromium Coatings 3 - 5 times longer Life Time compared to EDT Rolls (+ hard chromium plated) Constant Product Quality with TOPOCROM Rolls from the beginning (no running in-time) à High pressure cleaning of working rolls during operation is necessary
Requirements of steel works for working rolls: Life time of working rolls
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Requirements of steel works for working rolls: Schedule free rolling in HDG – Line № 2 of SZFG
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TOPOCROM – Texturing Technology: Benefits for Steelmakers
• Quality advantages for customers regarding formability and paint appearance
• Customized adjustment of all structure parameters
• Constant high surface quality of the metal sheets • Stable surface characteristics along the entire strip width and length
• Reliable reproducibility
• Significant increased Roll Life Time • Reduced number of roll changes
• Remarkable reduction in grinding and texturing costs • Increased total service life of the roll and total productivity due to less grinding operations
• Reduction of roll inventory • Higher productivity
• Reduced costs
• High wear resistance of TOPOCROM – Rolls allows Schedule Free Rolling • Increased productivity/higher mill availability
• Reduction of roll inventory
• Modest technological invest
• Low capital and manufacturing costs
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Advantages of PRETEX – Steel Sheet Surface Structure for Forming:
• Low Friction Coefficient • Building of closed Lubricant Pockets • High amount of Closed Lubricant Pockets with equal Distribution
improves formability and reduces abrasion in forming tools. • Customized surface structure/roughness/peak account
Advantages for Painting:
• Perfect Stochastic Distribution (no Moiré – Effect) • High Peak Count Values (Pc) together with higher Roughness Values • Homogenous Peak Distribution • Less Short Wave/Long Wave structures improve painting appearance
TOPOCROM structured Sheets: Trade Names à PRETEX® of Salzgitter AG and POSTEX® of POSCO
TOPOCROM® - PRETEX Surface Structure: Advantages for the automotive industry
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Structure of the Presentation
Ø TOPOCROM® - Electroplating Technology
Ø Demands of the automotive industry on the surface structure of cold rolled sheet metal
Ø Requirements of the steelmaking industry for texturing technology of working rolls for skin passing mills
Ø PRETEX Surface Structure: Prospects ◄◄◄
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PRETEX Surface Structure: Prospects
The automotive industry places increasing demands on painting appearance and processing properties of the delivered thin sheet metal. The TOPOCROM structure offers a high potential of optimization possibilities because of the independent customizability of the different structure parameters. In comparison to other texturing processes the TOPOCROM structure provides unique possibilities regarding the variety of structures. Therefore a steady further development of the surface structures by steelmakers is obligatory. To achieve this Salzgitter Flachstahl is linking process- and structure data. The most important milestones are: Ø Production accompanied by automated 3D-measurements and
automated qualification of roll and sheet surfaces Ø Development of process methods for TOPOCROM plating on the
basis of data mining Ø Systematic generation of PRETEX structures on thin sheet metal
optimized for painting appearance and formability Ø Cooperation with press and paint shops of leading automotive
manufacturers to adjust the results and support production-integration
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PRETEX Surface Structure – Prospects: Measuring Data
Ø Automated measurement of 27 surface-samples within 45 min
Ø Autonomous recognition and evaluation of calottes Ø Calculation of structure parameters by a mathematical alghorithm
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PRETEX Surface Structure – Prospects: Database, Datamining
Linking of production data: Communication between Topocrom-Structure-Database and other production systems including surface inspection.
Datamining: Evaluation of structural parameters to minimize imprints caused by dirt adhesions on work rolls.
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Laser
Optical Profile
Filter
Longwave (LW) 0,6-10mm
Shortwave (SW) 0,1-0,6mm
Substrat
ca.110 GE (bei 20°)
PRETEX Surface Structure – Prospects: Optimization for press and paint shop
Ø Laboratory trials for better formability and paint appearance
Ø Optimization of structure parameters in close
cooperation with automotive manufacturers Ø Integration of Pretex-Technology into production
processes and creation of new products
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TOPOCROM® – Texturing: Technology and Advantages
Thomas Routschek Salzgitter Flachstahl, Salzgitter (Germany)
Karl Müll TOPOCROM Systems AG, Weinfelden (Switzerland)
BAOSTEEL BAC 2013, Shanghai (China)