future trends in steel development, processing … in steel development, processingtechnologies...
TRANSCRIPT
'SCT2011
SCT2011Future trends in steel development,processing technologies and applications
Bringing the automotive, supplier and steel industries together
Edited by Dr.-lng. Hans-Joachim Wieland
and TEMATechnologie Marketing AG
Table of contents
Plenary Session 1
The steel industry - challenges and chances in a global market 2
Hans Jurgen Kerkhoff, Steel Institute VDEh, German Steel Federation, Germany
Volkswagen engineering - global production - local materials 2
Stephan Eisenberg, Volkswagen AG, Germany
Developments in forging technology - answers to changes and
challenges of the automotive industry 2
Hans-Willi Raedt, Hirschvogel Umformtechnik GmbH, Germany
Opening of the exhibition 2
Hans Jurgen Kerkhoff, Steel Institute VDEh, German Steel Federation, Germany
Light weight solutions with flat products 3
FutureSteelVehicle leading edge innovation for steel body structures 4
Martin Peruzzi, voestalpine Stahl GmbH, Austria; Antoine Gauriat, ArcelorMittal,
France; Marc Lambriks, Tata Steel Europe, The Netherlands; Oliver Hoffmann,
ThyssenKruppSteel Europe, Germany; Jody R. Shaw, US Steel Corporation,USA
Tubular steel components for light weight axle designs 12
Thomas Sauberlich, Benteler Tube Management GmbH, Andreas Frehn,
BentelerAutomobiltechnik GmbH, Germany
Innovations for automotive light weight solutions - the steel aluminium
hybrid blank 22
Enno Arenholz, voestalpine, Austria; Gerald Brugger, voestalpine EuroplatlnenGmbH Austria; Jurgen Bruckner, Fronius International, Austria
Innovative steels for trucks 27
Innovative lightweight steel solutions for commercial vehicles 28
Helmut Mebus, Christa Heigele-Hempowitz, Thorsten Boger, ThyssenKruppSteel Europe AG, Germany; Erik Seelen, ThyssenKrupp Tailored Blanks GmbH,
Germany
Use of higher-alloyed metallic materials and duplex steels for transporttanks of dangerous goods 29
Margit Weltschev, Ralph BaBler, BAM Federal Institute for Materials Research
and Testing, Germany
V
Tubes used as rotating components in gear box applications 38
Kara/a Klenke, Benteler Tube Management GmbH, Germany
Steel components - Strength properties of long products 42
The fibre flow in steel and its influences on mechanical properties 43
Andreas Schuster, Hirschvogel Umformtechnik GmbH, Germany
Influence of manganese sulfide inclusions on fatigue properties of AFP
steels 51
Nora Exel, Heinz Kaufmann, Fraunhofer-lnstitut fur Betriebsfestigkeit und
Systemzuverlassigkeit LBF, Germany
On the evaluation of strength of cold forged components made of high
nitrogen steels 58
Johannes Noneder, M. Merklein, U. Engel, Lehrstuhl fur Fertigungstechnologie,Germany
Press hardening I 66
Current and future trends in the field of hot stamping of car body parts 67
RalfKolleck, Robert Veit, Institute Tools and Forming, Graz University of
Technology, Austria
Production of load-adapted lightweight designs by partial hardening 75
Dieter Thomas, Thomas Troster, Holger Block, University of Paderborn,
Germany
Development of a close-to-production prototype of an induction heatingdevice for hot stamping of boron alloyed steels 83
Robert Veit, RalfKolleck, Christian Gasser, Gemot Wilfinger, Institute Tools and
Forming, Graz University of Technology, Austria
Significant insights and innovative processes for process-sure press
hardening of laser-welded seams in hotform blanks 91
Max Brandt, ThyssenKrupp Tailored Blanks GmbH, Germany
Profiles for body structure 100
Vehicle structure innovations by advanced rollformed solutions 101
Robert Wurzer, voestalpine Krems GmbH, Austria
VI
The HI-PAT project for new semi finished products for the roll
forming-tailor rolled dual phase steels 107
Andreas Wedemeier, Thomas Schulz, Salzgitter Mannesmann Forschung GmbH,
Germany; Adrian Istrate, Welser Profile GmbH, Germany; Jurgen Kotter, Schmitz
CargobullAG, Germany; Andreas Elvenkemper, Muhr und Bender KG, Germany;
Philip Beiter, Peter Groche, PtU TU Darmstadt, Germany; Frank Nehuis, Jan
Robert Ziebart, Thomas Vietor, IK TU Braunschweig, Germany
Passive safety and tubes made of high strength steels - a symbiosis 115
Kenan Ozdem, Benteler Tube Management GmbH, Germany; Michael Lueger,Benteler Tube Management, Switzerland
New methods for manufacturing 3D-bent lightweight structures made
from high-strength steel 120
Daniel Staupendahl, Christoph Becker, Matthias Hermes, A. Erman Tekkaya,Matthias Kleiner, TU Dortmund, Institute of Forming Technology and LightweightConstruction (IUL), Germany
Steel components - Made from long products 130
Experiences in manufacturing crown wheels with a forged pre-gearingfor commercial vehicle industry 131
Klaus Pfeiffer, Horst Schneider, Buderus Edelstahl Schmiedetechnik GmbH,
Germany; Frank Hippenstiel, Buderus Edelstahl GmbH, Germany
Oil tempered wire for high demanding applications - necessity of defect
management in the supply chain 140
Peter Janlien, ArcelorMittal Ruhrort GmbH, Germany; Malin Hallberg,Suzuki Garphyttan AB, Sweden; Hans Pengg, Johann Pengg AG, Austria
ArcelorMittal provides co-engineered solutions for high performance cars
components 147
Bruno Cofino, ArcelorMittal Long Carbon R&D, France
Influence coefficients of the production of steel bars on the further
production processes of engineering steels 148
Sven Kunow, Frank Wilke, Deutsche Edelstahlwerke GmbH, Germany
Press hardening II 156
Influence of silicon on intermetallic phases formation in Al coating
layer of HPF Steel 157
Baek Eungryul, Nandyo Alpalmy, Yeungnam University, South Korea;Cho Yeol Rae, POSCO Technical Research Laboratory, South Korea
VIII
Development of heat resistant galvanized sheet steels for press
hardening process 165
ll-Ryoung Sohn, Yeoi-Rae Cho, Sung-Ho Park, Wung-Yong Choo, POSCO, South
Korea
Challenges and advantages in usage of zinc-coated, press-hardenedcomponents with tailored properties 173
Thomas Manzenreiter, Thomas Kurz, Martin Rosner, voestalpine Stahl GmbH,
Austria; Andreas Sommer, Dieter Hartmann, Reiner Kelsch, voestalpine PolynormGmbH & Co KG, Germany; Gerald Brugger, voestalpine Europlatine GmbH, Austria
Properties and modelling of material behaviour of hot forming steels with
special emphasis of increased strength levels compared to 22MnB5 181
Thomas Gerber, Stephane Graff, Franz-Josef Lenze, Sascha Sikora,
ThyssenKrupp Steel Europe AG, Germany
ZnMg-Coatings 189
Zinc-magnesium coatings for automobile & trucks - a new dimension for
corrosion protection 190
Alain Besseyrias, Luc Diez, Christian Allely, ArcelorMittal, France
Tribological potential of zinc magnesium alloys 198
Anna-Elisabeth Raab, Erich Berger, Johann Freudenthaler, Franz Leomann,Christian Walch, voestalpine Stahl GmbH, Austria
MagiZinc Auto, a new HDG coating designed for automotive
applications 206
Nitte Van Landschoot, Vlot Margot, Tata Steel Strip Products Umuiden,The Netherlands
Modern steel design and heat treatment 207
New developments in the material and process design of forgedcomponents in the automobile industry 208
Christoph Keul, Linda Mosecker, Wolfgang Bleck, RWTH Aachen University,
Germany; Tim Rekersdrees, Henning Schliephake, Georgsmarienhutte GmbH,
Germany; Christophe Beyer, Hans-Willi Raedt, Hirschvogel Umformtechnik GmbH,Germany
Bainitic treatment and case hardening - latest development on heat
treatment technologies 218
Matthias Steinbacher, Foundation Institute of Materials Science, Germany;Franz Hoffmann, Brigitte Clausen, IWT-Bremen, Germany
IX
One piece flow-vacuum heat treating - integration of case hardeninginto the manufacturing-line 228
Klaus Loser, Volker Heuer, ALD Vacuum Technologies GmbH, Germany
New approach for intermediate induction heating of preformed forging
parts within a warm forming process chain 238
Martin Mach, Egbert Baake, Leibniz University of Hannover, Germany
New high strength steels 1 246
Development of cold rolled intercritically annealed multiphaseTRIP steels with a tensile strength above 980 MPa 247
Daniel Krizan, Andreas Pichler, Patrick Larour, Martin Gruber, voestalpine Stahl
GmbH, Austria; Ekaterina Bocharova, Dorothea Mattissen, Thomas Heller,
Annette Baumer, ThyssenKrupp Steel Europe AG, Germany
New advanced high strength hot rolled steels 255
Brigitte Hammer, Sarah Abraham, Thomas Heller, ThyssenKrupp Steel Europe
AG, Germany; Yoshimasa Funakawa, Akio Kobayashi, Katsumi Nakajima, Hayato
Saito, Kazuhiro Seto, Takeshi Yokota, JFE, Japan
Fabrication of load optimized truck members with variable cross
sections by flexible roll forming 263
Roland Hennig, Albert Sedlmaier, Andre Abee, data M Sheet Metal Solutions
GmbH, Germany
Microstructure-property relationships of bainitic high strength steel
grade SZBS800 271
Markus Krieger, Uwe Eggers, Magsud Masimov, Salzgitter Mannesmann
Forschung GmbH, Germany; Christian Pelz, Salzgitter Flachstahl GmbH, Germany
Testing of flat products 279
Characterization of the transition area at partial hardened car body
components by the 3-point bending test 280
Christian Hezler, Christine Kopp, Karl-Michael Bader, Bernd Griesbach, AUDI
AG, Germany; Marion Merklein, Lehrstuhl fur Fertigungstechnologie Universitat
Erlangen, Germany
Holistic approach for spotweld modelling in crashworthiness analysis 288
David Pieronek, Forschungsgesellschaft Kraftfahrwesen mbH Aachen (FKA),Germany; Andre Marx, Rolf Roettger, ThyssenKrupp Steel Europe AG, Germany
Thermographic testing of joints in automotive body structures 297
Ulrike Siemer, Volkswagen AG, Germany
X
Influence of manufacture-related imperfections on the fatiguebehaviour of spot welded high strength steels 305
Stephan Brauser, Michael Rethmeier, Gert Weber, Gaul Holger, Lutz-Alexander
Pepke, BAM Federal Institute for Materials Research and Testing, Germany
Modern steel design - Long products 313
Improvement working and utility properties of classical and new Mo
alloyed carburizing steels 314
Frank Hippenstiel, Buderus Edelstahl GmbH, Germany
Alternative alloying concepts for heat-treatable engineering steels 322
Herbert Schifferl, Sabine Zamberger, Albin Joller, voestalpine Stahl Donawitz
Gmbh, Austria
New air cooled steels with outstanding impact toughness 330
Hans Roelofs, Stephan Hasler, Swiss Steel AG, Switzerland; Mirkka Lembke,
SteeltecAG, Switzerland; Francisca G. Caballero, CSIC-CENIM, Spain
New high strength steels II 338
Hot rolled, hot-dip galvanized high-strength steel for automotive
applications 339
Markus Sonnleitner, Helmut Spindler, Matthias Flume, voestalpine Stahl GmbH,
Austria; Alfred Seyr, voestalpine Krems GmbH, Austria
Materials concepts for high strength and ultra high strength automotive
applications 347
Andreas Peters, Benteler Tube Management GmbH, Germany
Innovative high and ultra high strength steel concepts for cold formingapplications 355
Thomas Thulig, Dieter Krech, Gerald Zwickel, BILSTEIN GmbH & Co. KG,
Germany; RalfKolleck, Steffen Raschka, Techn. Universitat Graz, Austria
Collaboration of automotive and steel industry 363
VDA Werkstoffblatt 239: An approach for a global sheet steel
specification 364
Thomas Dettinger, DaimlerAG, Germany; Johann Hogerl, BMWAG, Germany;Heike Kantereit, Adam Opel GmbH, Germany; Carsten Lachmann, VolkswagenAG, Germany; Klaus Lamprecht, AudiAG, Germany; Albert Tonnessen,Ford-Werke GmbH, Germany
Application of material approval process in a globally acting company 371
Birgit Reichert, Klaus Unruh, Faurecia Automotive Seating, Germany;David Even, Faurecia Automotive Seating, France
XII
A VDA-approach on the development of a test method for quantifyinghydrogen embrittlement in advanced high strength automotive
steel sheets 379
Matthias Loidl, BMW Group, Germany; OlafKolk, BMW, Germany
A new laboratory corrosion test for cars and trucks 388
Karl-Heinz Stellnberger, Gerald Luckeneder, voestalpine Stahl GmbH, Austria;Stefanie Geisler, Steel Institute, Germany
Improved properties for long products 394
A new bainitic steel for cold heading applications 395
Stephan Hasler, Ulrich Urlau, Swiss Steel AG, Switzerland; Jochen Kruse,
ZF Lemforder GmbH, Germany
A high-strength and super clean heat-treatable steel for application in the
automotive industry 403
Rainer Fluch, Ingo Siller, Bottler Edelstahl GmbH & Co KG, Austria
Technological properties of the new high strength bainitic steel
20MnCrMo7 404
Serosh Engineer, Holger Justinger, EZM EdelstahlZieherei Mark GmbH,
Germany; Peter JanHen, ArcelorMittal Ruhrort GmbH, Germany; Michael Hartel,
Carsten Hampel, Continental Automotive GmbH, Germany; Frank Randelhoff,
A. +E. Keller Gmbh & Co. KG, Arnsberg, Germany
Research & Development of High Strength Fastener using
Hyper-Eutectoid Steel 412
You-Hwan Lee, Kim Dong Hyun, Kim Ji Soo, POSCO, South Korea;Lee Chong Soo, POSTECH, South Korea
Corrosion protection 417
Corrosion resistance of different metallic coatings on press-hardenedsteels for automotive 418
Laurence Dosdat, Jacques Petitjean, ArcelorMittal Maizieres Research, France;Thomas Vietoris, ArcelorMittal, Germany; Olivier Ciauzeau, Bohr Technologies,France
New coatings for hot press forming 426
Maria Koyer, Patrick Kuhn, Jens Kondratiuk, Manfred Meurer, Dortmunder
Oberflachencentrum GmbH, Germany; Franz-Josef Lenze, ThyssenKrupp Steel
Europe AG, Germany
Aspects of cosmetic corrosion performance of galvanized and
coil-coated steel substrates for car body applications 434
Gerald Luckeneder, voestalpine Stahl GmbH, Austria
XIII
2nd generation corrosion protection primers - further advances in
automotive corrosion prevention 440
Ingo Kluppel, ThyssenKrupp Dortmunder Oberflachencentrum GmbH, Germany;
Karl-Heinz Stellnberger, voestalpine Stahl GmbH, Austria; Stefanie Geisler, Steel
Institute VDEh, Germany; Thorsten Reier, Salzgitter Mannesmann Forschung
GmbH, Germany; Eric Jacqueson, ArcelorMittal, France
Electromobility 449
Steel solutions for electromobility 450
Oliver Hoffmann, ThyssenKrupp AG, Germany
Electrical steel - Current and future applications of a challengingmaterial in the automotive industry 451
Thomas Bohm, ThyssenKrupp Electrical Steel GmbH, Germany; Johann MQIIer,
ThyssenKrupp Steel Europe AG, Germany; Norbert Brachthauser, C. D. Walzholz
GmbH, Germany; Franz Dorninger, voestalpine Stahl GmbH, Austria; Stefanie
Geisler, Steel Institute VDEh, Germany; Sigrid Jacobs, ArcelorMittal, Belgium;Andreas Jansen, Rolf Stiller, ArcelorMittal Eisenhuttenstadt GmbH, Germany
Diesel-injection solutions 459
Advanced high-strength TRIP-aided steels for ultra high pressure
Dl-Diesel engine common rail 460
Kohichi Sugimoto, Nobuo Yoshikawa, Shinshu University, Japan
Requirements on Diesel Injection Tubes for Common-Rail-Systems 468
Karola Klenke, Benteler Tube Management GmbH, Germany
Injection Lines for Diesel engines - Simulation-based fatigue strength
engineering 478
Steffen Zimmermann, Lars Bremer, Alfred Ostermann, Salzgitter Mannesmann
Forschung GmbH, Germany; Uwe Lechtenfeld, Andreas Zaremba, SalzgitterMannesmann Prazisrohr GmbH, Germany
Ultrafine-grained steels for high loaded engine components 487
Matthias Kuntz, Manfred Bacher-Hochst, Friedrich Muhleder, Robert Bosch GmbH,
Germany; Shiro Torizuka, Yoshiyuki Furuya, National Institute of Materials Science,
Tsukuba, Japan
Hydrogen embrittlement / Weldability 495
Influence of microstructure on the susceptibility towards hydrogenembrittlement 496
Richard Thiessen, Thomas Heller, ThyssenKrupp Steel Europe AG, Germany;Klemens Mraczek, Arnd Nitschke, Andreas Pichler, voestalpine Stahl GmbH,Austria
XIV
Evaluation of hydrogen embrittlement for ultra high strengthsteel sheets 503
Norbert Rossler, ThyssenKrupp Steel Europe AG, Germany
Laserwelding of steel with cast-iron without filler material 512
Christian Eisner, Andreas Bunting, DaimlerAG, Germany
Mechanical properties and weldability of 700 MPa structural steels with
excellent formability 516
Jukka Komi, Rautaruukki Oyj, Finland; Mikko Hemmila, Tommi Liimatainen,David Porter, Pertti Mikkonen, Rautaruukki Oyj, Ruukki Metals, Finland
Modelling and Simulation 1 524
Parameter identification of damage parameters of LS-DYNA gurson
material model from a tensile test 525
Wolfgang Wallisch, Dynardo - Dynamic Software and Engineering GmbH,Austria; Johannes Will, Henrick Nilsson, Dynardo - Dynamic Software and
Engineering GmbH, Germany
Formability prediction of high strength steels for automotive
applications 533
Junhe Lian, Sebastian MOnstermann, Wolfgang Bleck, Institute of Ferrous
Metallurgy, RWTH Aachen University, Germany
Modelling the strain rate dependence of flow curves by improved yield
strength prediction 541
Kirsten Dahmen, Wolfgang Bleck, RWTH Aachen University, Germany;
Birgit Reichert, Faurecia Autositze GmbH, Germany
A method to determine the dynamic energy absorption by deformation
for the automotive steels 550
Fang Jian, Zhou Yedong, Baosteel Research Institute,Baoshan Iron & Steel Co., Ltd., China
Machinability / Stainless steels 558
New metallurgical concepts for improving machinability of steels 559
Peter JanlSen, ArcelorMittal Ruhrort GmbH, Germany; Serosh Engineer,EZM Edelstahlzieherei Mark, Germany
Machinability of high-strength bainitic steel 20MnCrMo7 567
Fabian Felderhoff, Robert Bosch GmbH, Germany; Dirk Biermann, Institut fur
Spanende Fertigung, TU Dortmund, Germany; Serosh Engineer, Holger Justinger,EZM Edelstahlzieherei Mark GmbH, Germany
XV
Machining of stainless steels used in cars and trucks 575
Denis Fofanov, Ingrid Hofmann, Deutsche Edelstahlwerke GmbH, Germany
Properties of laser welded H400 austenitic chrome-manganese stainless
steel sheets 583
Vanessa Quiroz, Gumenyuk Andrey, Michael Rethmeier,
BAM Federal Institute for Materials Research and Testing, Germany
Joining of flat products 591
Mechanical joining of hot stamped steel 592
Jan Kalich, Uwe Fussel, TU Dresden, Germany
Development of joining technologies for production of hybrid chassis
components 603
Jorn Tolle, Simon Potthast, Jurgen Krogmeier, Siegfried Fecke, Benteler
Automobiltechnik GmbH, Germany
High strength low alloy steel weldments with accommodated qualities
to the base metal 610
Rudolf Rauch, Stefan Kapl, voestalpine Stahl GmbH, Austria; Gerhard Posch,
Boehler Schweisstechnik Austria GmbH, Austria; Karl Radlmayr, voestalpine
Automotive GmbH, Austria
Joinability of thin steel sheets with new zinc-alloy coatings 618
Robert Sierlinger, Sabine Ritsche, voestalpine Stahl, Austria
Modelling and Simulation II 625
Virtual material development: From semi-finished material to crash
behaviour 626
Bianca Springub, Salzgitter Mannesmann Forschung GmbH, Germany; Alexander
Butz, Fraunhofer-lnstitut fur Werkstoffmechanik IWM, Germany; Markus Feucht,
Karl Roll, Sebastian Lossau, Frieder Neukamm, Daimler AG, Germany; Andre
Haufe, DYNAmore GmbH, Germany; Magsud Masimov, Salzgitter Mannesmann
Forschung GmbH, Germany; Franz Roters, Max-Planck-lnstitut fur EisenforschungGmbH, Germany; Rolf Schwarzer, Christoph Wagener, KirchhoffAutomotive
GmbH, Germany
Fatigue life estimation - a feature in virtual development of passenger
cars 634
Franz Ruprechter, Gerhard Kepplinger, Michael Hofer, MAGNA STEYR
FahrzeugtechnikAG & Co KG, Austria
XVI
A pragmatic strategy to take into account metal materials scatter in FEA ..642
David Even, Faurecia Automotive Seating, France; Birgit Reichert,
Faurecia Automotive Seating, Germany; Bjorn Carlsson, SSAB EMEA, Germany;
Marc Lambriks, TATA Steel Europe, The Netherlands
Numerical simulation of the staking process of clinching fasteners 651
Miriam Tofall, Richard Bergner Verbindungstechnik GmbH & Co. KG, Germany;
Marion Merklein, Raoul Plettke, Friedrich-Alexander-Universitat Erlangen, Germany
New high strength steels III 661
Reliably processable steel for chassis components with high structural
durability 662
Joachim Schottler, Volker Flaxa, Salzgitter Mannesmann Forschung GmbH,
Germany; Jurgen Guettler, Marcus Rieth, Christian Martin Erdmann, DaimlerAG,
Germany
Ultra high strength steels produced by thermomechanical hot rolling -
Advanced properties and applicationsMartin Klein, voestalpine Stahl GmbH, Austria 672
New austenitic high manganese steels with improved property profile 680
Harald Hofmann, Sinasi G6klQ, Helmut Richter, Ingo Thomas, Jens-Ulrik Becker,
ThyssenKrupp Steel Europe AG, Germany
Specialists for extreme purposes: Stainless steel for automotive
construction 689
Tobias Muller, Stefan Lindner, ThyssenKrupp Nirosta GmbH, Germany
Poster Presentations 696
Corrosion testing for stainless steels in automotive exhaust systems 697
Cristina Hoffmann, Paul Gumpel, University ofApplied Sciences Konstanz,
Germany
Efficient Welding Simulation of an Automotive Sheet Metal Assembly 704
William Perret, Federal Institute for Materials Research and Testing, Germany
XVII