Welcome. Bond voor Materialenkennis. OCAS, 29 October Sven Vandeputte. OCAS : a joint venture between ArcelorMittal and the Flemish Region

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1 Welcome Bond voor Materialenkennis OCAS, 29 October 2009 Sven Vandeputte OCAS : a joint venture between ArcelorMittal and the Flemish Region

2 OCAS - Shareholders structure Vlaams Gewest (Flemish Region) 50 % 50 % FINOCAS (FINancing OCAS) 77,5 % BVM ,5 %

3 OCAS - Missions Provide steel and metal-based products, services and solutions, to satisfy and anticipate our customer s needs To realise breakthrough developments To set up new industrial spin-off activities BVM

4 OCAS - Markets Industry includes appliances, mechanical construction and engineering, heavy plate, tubes and pipes, HVAC, radiators, drums, furniture, electro-magnetic applications, energy generation, transport and storage systems, off-shore applications etc. Covering product mix from 0,2 to 100 mm BVM

5 OCAS - Core expertise Steel grades for future hydrogen economy New alloys and coatings Steel grades for energy transport Surface functionalisation Plates for windmills Improved efficiency electrical steel Self-cleaning surfaces Steel solutions BVM Easy manufacturing Enhanced esthetics Increased corrosion resistance Structural design of components FEM simulations Welding Metal sheet rapid prototyping

6 OCAS - Typical examples of R&D contribution optimisation of customers processes rapid prototyping & production of small series (e.g. back panel refrigerator) environmental friendly pre-treated products weight reduction thanks to innovative product design and smart materials selection introducing ultra high strength steel (e.g. gas cylinder, agritipper) BVM

7 OCAS - Spin-offs and partnerships Incubation of new industrial activities and spin-offs by leveraging steel related product and solution expertise elytra: continuous manufacturing of light weight sandwich panels xcelcoat: industrial deployment of advanced functional coatings borit: embossed panels Leverage effect of R&D through partnerships Design and forming centre for industry (JV with AM TOP) Metal Processing Centre (JV with CRM) Flamac, a division of SIM Vederlichte oplossingen voor het zware werk! 2007 OCAS All rights reserved for all countries Roestvaststaal Koolstofstaal Aluminium Curv Glasvezelversterkte polymeren Composite Panel Solutions Elytra NV Lammerdries 18 e 2440 Geel Tel: 014/ info@elytra.be BVM

8 OCAS Day-to-day People year employees : 72 researchers, 60 technicians Mean age : nationalities, 45% researchers of non-flemish background 20 sponsored PhD s, 3 sponsored post docs 53 international trainees for a 3-9 month period Skills Metallurgy Surfaces Application technologies (forming, welding, numerical simulations, etc.) BVM

9 OCAS - History 1989 Creation of OCAS (Shareholders: Sidmar, Arbed, ALZ) 1995 SWB becomes shareholder in OCAS, Arbed LDD 1999 Aceralia becomes shareholder in OCAS 2001 Merger Arbed-Aceralia-Usinor: Arcelor 2003 Restructuring R&D Arcelor Innovation 2005 from competence centre towards market oriented research from automotive to industry research centre 2004 Ocas becomes joint venture Arcelor - Flemish Region 2005 Deployment of R&D Business Development Unit (BDU) 2006 Merger Arcelor - Mittal 2006 Creation of 1st spin-off Elytra 2007 Creation of 2nd spin-off XcelCoat 2008 Creation of Design and forming centre a joint venture with AM TOP 2008 Creation of Metal processing centre a joint venture with CRM 2009 Creation of Metal structures centre 2009 Creation of borit nv 2007 OCAS All rights reserved for all countries BVM

10 R&D topics - Substrate & Metallic Coating Development (1) Steel grades for mechanical construction Pearlitic-bainitic-martensitic multi-phase steels Steel grades for high temperature applications Weathering & fire resistant steels Steel for energy pipes and heavy plates Development of ultra high strength product range Optimisation of heavy plate metallurgy for wide range of applications Improving embrittlement resistance of steels Optimising hydrogen induced cracking corrosion (HIC) properties 2007 OCAS All rights reserved for all countries BVM

11 R&D topics - Substrate & Metallic Coating Development (2) Electrical steel grades Fully processed (high permeability, low loss) Grain-oriented electrical steel grades Electro-magnetic shielding Coatings for electrical steels Amorphous alloys Enamelling steel grades BVM

12 R&D topics - Substrate & Metallic Coating Development (3) Metallic coatings Mg in metallic coatings Basic research Precipitation Phase transformation Damage Texture control Modelling Hydrogen BVM

13 Example - Substrate & Metallic Coating Development Material characterisation - Girth welds of line pipe Request Characterization of different welding techniques for girth welds using a specific line pipe grade, wall thickness up to 30 mm high tensile strength steel grade tubes suitable for very low temperature usage showing H 2 S compatibility Interpretation of the results Approach Tests according to API 1104 : tensile test, nick break, side bend, hardness, Crack Tip Opening Displacement, chemical composition Additional characterization of the weld through: Charpy tests at different positions, cylindrical tensile tests on weld material Sulphide Stress Corrosion Cracking tests according to EFC/16 to demonstrate H 2 S compatibility 2007 OCAS All rights reserved for all countries Result Two out of three tested welding processes are suitable BVM

14 R&D topics Surface functionalisation (1) Passivation coatings Cr-free temporary protection / thin organic coating Universal substrate for organic layer deposition New functional coatings Steel with antibacterial / self cleaning properties Aesthetic and reflective surfaces Coating process development Chemical vapour deposition Thin organic / hybrid coatings BVM roll sheet

15 R&D topics Surface functionalisation (2) Appliance Corrosion resistance New concept for enamelling Material selection for laundry dryers Metal processing Ready-to-paint Construction BVM roll sheet

16 Example Longer lasting in-use properties Enhanced corrosion resistance for off-shore applications Reduce cost of corrosion protection by using better suited material Check corrosion resistance by accelerated testing Study corrosion mechanism by means of electrochemical techniques Atmospheric zone HIGH ATTACK Splash zone HAT LOW ATTACK Tidal zone LAT HIGH ATTACK Low water zone LOW ATTACK Immersion zone 2007 OCAS All rights reserved for all countries Soil zone Corrosion rate O,075 mm/year BVM

17 R&D topics Steel solutions and design (1) Concept and solution development using new products Problem-solving Co-design Co-engineering Feasibility Cost calculation Simulations Prototypes Applied research New solution concepts Deployment kits BVM

18 R&D topics Steel solutions and design (2) Numerical simulation AutoForm (process definition, sensitivity analysis) Prediction of gloss loss of pre-painted steel due to forming SIMULIA / ABAQUS Stiffness, crash / drop test analysis, buckling Clinching, vibration (modal analysis), etc. FE-Fatigue (ncode) Fatigue (coupled with work hardening effects after forming) COMSOL Multi-physics (heat transfer) Flux 2D for magnetic modelling CAD: NX-4 (I-Deas / Catia ) 2007 OCAS All rights reserved for all countries BVM

19 Examples - Steel solutions and design Co-engineering Optimize panel thickness of cabinet Request Thickness optimization of cabinet panels Change to more cost effective steel grade Approach Finite element modelling to simulate rigidity of cabinet Check simulation results with real life tests at customer Result Good correlation between experimental results and simulation Change of steel grade validated displacements [mm] Solution 1 illustrated 250 N 2007 OCAS All rights reserved for all countries upper d BVM

20 Examples - Steel solutions and design Co-engineering Design of new oven cavity Request Design new oven cavity optimising stampability and thermal behaviour during and after enamelling Approach Forming simulations to assess stampability Thermal calculations to study enamelling behaviour Results Customer agreed with our recommendations and asked us for rapid prototyping of final design Successful assembly and enamelling of prototyped parts by customer Stamping simulation Enamelling simulation 2007 OCAS All rights reserved for all countries Rapid prototyping final part BVM

21 Examples - Steel solutions and design Co-engineering Compete composite gas bottles Request Innovative steel answer to composite gas bottles Approach Reduce wall thickness by using high strength grade Include beneficial effect of work hardening of selected grade to pass burst test Check weldability Result Good correlation between experimental strain analysis and deep drawing simulation Successful testing at customer (weld, burst and drop test) Weight of innovative steel gas bottle < composite! Deep drawing simulation Burst simulation 2007 OCAS All rights reserved for all countries BVM

22 Examples - Steel solutions and design Co-design New design steep walled bathtub New design shower Request Deep drawing feasibility study Selection of steel grade Approach Deep drawing simulation to determine optimal Steel grade Geometry Blank geometry Springback analysis Result Development of softer enamelling grade Proposal to modify geometry in critical areas BVM

23 R&D topics Product Safety Air analysis Welding fumes and risk assessment Volatile organic substances (VOC) Volatiles emission from coated panels (Indoor Air Quality) Release of thermal degradation compounds Nano-particle analysis (sampling and characterisation) Real-time particle size distribution and concentration measurement Release into soil and water Leaching test, extraction Lixiviation of metals (Cr VI) Providing data REACH compliant As input for material data safety sheets (MSDS) 2007 OCAS All rights reserved for all countries BVM

24 OCAS - Sites Site Zelzate Pres. J. F. Kennedylaan 3 B-9060 Zelzate BELGIUM services@ocas.be Site Zwijnaarde Technologiepark 903B B-9052 Zwijnaarde BELGIUM BVM