Maßgeschneiderte Stähle und Technologien für überlegene Produkte

Transcription

1 Wir bringen unsere Kunden _einen Schritt weiter durch Technologie, Innovation und Nachhaltigkeit. Maßgeschneiderte Stähle und Technologien für überlegene Produkte Custom steel grades and technologies for superior products Uwe Diekmann Hannover,

2 Agenda Introduction to Metatech Motivation and objectives Agile Materials Development Productivity Tools for Materials Development StahlDat SX the leading European database for steels JMatPro practical software for calculation of materials properties Selected examples Conclusion and summary 2

3 Introduction to Metatech Metatech is an independent Engineering company founded 2008 Focus: Materials Technology Innovation Services: Consultancy Research & Engineering Materials Software Customers: Industrial clients (Steel industry, Foundries Tube Mills, Metalworking Industry, Heat-Treatment, Automotive) 3

4 Motivation and Objectives Get there faster: Faster time to market Reduced costs Higher profit Select and develop high strength steel grades Cost effective Better performance Eco properties (lightweight design) 4

5 Example: Ultra high strength steel saves ~ 20 kg weight CPDUR TM 2000 Super lightweight drive-shaft: - Tubular design - Tensile Strength > 2000 Mpa - Elongation > 10 % Small scale industrial production has been started 5

6 Agile Materials Development New Materials Solutions in a Short Time How to get there? Laboratory Simulation Knowledge & Inspiration Use best practices from other industries to speed up materials development cycles, e.g. SCRUM Use design collaboration in materials development, e.g. by interdisciplinary teams 6

7 Design Collaboration in Materials Development Solution design workshops bring people and tools together TEAM (4-8 People) Research & Development Marketing & Sales Manufacturing & Quality PRODUCTIVITY TOOLS - JMatPro V7: Breakthrough materials simulation - StahlDat SX Pro: The best knowledge base for Steels Requirements Solution design Lab Verification 7

8 Agile Materials Development How much time takes a development cycle? 2 Weeks 10 Weeks Preparation & Workshops Vacuum melting Hot and cold rolling Testing Key enablers: Solution design workshops Use materials simulation and databases in workshops Reduce number of melts and cycles by knowledge and simulation 8

9 Productivity Tools for Materials Engineers Materials Simulation Materials Databases Fast and robust calculations Influence of chemistry and process on microstucture and properties All European steel grades Data from standards and research projects

10 StahlDat SX - The Leading European Database of Steels Free Trial + Video Tutorials Powered by: Metatech using 10

11 StahlDat SX Online Register of Steels (Stahl-Eisen-Liste) Die offizielle Europäische Stahl-Registratur Thermophysikalische Eigenschaften Lieferanten/Produktformen Referenzen zu Normen/Lieferbedingungen TTT-Database Isotherme und kontinuierliche ZTU, ZTA Härtbarkeit Steel sheet database Feinblech-Daten für den Automobilbau Originaldaten nach SEP 1240 plastische, elastische, zyklische Kennwerte, Grenzformänderungsdiagramme

12 StahlDat SX Online current modules Library Wärmebehandlungsatlas der Stähle I-IV Ausscheidungsatlas Alle digitalen FOSTA-Berichte Alle Inhalte im Volltext durchsuchbar Flow-Curve Database (Mit Unterstützung seitens Institut für Metallformung / TU BA Freiberg) Warm/Kalt Parametrisch Vergleichbar Exportierbar in CAE

13 JMatPro The Materials Property simulation CalPhad: Calculation of phase diagrams for multi-component systems JMatPro User-friendly application of CalPhad Calculation of materials properties 13

14 JMatPro at a glance Prediction of amount and composition of each phase Thermodynamics Physical models Calculation of properties for each phase as a function of temperature and composition Materials: Al-alloys Co-alloys Mg-alloys Fe-based alloys Ni-based superalloys Ti-based alloys Zr-based alloys Solder alloys Calculation of materials properties as a function of amount of phases and morphology using a mixture model Data export to FEA packages FEA Exporter: Ansys Forge Deform Deform HT Simufact Magma, etc

15 Information from JMatPro 1. Stable and metastable phase equilibria - Step temperature calculation - Step concentration calculation 2. Physical and thermophysical properties - Enthalpy, Cp, Latent heat - Volume change, density, and solidification shrinkage - Thermal expansion coefficients - Thermal conductivity and diffusivity - Electrical conductivity and resistivity - Liquid viscosity and surface tension - Young s, bulk and shear modulii 3. Microstructure evolution during processing - Solidification, Precipitation, Phase transformations, Reaustenitisation 4. Mechanical properties - Strength & hardness, - Creep, - Stress-strain curves

16 Phase equilibria of multicomponent alloys Get a feeling for effects of compositional changes

17 Example Boron-Steel: Optimize Titanium-Nitrogen Balance Objective: Maximize free Boron in Austenite

18 Physical Properties from JMatPro (metastable equilibrium example)

19 Phase Transformations Calculation of CCT/TTT Diagrams Use case: Heat treatment, Welding cycles Exporters: Simufact, Deform HT, Sysweld

20 High Temperature: Precipitation Calculation (JMAK), Strength Use case: Long term stability, Heat treatment

21 Flow Stress Analysis Use cases: Forming simulation and Heat treatment simulation Exporters: Forge, Simufact, Deform HT,

22 Technical center and Laboratory Technical center Laboratory Vacuum melting kg Forging Rolling (Hot, Cold) Heat Treatment (Vacuum, Cryo) Mechanical Testing, FLC, Fatigue, etc. Thermo-physical Testing Simulation (Deform HT) Metallography, REM, EBSD

23 Selected results ASR (Accelerated Sphaerodisation and Refinement) 100CrMnSi6-4: Improved wear resistance by ultrafine microstructure C+: Heat-resistant Ni-Alloy for furnace charging frames - High dimensional stability, temperature resistance, carburisation resistance 24

24 Summary Application oriented development of new steel technologies can be accelerated: Bringing together motivated teams (agile processes) Productivity tools like JMatPro and StahlDat SX JMatPro is designed for usability, robustness and performance and has a good acceptance in industrial practice By using JMatPro in early design stages the amount of subsequent experimental tests can be reduced significantly

25 Thank you! Discover more: Metatech GmbH Lünener Straße 211/212 D Kamen Tel: + 49 (0) Fax + 49 (0) [email protected]