Ecole thématique Métallurgie Mécanique ArcelorMittal ... · Ecole thématique Métallurgie...
Transcript of Ecole thématique Métallurgie Mécanique ArcelorMittal ... · Ecole thématique Métallurgie...
Ecole thématique Métallurgie Mécanique
ArcelorMittal : Transforming Tomorrow Through
Innovation
Thierry IUNG, with the contribution of
M. BABBIT, N. POTTORE, N. LOUKACHENKO, S. CORRE, A.
PERLADE, R. JACOLOT, B. DONNAY, P. BARGES, I. ZUAZO, D.
VERCHERE, C. ALLELY, J. PETITJEAN, J.C. HELL, S. ALLAIN, B.
WEBER, X. LEMOINE, P. DIETSCH, K. TIHAY, F. BONNET, D.
JACQUET, ….
October 26th, 2016
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Outline
• Fe-C phase diagram
(effect of alloying elements)
• Texture in steel sheet
• CCT and TTT : continuous cooling and
isothermal phase diagram
• Steel standards :
– Description of XC 50, XC55, XC60, XC65 …. XC 80
– From 22MnB5, 30MnB5, 36MnB5, …. to 54 SCV 6
– Adamantium
1
Austénite +
Carbon content
(wt.%)
Carbon content
(at.%)
fiber a : <110> // D.L. fiber g : <111> // D.N.
a and g fibers
DL
DT DN
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Outline
• Fe-C phase diagram
(effect of alloying elements)
• Texture in steel sheet
• CCT and TTT : continuous cooling and
isothermal phase diagram
• Steel standards :
– Description of XC 50, XC55, XC60, XC65 …. XC 80
– From 22MnB5, 30MnB5, 36MnB5, …. to 54 SCV 6
– Adamantium
2
Austénite +
Carbon content
(wt.%)
Carbon content
(at.%)
fiber a : <110> // D.L. fiber g : <111> // D.N.
a and g fibers
DL
DT DN
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Outline
• History and trends for steel, focus on ArcelorMittal, main markets
• Market request and steel answers, examples
Corrosion resistance and surface function
Energy and gas transport
Automotive
Long products application
• Microstructure engineering during elaboration processes to control final
performance
3
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Outline
• History and trends for steel, focus on
ArcelorMittal, main markets
• Market request and steel answers, examples
Corrosion resistance and surface function
Energy and gas transport
Long products application
Automotive
• Microstructure engineering during elaboration processes to control final
performance
4
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From the ‘iron age’ to the era of advanced,
sustainable, eco-efficient steels
5
–Steel has now to compete with other materials (weight, cost, design)
–Needs for constant new offer – Increase of steel properties (a third of the present steel grades did not exist 5 years ago).
• The end-user functions drive the new development – from steel grades to complex parts (steel solution design, Tailored blanks,
steel in association with other materials, …).
Now and tomorrow
800 BC
4000 BC
1700
1870
1950
1973
Iron was discovered in the middle-east area more than 6000 years ago • Mostly pure iron, very soft and ductile, used for decorative purposes
• Sometimes more expensive than gold, sometimes hated as a devil’s metal owing to its rusty
color
Discovery of carburization and quenching by the Celt people (800-600 b.c.) • Iron competed successfuly with bronze for sword manufacture
• Smith became a major craftsman
The modern era definitly started at the end of the XIXe with the invention of
the blast-furnace and the converter to make steel : Buildings, bridges,
railways, weapons, …
5
The use of the coke at the beginning of the XVIIIcentury allows to produce
large quantity of cast iron (iron with more than 2% carbon) for construction
and cannons
After the second world war, coal mines and steel industries were the major actors of the rebuilding : Customers had to adapt to the quality and the quantity provided by the steel makers (!)
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World steel production
Reference in 1973 : around 600Mt
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Still a lot of players in the steel industry
ArcelorMittal is the only non-asian in the top ten
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Geographical reach
* Latin America includes Mexico.
Industrial and commercial network focus on our franchise businesses
Market position by region
Leader in
North America
Leader in
Latin America*
Leader in
Europe Major producer
in the CIS
Leader in
Africa
9
JV’s in China and the Middle East
ArcelorMittal
Others
ArcelorMittal : The world’s leading steel
and mining company
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ArcelorMittal key figures
2015 2014 2013
Sales (US$ billion) 63.6 79.3 79.4
Ebitda (US$ billion) 5.2 7.2 6.9
Operating income / (loss) (US$
billion)
(4.2) 3.0 1.2
Net income / (loss) (US$ billion) (7.9) (1.1) (2.5)
Steel shipments (million tonnes) 84.6 85.1 82.6
Crude steel production (million
tonnes)
92.5 93.1 91.2
Own iron ore production (million
tonnes)*
62.8 63.9 58.4
Around 210,000 employees
in more than 60 countries
Allocation of employees in 2015
according to geographic location
(full-time equivalent)
*Own iron ore and coal production excluding strategic long-term contracts.
ArcelorMittal is the world’s leading steel and mining company
10
0%
39%
14%
14%
9% 16%
5%
EU28
Other European countries
North America
South America
Asia
Middle East and Africa
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Global R&D: Scope and Mission • 1,300 full time researchers
• Broad, comprehensive portfolio and programs addressing business needs
• Worldwide network of laboratories: 12 labs in Europe and Americas
• Budget spending by focus area and range of activities:
Exploratory
Process Product
R&D effort fully aligned with group strategy: geography, value chain, product differentiation 11
mill
support
application
support and
co-engineering
new process
and product
developments
customer
technical
assistance
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… across 12 research centres and at
customer locations on 3 continents…
Canada
Hamilton
USA
East
Chicago
France
Gandrange
Le Creusot
Maizières
Montataire
Forbach (*)
Spain
Asturias
Basque Country
Luxembourg
Esch-sur-
Alzette
Belgium
Gent
Liège (*)
Czech
Republic
Ostrava
(*) Strategic partner
- Forbach: CPM
- Liège: CRM
Brazil
Tubarão
On-site product-portfolio deployment: Product Development Engineers
Automotive Residents, Process Development & Deployment Specialists
Canada, USA Spain, France, Germany,
Italy
China, South Korea,
Japan
12
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Date R&D Lab/Dept – Title of the presentation 13
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Wide market applications , large spectrum of performances
• Automotive: compromise between weight reduction, comfort, safety & durability
• Packaging: cost effectiveness, easy processing, weight reduction, innovative look, food
compatibility, green products
• Appliances: cost reduction, antibacterial, aesthetics, environmental friendly…
• Construction: energy-efficiency, environmental issues, safe buildings, durability, fast
erection, health & comfort, aesthetics,…
• Metal Processing: weight and cost saving, corrosion resistance, safety, reduced total
cost of ownership, high temperature resistance
• Electrical Engineering: higher efficiency and power density machines through low loss,
high permeability, high strength electrical steels
• Energy pipes: heavy gauge, high strength, corrosion resistance, improved welding
14
Customers’ needs, examples
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Our steel – the fabric of life
Through innovation, steel remains the material of choice
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Superconducting Supercollider Magnets
• CERN needed 50,000 tons of magnets with strictly identical
properties for the most complex experimental facility ever built –
the Large Hadron Collider (LHC) – the particle accelerator that
fires trillions of protons around a 27km tunnel at 99.99 percent
of the speed of light …..built with ArcelorMittal’s Magnetil®
16
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Shipbuilding - Luxury Cruiseliner
17
• ArcelorMittal supplied 100 percent of the steel used in the
world’s largest cruise ship: Harmony of the Seas
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18
Skyscrapers
• Customer Broad Sustainable Building recently made headlines in the architecture
world when they completed the construction of a 57-storey high-rise in Changsha,
China, in a record 19 days – the equivalent of three storeys per day. ArcelorMittal
played a pivotal role in bringing this ambitious project to fruition, by providing over
10,000 tons of HISTAR® for the structure, as well as technical advices.
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Construction – Olympic Stadium
• ArcelorMittal Brazil supplied more than half the steel used for
infrastructure work related to the 2014 World Cup and 2016 Rio
Olympics in Brazil for a variety of buildings from stadiums, to
train stations to giant aquariums.
19
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Nuclear Containment – Chernobyl Sarcophagus
• ArcelorMittal has supplied over 100,000 m² of steel for a state of
the art containment structure for the Chernobyl nuclear power
plant in Ukraine – the Chernobyl sarcophagus.
20
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Coastal Protection - Floodgates
• ArcelorMittal supplied over 100,000 metric tons of sheet piling to
the Mose project in Venice, intended to build 78 floodgates to
protect the ancient city.
21
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Bridges
22
• Tailor-made plates for the construction of key bridge arch components for the new
bridge spanning the Moselle, linking Grevenmacher in Luxembourg and Wellen in
Germany. Strong and lightweight materials were used to achieve the refined,
streamlined design in a very tight four-and-a-half month construction schedule to
minimize traffic disruption
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23
Rails for High Speed Trains
• ArcelorMittal has supplied more than 1,5 million tons of rails that combine
excellent reliability, geometrical precision, strict flatness tolerance and the
highest quality for high speed railway networks in Spain, France, Germany,
Portugal, Turkey, Saudi Arabia and Morocco.
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Outline
• History and trends for steel, focus on ArcelorMittal, main markets
• Market request and steel answers, examples
Corrosion resistance and functions
Energy and gas transport
Automotive
Long products application
• Microstructure engineering during elaboration processes to control final
performance
24
SURFACES
CRYOGENIC APPLICATION
STEEL SOLUTIONS
SHORTEN PROCESS ROUTE
MACHINABILITY
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What is at stake in corrosion protection ?
• Corrosion protection represents 2% of world GDP !
• Among solutions: paints, surface treatments, … and metallic coatings
• One target: improve protection given by the metallic coating
• With two main approaches on the market:
- Increase protection while keeping production costs constant
Improve metallic coatings performances compared to existing solutions
- Keep protection constant while decreasing production costs
Reduce amount of raw materials required for corrosion protection
Very competitive field !
SURFACES
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What is the ArcelorMittal product offer ?
Hot-dip coating Electrodeposition
Zn (Z) Zn-Fe (ZF) Zn-Al (ZA)
Extragal
Galvannealed Galfan
Al-Zn (AZ)
Aluzinc
Al
Alupur
Al-Si (AS)
Alusi
Zn (ZE)
Electrogalvanized
Metallic coating
Zn-Al-Mg (ZM)
- Magnelis (Industry)
- ZnAlMg (Auto)
~ Pure zinc
Primary zinc
dendrite
Ternaire
Zn/Al/Mg
ZnAlMg
SURFACES
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How Aluminium and Magnesium improve
protection • Benefits of Aluminium and Magnesium added in Zinc
demonstrated for years (Galfan, NSC’s Superdyma, …)
• Understanding only recently possible :
Compact
corrosion
products
High
inhibition
ZHC / AlMg LDH
ZnAlMg coating
Porous
corrosion
products
Low
inhibition
ZnO
Zn coating
ZnAlMg
10µm
Zn
10µm
SURFACES
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14/11/2016 Didier Verchère 28
New surface functions for construction,
appliances or packaging market
SURFACES
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14/11/2016 Didier Verchère 29
Organic Coating solution on coil coating line
Metallic
coating Steel
Ste
el s
ub
str
ate
0,4
to
1m
m
Primer
Top-coat
Backcoat 5 to 12 µm
5 to 30 µm
20 to 200 µm
Surface
treatment
Surface treatment
SURFACES
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Oil & Gas Pipeline Design
30
Steel Solutions in Transport
Oil LNG
Tank car Oil tanker LNG liquefaction LNG tanker
Tank car and shipbuilding plate Crogenic plate, pipe, bar (Ni, CRA)
o
o
o
o
o
o
o
CRYOGENIC APPLICATION
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Typical LNG chain
- Cryogenic structural Ni alloyed steel steel grade
- 9%Ni steel (Industeel) : widely used as a main material of inner
walls of LNG tanks and LNG transportation vessels due to the high
strength properties, excellent toughness level and crack arrest
properties exposed at very low temperature
9% Nickel
steel
Storage and transportation of LNG
7%Ni steel (CryElso™ 7) concept : a cost-effective lean high strength steel
with 9%Ni properties for cryogenic applications
CRYOGENIC APPLICATION
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7%Ni versus 9%Ni : equivalent properties
Developed 7%Ni steel → level of strength and toughness properties
down to LNG service temperatures equivalent to
those of conventional 9% Ni quenched and tempered steel
0
50
100
150
200
250
300
500 525 550 575 600 625 650 675 700 725 750
Charp
y a
v. v
alu
es
at
-196
°C,
J
YS at T room, MPa
CryElso®9Q
CryElso®7
A553M
0.2
YS m
in v
alu
e
A553M type III Charpy min value (Transv. Dir.)
A553M type III Charpy min value (Long. Dir.)
625
650
675
700
725
750
775
800
825
500 525 550 575 600 625 650 675 700 725 750
TS a
t T
room
, M
Pa
YS at T room, MPa
CryElso®9Q
CryElso®7
A553M
0.2
YS m
in v
alu
e
A553M TS min value
• Satisfactory crack arrest properties (no break for all
specimens tested at -196C)
•Drop weight test according to ASTM Standard E 208
•Energy used for the test : ~400J
CRYOGENIC APPLICATION
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ArcelorMittal Automotive Worldwide
33
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What’s a car made of?
34 34
Steel
57% (44% flat/13% long)
Plastic,
glass
and other
materials
22% Alu
min
ium
9%
Ir
on 8
%
Various m
eta
ls: copper,
zin
c,
…
4%
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• Global platforms: Carmakers
demand that the same products be
delivered to their production
facilities worldwide, to support
global platforms that are designed
centrally. The percentage of
vehicles built on global platforms
will increase from 46% in 2014 to
63% in 2020
• Regulation: Shift in product needs
to meet regulatory targets for fuel
economy as well as passenger
safety during crash events
• ArcelorMittal offers
the specific solutions
to address these
challenges
• ArcelorMittal
maintains both its
geographical and its
technological
leadership in the
automotive market
Key automotive industry requirements
ArcelorMittal well positioned to meet automotive industry requirements
35
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Drawing steels
High strength IF steels
Bake Hardening steels
HSLA steels
Dual Phase steels
Hot rolled ferrite-bainite steels
Complex Phase steels
TRIP steels
Steels for cold stamping - Fortiform®
Steels for Hot stamping - Usibor® Ductibor®
MartINsite® steels
The broadest product offer in the world
36
ArcelorMittal steels for automotive cover all metallurgical families of steels and
offer a full range of compromises between formability and weight reduction
STEEL SOLUTIONS
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The “body in white” weight reduction needed to achieve emission targets can be achieved
at attractive cost and without impacting vehicle performance
with existing steel grades and solutions, with further potential from new grades
From a steel provider, to a global solution provider
S-in motion®
C-Segment Vehicle
Achieved 20% BIW
weight reduction
from 2009 baseline
2010 2012
S-in motion® Battery
Electric Vehicle
Achieved 11% BIW
weight reduction
from 2011 baseline
2014
S-in motion® Pickup
Truck
Achieved 23% BIW
weight reduction
from 2013 baseline
S-in motion®
Electric &
Plug-in Hybrid
C-Segment
Vehicles
2013
S-in motion®
Light Commercial
Vehicles
Achieved 20%
underbody weight
reduction
2012
37
A long tradition of development of steel solutions, even before ArcelorMittal was
created
STEEL SOLUTIONS
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Baseline Representative of US Market. Midsize vehicle
Near term grades Solution
Component Total Mass
Vehicle curb weight 1478.2kg
BIW 324.4 kg
Front Doors 16.5 kg (x2)
Rear Doors 13.9 kg (x2)
Total BIW + doors 385.2 kg
~ 100kg weight savings
with near term steel grades
Component Total Mass Weight savings
Vehicle curb weight 1378.6kg 7%
BIW 235.0 kg 28%
Front Doors 14.1 kg (x2) 15%
Rear Doors 11.2 kg (x2) 19%
Total 285.6 kg 26%
Automotive Applications: S-in motion®
STEEL SOLUTIONS
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Automotive solutions in Long Products…examples
Product
segment Current Offer
Automotive
Applications
Innovations / Developments
Products Targets
Cold
Heading
Cold Heading from
5.5 to 52 mm in
Wire Rod (market full
range)
Fasteners
Ball joints
Extruded parts
High Strength (>1500
MPa) maintaining H2
resistance Freeform®
M1500 H2
Screws for con-rod
caps, crankshaft bearings
& engine flywheel
Screws for chassis
Class 12.9 with improved
H2 resistance
Spring
Super Clean
spring grades
Clutch spring
Valve springs
High Strength > 2000
MPa
Corrosion resistant
Spring Steel
reduce weight of
springs
Increase durability
Free-
Cutting
High Speed
Free-Cutting steels
Components for
camshafts
Injector pieces
High strength and
machinable steels
reduction of tool wear
Lead-free solutions
Avoid heat treatment
Forging
Hot forging micro-
alloyed steels
Full Bar / Billet
dimensional range
Steering knuckle s &
lever
Con-rods
Rocker arms
Crankshafts
High Strength steels
bainitic steel
SOLAM ® family
Also solutions adapted
to induction hardening
Reduction of
processing costs
(avoid heat treatment)
Reduce weight of part
STEEL SOLUTIONS
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Lighten & high mechanical & corrosion
resistance : suspension spring steel application
40
1500
1600
1700
1800
1900
2000
2100
2200
2300
500 600 700 800 900 1000 1100 1200 1300
Maximal shear stress on spring (MPa)
Ultim
ate
te
nsile
str
en
gth
(M
Pa
) Evolution of springs with high characteristics
STEEL SOLUTIONS
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41
Example of design (S-in motion)
Solution
1.9 kg
Comparison Weight: -21%
Base
2.4 kg
Key properties
• Decrease in the number of active rings and in the wire diameter
• Increase in the ultimate tensile strength
• Fatigue limit after corrosion: decrease < 30% & increase by 10% towards 54SiCr6
54SiCr6
UTS: 1900 MPa
Z: 38.8%
Agt: 12.1%
Fatigue ratio: 0.36
New spring grade
UTS: 2050 MPa
Z: 38.7%
Agt: 10.8%
Fatigue ratio: 0.42
STEEL SOLUTIONS
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42
Lighten & shorten the process route
Solam ® B 1100 for forging application
Range of properties
allowing weight
saving or higher
power
STEEL SOLUTIONS : weight reduction and short processing route
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SOLAM® B 1100:
an economical and environment friendly grade
43
• Low carbon grade C ≈ 0,16-0,2%
• Microalloyed with :
– Mn ≈ 1,6-1,9%, Cr ≈ 0,8-1,2%, Ni ≈ 0,2 -
0,5%
– Niobium, Vanadium, ...
• Formation of bainite for cooling rates compatible
with main hot forging process
• Reinforced ferritic matrix
Natural or Controlled*
Forging
Cooling
Quenching
Tempering
Austenitisation
Traditional Process
using 42CrMo4
Forging
Cooling
Advanced Process
using SOLAM® B 1100
Straightening
Process
Eliminated
=
Cost &
Energy
Savings
Light Straightening
STEEL SOLUTIONS : weight reduction and short processing route
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44
SOLAM® B1100: S-in motion project
Baseline comparison
Upright+bearing
Weight: -0.9 kg, -14%
5.5 kg
Cast iron baseline
Upright+bearing
6.4 kg
Highlights
•Cast iron baseline compared to two forging
solutions providing different bearing fixing
•Weight estimation including bearing and fixing
bolts
Bearing
Cast iron
YS=250MPa - UTS=400MPa
New
bearing
Baseline comparison
Upright+bearing
Weight: -1.2 kg, -19%
5,2 kg
Bainitic steel SOLAM B1100
YS=850MPa – UTS=1100MPa
Bainitic steel SOLAM B1100
YS=850MPa – UTS=1100MPa
STEEL SOLUTIONS : weight reduction and short processing route
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Optimisation of process route & costs at the customer : Machining
Targets
- Machining of new High Strength Steel for
weight reduction application
- Reduction of the machining costs
- Improvement of the chip breakage
- Improvement of surface quality
- Increase in tool life
STEEL SOLUTIONS : improved machinability
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46
- Resullfurization
- Ca treatment
- Controlled oxides
…to protect the tools
Creation of a Built Up Layer at the interface tool/material which acts as a :
-Lubricant
-Thermal shield
-Anti diffusion barrier
Chip
Work piece Built Up Layer
Tool
STEEL SOLUTIONS : improved machinability
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Outline
• History and trends for steel, focus on ArcelorMittal, main markets
• Market request and steel answers, examples
Corrosion resistance and surface function
Energy and gas transport
Long products application
Automotive
• Microstructure engineering during elaboration
processes to control final performance
47
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The process-product relationship
Oct 2015 Steel for steel people 48
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14/11/2016 Author 49
49
Automotive needs for new performance : Design & Development of Next Generation Steels
Maximize Steel’s Advantages Address Steel’s Limitations
Stiffness-Limited
•C-Pillar Ring
•Closures
•Floor Pans
•Chassis
Strength-Limited
•Rockers
•Cross Members
•Rail Extensions
•A-, B-Pillars
Energy -Limited
•Rails
•Lower B-Pillar
•Windshield
Members
Push UTS
beyond 1500
MPa
Develop High
UTS plus High
Elongation
Develop Low
Density Steels
Develop High
Modulus Steels
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What defines a microstructure
• Large variety of constituents :
Austenite (CFC), Ferrite, Bainite, martensite (CC),
Cementite (iron carbide).
Pearlite (Lamellae ferrite/cementite)
• and for each constituent
– Size and shape (grain size, interlamellar spacing, …)
– Solute elements : Mn, Ni, C …
– Precipitates : AlN, TiN, Nb(C,N), ...
– Crystallographic texture
Ferrite (Drawing application) Ferrite – Martensite (DP for automotive) Pearlite (for rails) Oct 2015 Steel for steel people 52
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Microstructure engineering : Macro
Microstructure Nanostructure
Optical Microscopy (grains)
Electron Microscopy (atoms)
Optical Macroscopy (macro-deformations)
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Microstructure scales :
ATOM
10-10 m PRECIPITATE
from 10-9 to 10-6 m
GRAIN
from 10-6 to 10-3 m
CAN
Oct 2015 Steel for steel people 54
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Date R&D Lab/Dept – Title of the presentation 55
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Microstructure control all along steel elaboration process :
Quantification and observation, understanding and modeling
precipitation and dissolution of precipitates
work-hardening and
recrystallization
phase transformations
(texture formation)
work-hardening
Texture formation
precipitation and dissolution of precipitates
recrystallization
texture formation
phase
transformations
work-hardening
(texture formation)
precipitation
phase transformations
Slab
reheating
Hot rolling
Cooling
Coiling
Cold rolling
Heating
Soaking
Cooling
Overageing
Annealing Temper
rolling
HOT STRIP MILL COLD ROLLING PLANT STEELMAKING
PLANT
Steelmaking
Casting
Having unique elaboration processes to get long term
competitive advantage
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Microstrucure
control :
Deformation at
high temperature
Unit 1
Austenite flow behaviour
Possible dynamic + Post dynamic recrystallization
Recrystallised
Deformed
Recovered
Legend
Unit 2
Static recrystallisation
Unit 3
Recovery
Unit 4
Precipitation
Unit 5
Normal grain growth
Unit 6
Averaging
Microstructure
before pass n°i
Fe-70Ni alloy, 700°C, =0.8 [H. Réglé]
t=10s t=1000s
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Use of Nb to control microstructure during
deformation
Microstructure
before pass n°i Microstructure just
after pass n°i
Microstructure
just after pass n°i
Microstructure just
before pass n°i+1
Recrystallised
Deformed
Recovered
Legend
Austenite flow behaviour
Unit 1
Austenite flow behaviour
Unit 1
Dynamicrecrystallization
Unit 2
Dynamicrecrystallization
Unit 2
Post-dynamicrecrystallization
Unit 3
Post-dynamicrecrystallization
Unit 3
Staticrecrystallisation
Unit 4
Staticrecrystallisation
Unit 4
Normal grain growth
Unit 7
Normal grain growth
Unit 7
Averaging
Unit 8
Averaging
Unit 8
Recovery
Unit 5
Recovery
Unit 5
Precipitation
Unit 6
Precipitation
Unit 6
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Static recrystallization: Main equations
extXexp1X
3t
0rexst dt)t(G)t(MNX
r2
F3b
2
1)t(G v2 g
Driving force for recrystallization
A stored energy of deformation term
A retarding zener term
1
epure M
1
M
1)(f)t(M
Grain boundary mobility
Mpure according to the Turnbull
estimation
Solute drag effect of various elements
(Mn, Si, Mo)
Effect of strain on fragmentation
(progressive misorientation between cells):
A
SvkNrex
Site density for recrystallization (m-3)
Sv= the grain surface area per unit volume
A is the area occupied by each nucleus= R2,
R is the mean radius of dislocation cells R=Kc/
k is a constant
Extended recrystallized fraction
Microstructure
before pass n°i Microstructure just
after pass n°i
Microstructure
just after pass n°i
Microstructure just
before pass n°i+1
Recrystallised
Deformed
Recovered
Legend
Austenite flow behaviour
Unit 1
Austenite flow behaviour
Unit 1
Dynamicrecrystallization
Unit 2
Dynamicrecrystallization
Unit 2
Post-dynamicrecrystallization
Unit 3
Post-dynamicrecrystallization
Unit 3
Staticrecrystallisation
Unit 4
Staticrecrystallisation
Unit 4
Normal grain growth
Unit 7
Normal grain growth
Unit 7
Averaging
Unit 8
Averaging
Unit 8
Recovery
Unit 5
Recovery
Unit 5
Precipitation
Unit 6
Precipitation
Unit 6
32
K
[E. Galindo et al.]
[E. Galindo et al.]
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Example of applications of process/microstructure
model for hot rolling
0
500
1000
1500
2000
2500
3000
3500
0 500 1000 1500 2000 2500 3000 3500
Measured load (T)C
alc
ula
ted load (
T)
Non microalloyed
Microalloyed
Prediction of rolling loads
2nd finishing stand - Fos
F0 F5 F6 F7 F8 F9 F10
E0 FSB
14,6 m 5,8 m 5,8 m5,8 m 5,8 m 5,8 m
F0 F5 F6 F7 F8 F9 F10F0 F5 F6 F7 F8 F9 F10
E0 FSB
14,6 m 5,8 m 5,8 m5,8 m 5,8 m 5,8 m
Flow stress in the roll bite
Forward slip
Rolling loads and friction coefficient
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The model enables the design of the rolling
schedules to obtain desired microstructure :
grain size, recrystallisation, …
• Objective: Replace the simplistic Tnr-parameter by “processing regime maps”
which combine temperature-time-deformation history with enhanced
knowledge of the operational metallurgical mechanisms
• The application has been tested in the frame of product development to
optimize new and improved hot rolling schedules and steel chemistries
2 3 4 5 6 800
850
900
Final tickness (mm)
FRT
(°C
)
X_rec
0-0,1 0,1-0,2 0,2-0,3 0,3-0,4 0,4-0,5 0,5-0,6
2 3 4 5 6 800
850
900
Final tickness (mm)
FRT
(°C
)
X_rec
0-0,2 0,2-0,4 0,4-0,6 0,6-0,8 0,8-1
0.1%C – 2%Mn 0.1%C – 2%Mn – 0.08%Nb
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Drawing steels
High strength IF steels
Bake Hardening steels
HSLA steels
Dual Phase steels
Hot rolled ferrite-bainite steels
Complex Phase steels
TRIP steels
Steels for cold stamping - Fortiform®
Steels for Hot stamping - Usibor® Ductibor®
MartINsite® steels
Next generation of steel for automotive
62
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• Microstructure engineering : define the appropriate combination
to reach properties and performances
Control of microstructure evolution:
3er generation steels - complex microstructures
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Control of microstructure evolution:
3er generation steels - complex microstructures
Phase identification of
complex phases
Martensite
Ferrite a
Ferrite a
Martensite a’
Martensite a’
Austénite g twins
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Nanostructured Carbide Free Bainitic Steels • Multiphase microstructure
– A ferritic matrix (αb) with a lath morphology
– Retained austenite (γ) (interlath and granular) stabilized at RT by carbon partitioning during the bainitic transformation (carbide precipitation delayed thanks to Si addition)
– Fresh martensite (α’) obtained during final cooling
Temperature
Time
α + Fe3C ferrite
martensite
Statis => Incomplete transformation
C diffusion in austenite
Caballero, FG; Allain, S; Cornide, J; Puerta Velásquez, JD; Garcia-Mateo, C; Miller, MK ;
Design of Cold Rolled and Continuous Annealed Carbide-Free Bainitic Steels for Automotive Application,
MATERIALS AND DESIGN 49 (2013) p667-680
Typical TTT diagram
Fully austenitic soaking
No carbide precipitation
Partial formation of fresh martensite
Control of microstructure evolution:
bainite
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o Complex hierarchical and intricate
microstructures
o Bainitic lath thickness about 300 nm
o Films of retained austenite 50 mm
αb
αb
γ
γ
MA = α’+ γ
αb+γ
prior γ grain
Hell, JC; Dehmas, M; Allain, S; Prado, JM; Hazotte, A; Chateau, JP;
Microstructure - Properties Relationships in Carbide-free Bainitic Steels,
ISIJ INTERNATIONAL 51 10 (2011) p1724-1732
FEG-SEM EBSD FEG-SEM SE
High mechanical performances
Nanostructured Carbide Free Bainitic Steels
Control of microstructure evolution:
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14/08/14 67
1
2
3
4
5 6
7
8
9
180 nm
Blocks (50-60°)
Laths (0,5-5°)
Laths (0,5-5°)
Laths (0,5-5°)
1µm
Sub-blocks of 2 variants
Laths
Sub-blocks of 2 variants
Laths
Sub-blocks of 2 variants
Laths
Sub-blocks of 2 variants
Laths
Sub-blocks of 2 variants
Laths
Sub-blocks of 2 variants
Laths
(47-67°)
(20-45°) (5-15°)
(<5°)
Structure of
lower bainite
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Undissolved
cementite
No cementite, finer
microstucture
Mn
7 à 20%Mn 6 à 10%Mn
Mn profile
Mn profile
0.8-1.4%C in austenite 0.3-0,6%C in austenite
Mn
Standard cycle New cycle
Control of microstructure evolution:
Local chemistry evolution during phase transformation
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Date R&D Lab/Dept – Title of the presentation 69
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Work hardening in multiphase steels
• Tensile behaviors depend strongly on the microstructure
– Fractions and strengths of the ferritic components
– Stability of the retained austenite (carbon content, size, local environment)
• Best formability reached when TRIP effect is efficient
– TRIP = dynamical strengthening mechanism
– Strain induced transformation of retained austenite into fresh and carbon saturated martensite
0 5 10 15 20
0
200
400
600
800
1000
1200
1400
1600
Ms-50°C
MS (330°C)
Ms+50°C
En
gin
ee
rin
g s
tre
ss
(M
Pa
)
Elongation (%)
0.00 0.05 0.10 0.150.0
0.1
0.2
0.3
0.4
0.5
n() =
n =
.d
/
.d
True strain
TRIP like behavior
Hell, JC; Dehmas, M; Allain, S; Prado, JM; Hazotte, A; Chateau, JP;
Microstructure - Properties Relationships in Carbide-free Bainitic Steels,
ISIJ INTERNATIONAL 51 10 (2011) p1724-1732
TRIP like behavior
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• We use ISO-W approach for multiphase steels.
• Excellent correlation with experimental data
– Work hardening well described
– CFB present a high YS above 900 Mpa Retained austenite appears to be the
softest phase
71
0
500
1000
1500
2000
2500
3000
3500
0 0.1 0.2 0.3
Tru
e s
tre
ss
(M
Pa
)
True strain
FM
TrM
RA
B
Model
Experiment
Ms+50 C
Work hardening in multiphase steels
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Precipitation hardening used as complementary
Strengthening mechanisms
Matrix
Precipitates
500 nm
Dislocations
Ex-situ OBSERVATION of
Interaction between dislocations and
carbides
Joël DOUIN CEMES-CNRS
X 200 000
SIMULATION of
Interaction between dislocations
and carbides
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50 nm
002
022
Zone axis [100]
002
Austenite
V(C,N)x
022
020
x
Characterization of precipitation morphology :
importance for hydrogen trapping
Orientation relationship
cube/cube between MX and
austenite matrix and shape
determination.
(111)g II (111)V(C,N)
Tomography
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Key issue on multiphase steels : damage
control Without coupling
With
coupling
Growth
of voids
FractureNucleation
Coalescence
N =number of cavities
studied volume
DP11
Decohesion criterion
DP11
Decohesion criterion
DP11T DP62
Fracture criterion
DP11T DP62
Fracture criterion
X-ray tomography
Local mechanical state, control of morphology/Size, hardness
difference
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Slide 75
Development of micro-macro metallurgical-
mechanical models
Understanding
microstructure by
experimental
analysis
Metallurgical -
Mechanical Model
Implementation in FE
Code
Comparison forming
prediction/experimenta
l measurement
Metallurgical – Mechanical
From microstructure to the
structure Optical Micrograph
X-ray
tomography
Holographic
Reconstructio
n
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Summer School Dortmund,
7. September 2012 Slide 76
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• Example : influence of a plastic pre-strain on the high cycle
fatigue properties of high strength steel sheets:
In-use performance of avanced steels
200
250
300
350
400
450
104
105
106
107
Dual Phase steel
R
Str
ess
Am
pli
tud
e,
0 (
MP
a)
Number of cycles to failure, N
Unbroken
Initial Grade Pre-strained grade, ||Eps
|| = 20 %
320 MPa
250 MPa
pspsps EEE :3
2
Eps = plastic strain tensor
Fatigue properties evolution
Fatigue tests are specimens and time consuming, development
of self heating experiments to predict fatigue limit
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Example : Fatigue behaviour of welds
Gap
1mm
Gap
1mm
In-use performance of avanced steels
No straightforward influence of stress concentration (Kt), we can explain this by the combined
effect of irregularities in the geometry of the weld, the presence of local defects, porosities,
distribution of residual stresses and so on product validation on prototypes
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• Test conditions and results: – Severe impact conditions to obtain failure
– Usibor®1500 1.8mm + closing plate Mild Steel 1mm
– Impact at 8m/s (Mass = 430 kg)
In use performance : Crash resistance on B-Pillar in Usibor®1500
Experimental test
After 16ms
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Strain at same displacement
= Failure strain
• Plane strain is the most critical strain state for crash application
– Thus, its characterization is mandatory to run any FE failure analysis
• Failure in plane strain is accurately measured through coupling of
experiment and FEA:
Failure strain characterization Highlight on plane strain failure characterization
Displacement at failure
FE simulation with
accurate material law
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Validation on B-Pillar in Usibor®1500 Simulations with LS-DYNA MAT224
(*MAT_TABULATED_JOHNSON_COOK)
1st deletion at 12ms 1st deletion at 12ms
1st deletion at 14ms
-2 -3
-4 -5 -3 -7
Plastic Strain
Accurate failure prediction
for all mesh size
5mm
2mm 3mm
More accurate model:
LS-DYNA MAT224 failure
modeling takes into account
deformation path
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14/11/2016 Author 82
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Automotive needs for new performance : Design & Development of Next Generation Steels
Maximize Steel’s Advantages Address Steel’s
Limitations
Stiffness-Limited
•C-Pillar Ring
•Closures
•Floor Pans
•Chassis
Strength-Limited
•Rockers
•Cross Members
•Rail Extensions
•A-, B-Pillars
Energy -Limited
•Rails
•Lower B-Pillar
•Windshield
Members
Push UTS
beyond 1500
MPa
Develop High
UTS plus High
Elongation
Develop Low
Density Steels
Develop High
Modulus Steels
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rmation Grade designed for stiffness: 15% weight-saving can be achieved with 7% density
reduction and 8% weight saving via higher Young E-modulus.
Standard steels: E=200GPa, ρ=7.85 kg/dm3.
High Modulus FeTiB2 steel: E=240GPa, ρ=7.32 kg/dm3
Concept: In-situ precipitation of fine TiB2 particles in steel matrix during solidification.
Compact Strip Production process is required to achieve rapid cooling and control particles
size & distribution.
Precipitation of TiB2 in steel matrix
20 m
Cold stamping formability
is confirmed
Application: A large range of strength/ductility compromises
can be achieved through metallurgical designs to fulfill
automotive BIW & chassis applications.
500
600
700
800
900
1000
200 300 400 500 600 700 800 900
UT
S,
MP
a
YS, MPa
Lab casting
Industrial casting
Forming Limit Curve Ys-UTS accessible range
High Young Modulus TiB2 composite steel
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Reduced density : Al added steels
Three types of products can be achieved
• Fully ferritic steels (a): 10% density reduction,
Al~6-8%, Low Carbon
Typical Grades 500-600MPa
• Duplex steels (a+g): 10% density reduction,
Al~6-8%, Mn~4-8%, C~0.1-0.3%
Typical Grades 700-1000MPa
• Triplex steels g+few (a + 3rd phase): 14% dens. red.,
Al~6-10%, Mn~20-30%, C~0.9-1.3%
3rd phase is Kappa carbide
Typical grades 1000-1300MPa, 30-40% elongation
a
a
g
a
g
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Concluding Remarks
• ArcelorMittal, the world’s largest steel and mining company
and the leader in every major global steel market, including automotive,
construction, household appliances and packaging, with leading R&D
and technology and outstanding distribution networks, offers products
and steel solutions to serve most customer needs.
• Talented, Creative and Innovative Individuals…..
– with a Passion to Safely and Sustainably Lead the…
– Design, Development and Industrialization of…
– Products and Processing Technologies…
– to Boldly Resolve umpteen Challenges….
– with Steel Solutions that will Transform Tomorrow…
– should find plenty of Opportunities at ArcelorMittal
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