Steel is in a battle to retain market share as automotive engineers face tough decisions about how to reduce weight. Steel producers have introduced advanced steels that are lower weight and higher quality than the mild steels they replace. However, engineers are not happy with the quality control on much of the steel the receive, based on comments made on a recent Design News survey conducted by RBI Research in Waltham, MA. A few examples:
“The material that I have been getting lately is not rolled into a true rectangular profile. One side of the longer edge is often slightly curved, near the shorter edge.” The criticism refers to AISI 1018 cold-rolled steel (low-carbon, manganese-rich).
”Need a better micro structure.” Referring to 8620 steel, a hardenable chromium, molybdenum, nickel low-alloy steel often used for carburizing.
”(I need) better consistency of crystalline structure for low alloy steels.” Referring to low alloy (2.25%Cr - 1.0% Mo) steels
”Need better resistance to corrosion from H2S and organic sulfur and corrosion from naphthenic acids in crudes /bitumens.” Referring to A516 series of carbon steel and TP 316/317 types of 18-8 stainless steel.
”Need better avaialblity of cold-heading quality of 8640 alloy steel in diameters needed to produce 1-inch to 1 ½-inch fasteners.
”Better finish. Less scale.” Hot-rolled steel.
”Better varnish for magnet wire.”
”Get increased surface hardness along with better corosion resistance.” Referring to stainless steel generally.
Admittedly, some of the problems relate to poor quality from Asian suppliers, where definitions of specifications can vary widely, to be generous. One survey respondent said: “There needs to be a clear expectation with regards to rusting/corrosion with type 304 and others as it relates to Cr and Ni content. The ‘junk’ from China is usually at the minimum for Ni.”
But many comments indicated there is a significant problem in consistency from all sources, either in grain structure, or chemical composition or in forming. More than 200 engineers participated in the survey, and they were promised confidentiality. Thanks to our readers who participated. A detailed report of the composite findings will be published in the Design News Trend Watch supplement in August. I’m going to cherry pick more of the specific comments in this blog over the next few weeks. Hopefully, some suppliers are reading, and take notes on potential improvements.
Just in time for Earth Day, chemicals leader Bayer MaterialScience reported from the UTECH Europe 2015 polyurethane show on programs and applications using its materials to help reduce energy usage. The company also gave an update on its CO2-based PU as that eco-friendly material comes closer to production.
A slew of announcements about new materials and design concepts for transportation have come out of several trade shows focusing on plastics, aircraft interiors, heavy trucks, and automotive engineering. A few more announcements have come independent of any trade shows, maybe just because it's spring.
At the JEC Europe 2015 composites show in Paris last month, makers of composite materials, software, and process equipment showed off their latest innovations. This year's show saw some announcements related to automotive applications, but many of the improvements came in the world of aerospace.
The DuPont-sponsored Plastics Industry Trends survey shows engineers want improved performance in a broad range of plastics and better recycling technology. These concerns top even processing enhancements that improve productivity.
Plastics leader SABIC recently announced a global initiative to help its customers take advantage of additive manufacturing (AM) and also advance 3D printing (3DP) technologies in several application areas. The company's plans go way beyond materials, and also include design, processing, and part performance.
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