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.
Many of the new adhesives we're featuring in this slideshow are for use in automotive and other transportation applications. The rest of these new products are for a wide variety of applications including aviation, aerospace, electrical motors, electronics, industrial, and semiconductors.
A Columbia University team working on molecular-scale nano-robots with moving parts has run into wear-and-tear issues. They've become the first team to observe in detail and quantify this process, and are devising coping strategies by observing how living cells prevent aging.
Many of the new materials on display at MD&M West were developed to be strong, tough replacements for metal parts in different kinds of medical equipment: IV poles, connectors for medical devices, medical device trays, and torque-applying instruments for orthopedic surgery. Others are made for close contact with patients.
New sensor technology integrates sensors, traces, and electronics into a smart fabric for wearables that measures more dimensions -- force, location, size, twist, bend, stretch, and motion -- and displays data in 3D maps.
As we saw on the show floor this week at the Pacific Design & Manufacturing and co-located events in Anaheim, Calif., 3D printing is contributing to distributed manufacturing and being reinvented by engineers for their own needs. Meanwhile, new fasteners are appearing for wearable consumer and medical devices and Baxter Robot has another software upgrade.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.