The Nanomaterials in the Industrial Process of GERDAU
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1 The Nanomaterials in the Industrial Process of GERDAU NANOSAFETY & EHS ADVANCE
2 Global Presence 2
3 Products and End Users 3
4 Special Steel Locations 4
5 Product Portfolio: SBQ 5
6 Shipments: Special Steel 6
7 Special Steel in Europe Steel Mills Basauri Crude Steel Capacity: t Rolled Steel Capacity: t Gerdau is one of the main steelmakers of Special Steel in Europe and almost the 70% of its production is for Automotive Industry Reinosa Crude Steel Capacity: Rolled Steel Capacity: Parts Capacity: t t t Azkoitia Rolled Steel Capacity: t Vitoria Rolled Steel Capacity: t Steel Mills Representative Offices Downstream units 7
8 New Challenges for the steel in the car industry Reduction of emissions and consumption Reduction of the weight of the vehicle FUTURE: Use of the nanotechnology to cope with the challenges Increase of the specific tensile strength Hardening of steel 8
9 Use of nanoparticles in steel industry. Hardening Mechanisms Nanoparticles (oxides TiO2, CeO2 ) are stables in all kind of conditions How nanotechnology works in hardening mechanisms Grain refinement & precipitation Number of precipitates Size of those precipitates Avoid risk of growth and coalescence with the increase of temperature 9
10 Use of nanoparticles in steel industry DISAUTO, project supported by the Basque Government (ETORGAI program). Use of nanotechnology for components assembled in powertrain and steering. DISAUTO Tecnalia Gerdau Aceros Especiales Europa Alcorta Forging Group GKN Driveline Gerdau I+D 10
11 Use of nanoparticles in steel industry. Applications Through addition of nanoparticles in: Microalloyed steels The tensile strength in the steel is reached through thermomechanical treatment, by grain refinement or by precipitation More effective with the addition of nanoparticles Carburizing steels Carburizing steels are steels with high hardness in the surface and good toughness in the core When nanoparticles are well distributed, no dissolution of them will happen at high temperatures and that means a good control of grain size in the steel 11
12 Applications. Powertrain Crankshaft manufactured with microalloyed steel 12
13 Applications. Powertrain Rail of common-rail microalloyed steel The housing and the head of hydraulic pump are manufactured with carburizing steel 13
14 Applications. Powertrain Carburizing and nitrocarburizing steels Gears Primary shaft Secondary shaft 14
15 Applications. Steering These components transmit the power of the car from the engine to the wheels Carburizing component 15
16 Use of nanoparticles in steel industry. Conclusions Process scale Laboratory: First test with pure iron (1 kg cast) Laboratory: Vacuum induction furnace (35 kg cast) Industrial test: Addition of nanoparticles to a microalloyed steel Chosen nanoparticles Different nanoparticles and addition percentages have been evaluated TiO 2 nanoparticles have been chosen, in percentage of 1% in weight Characterization methods To confirm the improvement of the steel adding nanoparticles Optical Microscopy, Scanning Electron Microscopy, Image Analysis Software, as well as mechanical tests 16
17 Use of nanoparticles in steel industry. Safety issues Analyses for estimation of risks Risk of explosion and flammability of nanopowders Use of conventional protective devices to handle nanoparticles Nanotoxicology Suggestions for save procedures Use of dispersed or agglomerated nanoparticles Inertisazed processes Efficient exhaust systems with particles filters Use of Personal protection equipment: nitrile gloves, mask, suits and safety shoes 17
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