SCHWERTE SPECIAL STEEL PROFILES Custom-made Components and Structural Elements

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1 SCHWERTE SPECIAL STEEL PROFILES Custom-made Components and Structural Elements

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3 Contents Precision-made, Quality delivered 4 Specific Solutions for Specific Applications 6 Automotive 6 Railroad Technology and Rail Track Construction 7 Railroad Cars and Aircraft 8 Construction and Agricultural Machinery 9 Materials Handling 10 Mechanical Engineering 12 Plant Building and Power Station Engineering 13 Building Industry 14 Armatures and Piping Systems 15 Material-specific Solutions 16 Production Technology 18 Hot rolling 18 Hot extruding 19 Cold drawing 20 Laser welding 21 Quality Management 22 Environmental Protection 23 3

4 Precision-made, Quality delivered Special Profile as Guide Cars used in Linear Motion Systems Earlier guide cars were machined out of flat steel and 25 kg/m were lost as a result. The material loss using our special profile is only 12 kg/m a saving of more than 50%. ECONOMIC PRODUCTION The different profiling processes make it possible to form the material so that it can meet all respective economical, structural and optical conditions. The use of special profiles offers many industries and individual users distinct advantages, e. g. best shape properties and fitting accuracy by maintenance of the tightest tolerances different material thicknesses within one profile cross-section thus allowing specific reinforcement of highly stressed segments of structural components seamless structure of solid and hollow sections, which have to withstand the demands of temperature, pressure, and aggressive media Machining can be minimized and weight saved by choosing an optimum cross-section, and bottlenecks in machining capacity can thus be avoided. Special Profiles as Tensioning Shoes used in Precision Clamping Tools In the past, these were based on forged blanks. The subsequent compulsory and essential all around machining of that blank was completely eliminated by the change to a special profile. 4

5 Hoesch Schwerter Profile GmbH develops special steel profiles in close collaboration with individual users or branches of industry. In contrast to the mass production of other suppliers, however, the Schwerte plants make products whose properties are determined by the customers according to their requirements. Every profile that leaves the works in Schwerte solves a special construction or manufacturing problem. You know these products as guide rails, clamps, rails, troughs, hinges or frame profiles, which, when conventionally produced, require enormous manufacturing effort. Hoesch Schwerter Profile GmbH, is able to offer far more economical solutions by manufacturing steel profiles using state of the art technology. Why? Costly processes such as welding, straightening, grinding, milling or turning can be eliminated. Material and labour time can be saved during downstream machining due to the near-net cross-section of the profile. The multitude of possible cross-sections often creates the possibility to fulfil the functions of adjacent components with a single special profile. Steel is a material with a huge structural, economical and ecological potential. Easily shaped, fully recyclable and highly durable, these material advantages can be further enhanced using special profiles, because our customers are not necessarily bound to high tooling charges and long tooling-up times as a result of the various production processes available in Schwerte. Moreover, small batches of special profiles can also be manufactured economically. Four production processes are available at the Schwerte location: Hot rolling Hot extruding Cold drawing Laser welding To find out if a special profile or a conventionally produced product offers design or economic advantages for your requirements, ask for a personal discussion with our profile and applications advisors. FURTHER PROCESSING To round off our procution program, we also offer our customers the following additional processing steps: sawing milling turning grinding submerged arc welding drilling thread cutting heat treatment surface treatment Special profiles as rails used in horizontally adjustable shelving and archiving systems. 5

6 Specific Solutions for Specific Applications Automotive Extreme resilience, low weight, continuous accurate processing, no excess material: our automotive industry customers value these advantages. For many years they have used our special profiles, to remain in the overtaking lane in a very competitive market. Hoesch Schwerter Profile GmbH, continues to be an innovative partner for automotive manufacturers and automotive suppliers. Special profiles as hinges used in car and truck doors Special profiles as valve bodies used in truck diesel engines Special profiles in 2-column high-load car lifts 6

7 Railroad Technology and Rail Track Construction For decades Hoesch Schwerter Profile GmbH, has been right on track as an innovative partner. Whether for rail fasteners or for technological applications in the field of rail track construction, special profiles fulfil special demands and solve customer-specific problems. Power rail and stator pack hanger for the magnetic levitation train, Transrapid Special profiles for noise-reducing rail system ( whisper rail ) Special profiles as rail fasteners, structural components for railtrack construction and rails of non-standard dimensions 7

8 Specific Solutions for Specific Applications Railroad Cars and Aircraft Special profiles for railroad cars Whether it be high-precision rails for sliding automatic doors in trains or trams or the demanding material requirements of the aircraft manufacturing industry, the wide variety of potential cross-sections and the utilisation of an extensive range of materials make the Schwerte special profile plants a sought-after and competent contact for many companies within these industrial sectors. Special profiles for rails in automatic sliding doors Special profiles for jet rings in aircraft engines 8

9 Construction and Agricultural Machinery Special profiles for construction machinery The answer is often hidden in the detail: Schwerte special profiles form essential components in the production of construction and agricultural machinery. From frame profiles and special slewing ring shapes to clamping rails and blade-holder profiles, often complex parts are manufactured according to the individual demands of our customers. Special profiles for ball bearing slewing rings Special profiles for agricultural machinery 9

10 Specific Solutions for Specific Applications Materials Handling For many years the manufacturers of storage systems and industrial lift trucks have fallen back on the know-how and experience of Hoesch Schwerter Profile GmbH. The design of special profiles for these industries requires a profound understanding of the logistical requirements. Additionally, the profiles must be able to withstand extreme stresses and strains. Stressable joints, lifting equipment for heavy loads, good visibility and stability are all specific functions required in the industrial lift truck industry, all of which can only be fulfilled by Schwerte special profiles. We produce special profiles of varying load capacities for use in materials handling equipment, from the smallest stackers up to heavy duty industrial forklift trucks, as well as for high storage and shelving systems. Special profiles for forklift truck attachments Special profiles as masts used in electric stackers for shelf-loading 10

11 Special profiles as masts used in forklift trucks Special profiles for mast and telescopic guide rails in high storage systems 11

12 Specific Solutions for Specific Applications Mechanical Engineering Special profile for chain saw drive sprocket Special profiles as chain guide rails in chipboard manufacturing plants Precision and durability are essential criteria for components used in mechanical engineering. Whether for high-precision tools or industrial production facilities, or machines for the textile and the wood working industries, highly innovative manufacturing technologies are required to satisfy the extreme demands of different machine manufacturers. Special profiles for components of linear guide rail systems 12

13 Plant Building and Power Station Engineering Special profile as stator element in generators Compared with the rest of the world, German heavy plant builders and power plant construction companies have maintained a leading position in this market for many years. Profitability and reliability are the distinguishing factors of the projects. Hoesch Schwerter Profile GmbH is seen as a competent partner for the development and manufacture of special components for heavy industrial and power generating plants. Finned, omega and double omega tubes for gas-tight membrane walls in boiler construction as well as tubing for walking beam furnaces Special profiles for X-ray equipment 13

14 Specific Solutions for Specific Applications Construction Industry Special profiles for expansion joints in bridge building Special profiles for façades Aesthetics, precision and variety of form: Schwerte special profiles offer the construction industry advantages in many fields. On a daily basis, profiles are shipped from Schwerte to construction sites all over the world in a multitude of various forms. They could be facade profiles for ambitious architecture projects or locking profiles for technically demanding sheet piling structures or even expansion joint profiles for use in bridge building. In every profile you will find minimum weight combined with maximum load capacity. Furthermore, architects and engineers value the collaboration with Hoesch Schwerter Profile GmbH, because expensive welding and downstream mechanical manufacturing processes are not necessary. Special profiles as corner and locking profiles for sheet piling 14

15 Armatures and Piping Systems Hoesch Schwerter Profile GmbH supplies to the excavation and deep mining industries as well as to structural engineering companies. This is one of the areas where the Schwerte plants put a decisive stamp on the German and international markets. Hoesch Schwerter Profile GmbH, supplies highly innovative components in the fields of water and gas transportation as well as for heating and ventilation systems, thus contributing to the continuous development of trendsetting technologies. Special profiles for pipe couplings Special profiles made from stainless steel for high-pressure valve and ball valve bodies Special cross, T and angle profiles for high pressure valve joints 15

16 Material-specific Solutions Special profiles for façade construction Special profiles, standard shapes and seamless solid and hollow sections made from corrosion and heat resistant stainless steels form a large part of our extensive production program. Thanks to their outstanding chemical and mechanical characteristics these materials have created new and fastgrowing fields of application, e.g., in the chemical industry, in reactor technology, in power plant engineering, in the foodstuffs and in the construction industries. Depth measurement indicator Hollow sections for ball valves 16

17 Special profile for pump impellers for feed pumps Special profile or standard shape? A thorough discussion with our profile and applications advisors can help you decide which profile is the most economical for your needs. Hoesch Schwerter Profile GmbH, offers standard profiles made from corrosion and acid-resistant stainless steel, according to DIN EN /DIN with the following dimensions: a Equal angles dimensional range*): mm b a Unequal angles Dimensional range*): 30 x 20 mm to 200 x 150 mm b Conveying pinion in meat processing machinery b h T-profiles, wide flange, equal and deep-webbed Dimensional range*): height = mm width = mm b h I-beams, narrow and wide flange (similar to DIN 1025) Dimensional range*): height = mm width = mm b Special profiles for handrails on bridges h U-profiles Dimensional range*): 30 x 15 mm to 400 x 110 mm *) Thickness depends on profile circumscribed circle and type of material. 17

18 Production Technology Hot rolling During the production of special profiles by hot rolling the input billet or slab is formed into lengths up to 70 m using two oppositely rotating cylindrical rolls. The products of this forming technique are used in a multitude of industrial applications. Hot rolled special profiles offer innovative solutions whether it be for automotive, materials handling or railroad use. Hot rolled profiles are roller straightened and sheared into production lengths or sawn into fixed lengths according to customer wishes. The advantages of hot rolled special profiles include, amongst others targeted strengthening of highly stressed areas of component parts best mechanical properties through uninterrupted grain orientation best shape properties and fitting accuracy by maintenance of the tightest tolerances Technical possibilities Dimensions: circumscribed circle up to 220 mm Ø; for flat shapes up to 320 mm wide minimum wall thickness: 4 mm Lengths: up to 19,500 mm; cold sheared length ± 50 mm; fixed lengths (sawn) ± 1.5 mm Weights per meter minimum c. 7 kg/m maximum c. 80 kg/m Cross-sectional tolerances/ straightness tolerances: Plant Standard 1.5 mm/m longitudinal camber 1 /m for twist, according to norms for comparable cross sections or by individual agreement Forklift Mast Rails (fine tolerances) 1 mm/m for longitudinal camber 0.5 /m for twist or by agreement Surface: as rolled; shot blast, pickled and/or primer coated by prior agreement Materials/Treatments: mild, carbon and alloy structural steels or customer-specific alloys treatments by agreement, e. g. stress-relieved annealing, soft annealing, normalizing, hardening and tempering 18

19 Hot extruding During hot extrusion a round steel billet is pre-heated and, after leaving the furnace, is pushed through a forming die into a profile bar using a ram with an extrusion force of 2,200 t. Hot extrusion offers substantial advantages in comparison with hot rolling, forging or machining. Hot extrusion can be used to make complex profile shapes even using metals which are difficult to form. In addition, small lot sizes can be produced economically. Hoesch Schwerter Profile GmbH possesses highly sophisticated CAD and CAM systems which are used to support our customers during the design and engineering phases. Hot extruded profiles offer the benefit of: different material thicknesses within one profile cross-section the possibility to use in highly sensitive areas, where the special profiles must withstand specific demands of temperature, pressure, aggressive media or hygienic requirements seamless structure of solid and hollow sections Technical possibilities Dimensions: circumscribed circle for solid and hollow profiles up to 240 mm Ø inside diameters or diagonals for hollow profiles of at least 20 mm to a maximum of 160 mm minimum wall thickness: 4 mm Lengths: c. 3,000 up to c.16,800 mm (depending on profile cross-section); with sawn ends, (fixed lengths by agreement) Weight per meter: minimum c. 1.5 kg/m maximum c. 100 kg/m Cross-Sectional Tolerances/ Straightness Tolerances: by agreement, depending on the profile crosssection and material grade; reductions possible, e.g. for functional areas, by agreement Surface: as extruded; descaled or pickled on request Materials/Treatments: nearly all quality and stainless steels in the iron and steel list, special steels, non-ferrous heavy metal alloys all required heat treatments are available 19

20 Production Technology Cold drawing Technical possibilities Dimensions: circumscribed circle up to approx. 200 mm diameter; for flat steel up to approx. 300 mm wide minimum wall thickness: 4 mm Lengths: up to 11,000 mm (depending on profile cross-section), with sawn ends (fixed lengths by agreement) The process of cold drawing is a procedure by which metal is formed in order to achieve complex profile cross sections of excellent precision. After careful pre-treatment and descaling the special profile bars are drawn through a forming die. This operation can be repeated up to three or four times. Cold drawing of hot rolled and hot extruded special profiles tightens the cross-sectional tolerances, thus leading to significant improvement in dimensional accuracy and surface quality. Cold drawn special profiles offer the same precision achieved by machining but without the waste. Cold drawn special profiles offer extensive advantages, among other things: smooth and scale-free surface sharp edges uninterrupted grain orientation increased tensile strength and yield point Weight per meter: minimum c. 1.5 kg/m maximum c. 120 kg/m Cross Sectional Tolerances/ Straightness Tolerances: Dimensional tolerances by agreement up to max mm, depending on cross- section and materials Straightness tolerances and twist: 1 mm/1 m on supply length or by special agreement Surface: cold drawn Materials/Treatments: nearly all quality and stainless steels in the iron and steel list, special steels, non-ferrous heavy metal alloys all required heat treatments are available 20

21 Laser welding Technical possibilities Dimensions: web width mm web thickness mm flange width mm flange thickness mm Lengths: component lengths up to max. 7,000 mm Material: corrosion, acid and heat resistant grades, unalloyed C-steels suitable for welding For the production of laser welded special profiles both standard geometries such as sheets, tubes or angles and extruded or hot rolled pre-shapes can be used. Hoesch Schwerter Profile GmbH hydraulically clamps the individual parts which can be up to seven meters long, and subsequently welds them together with a 12 KW CO 2 laser. Of particular significance is the low thermal stressing of the work piece. This enables lowdistortion or, in the main, distortion-free production. Due to the filigree and clean welding seam laser welded profiles find a wide spectrum of uses within the architecture and building industry, among others. The applications of laser welded special profiles are as varied as the forms of the profiles themselves; angles, channels, T-profiles, beams, rectangular hollow profiles, standard hollow profiles and special forms can be produced. Laser welded special profiles are particularly suited for optically sophisticated and durable designs and also offer the following advantages: precision fit free-form shapes optimum weight free from further processing 21

22 Quality Management Hoesch Schwerter Profile runs a management system to ensure quality and environmental protection which is certified by an independent accredited institute (DQS) in accordance with ISO TS and based on ISO It is authorized to produce according to AD Code of Practice WO/TRD 100 Test No. 4/ /9 of TÜV and general building regulations. It has ÜHP and ÜZ licensing for steel products according to building regulation list A, Part 1. The following list of norms determine our supply conditions: National standards and regulations, including DIN EN standards as well as international EN ISO standards; Technical Rules for Pressure Vessels (TRD), Stahl-Eisen Werkstoffblätter (SEW), AD Code of Practice (Association of Pressure Vessel Manufacturers), Vd-TÜV Material Sheets, ASTM (USA), BS (Great Britain), AFNOR (France), SIS (Sweden) and many more. If required, the following tests can be carried out: Mechanical Tests Tensile test Hot Tensile test Impact test at room temperature and lower temperatures Brinell / Rockwell / Vickers hardness test Corrosion Tests Test for inter-granular corrosion Huey-Test according to ASTM A 262 or stamicarbon regulation Physical Tests Spectroscopic identification test Permeability determination Ferrite determination Non-destructive tests Ultrasonic test Surface crack test with magnetic particles and dye penetrants Hydrostatic pressure test Eddy current test The material tests can be certified according to DIN EN

23 Environmental Protection Hoesch Schwerter Profile GmbH maintains a corporate policy which is not only focused on high product quality and optimum economic efficiency, but also concentrates in equal measure on comprehensive environmental protection, safety and health. Thus environmental protection is not detached from other goals but is an integral component of a business strategy geared towards long term appreciation. All production processes are examined regularly for their environmental effects and are adjusted appropriately in a continuous improvement process. Environmental protection for Hoesch Schwerter Profile GmbH means: continuous improvement of production processes with regard to the highest possible environmental compatibility preservation of resources continuous monitoring and assessment of environmental effects which result from current and planned activities application of necessary and practical measures for the continuous reduction of environmental pollution The existing environmental protection system was adapted to the international standard specification DIN EN : 2004 and applies uniformly for all product areas. development of products which are characterized through longevity employment of materials with high recycling capabilities 23

24 Hoesch Schwerter Profile GmbH Eisenindustriestrasse 1 D Schwerte Tel.: ++49 (0) Fax: ++49 (0) info@hoesch-profile.com Internet: