UDDEHOLM GRADES IMPROVE PERFORMANCES IN THE PRODUCTION OF MANNESMANN DMV STAINLESS STEEL TUBES FOR AUTOMOTIVES - COLD WORK EXPERIENCES - Sunne, Sweden - 9 February 2007
DMV Mission Mannesmann DMV Stainless (short: DMV) is a global player in stainless seamless tube production DMV puts the customer in the focus of all its activities and acts as their business partner DMV always aims for improvement and perfection in quality and service and develops innovative approaches
Mannesmann DMV Stainless at a glance Dalmine Mannesmann Vallourec 1994 2003 100% Mannesmann Röhrenwerke 2006 Manufacturer of seamless stainless steel and nickel basis tubes 320 Mio. sales approx. 1.100 employees 32.000t (~10.000km) p.a.
Mannesmann DMV Locations Houston/Texas USA Mülheim (HQ) Remscheid Germany Montbard France Costa Volpino Italy
Costa Volpino plant presentation Mannesmann DMV Stainless Italia Srl - Via Piò, 30 24062 Costa Volpino (Bergamo) - Italy Homepage : www.mannesmann-dmv.com Phone ++ 39-(0)35-975.611 - Fax ++ 39-(0)35-975.803
Costa Volpino main figures (2006) PRODUCTION : 8800 T/year (~8000 Km) OVERALL SALES : 110 million EMPLOYEES : 292 INDUSTRIAL SITE : 155000 sq.m DMV PLANT : 70000 sq.m (covered and uncovered area)
DMV products & applications Max. Ranges Diameter 5 250 mm Wall thickness 0.5 50 mm Length up to 25 m Main Applications Chemical and petrochemical industry Energy industry and power plant manufacturing Environmental technology and waste incineration plants OCTG (Oilfield applications) Mechanical engineering and automotive
Sales by market segments SALES BY MARKET SEGMENT - 2006 FIGURES Oil & Gas 4% Power Generation 9% Others 14% Mechanical Engineering and Automotive 13% Chemical- Petrochemical 60%
DMV products material groups Stainless Steel Corrosion Austenitic Steels 304 L 316 L Super Austenitic Steels 904 926 954 Duplex & Super Duplex 18.5 22.5 25.7 N Nickel Basis Alloys Corrosion and Temperature Pure Nickel Materials 200 201 Nickel-Copper Alloys 400 500 Austenitic Nickel Alloys 800 600 625 617 Ferritic Steels 410 446 Stainless Steels Temperature Special Materials 304 H/HCu 310 310 N 347 H 800 H AC 66 Titan Alloys Grade 1 Grade 2
DMV products Automotive applications Main automotive applications: Tubes material: DMV 304 L (UNS S 30403) - 10 x 1 mm: Oil stick tube for top class cars - 13,2 / 17 x 2 mm: fuel injection collector (four cylinders) - 20 x 2 mm: common rail collector (2007 project) EXAMPLE IMAGES
DMV products Automotive applications Other applications: Tubes material: DMV 304 L (UNS S 30403) / DMV 316 L (UNS S 31603) Dimension: 6 x 1 mm, 7 x 1 mm, 8 x 1 mm, 8 x 1,5 mm: - Heating system for windows cleaning tank - Cooling circuit - Fuel feeding - Braking circuit system - Airbags - Headrest - Seats main structure - Side impact bar (cold hardened) EXAMPLE IMAGES
The DMV production technologies Hot production Cold working Billet Extrusion mandrel Pilger mandrel Tube Extrusion ram Billet container Die Tube Tube blank Plug drawing Pilger rolls Tube Tube blank Drawing ring
Overview of pilger mill (Meer SKW 50 type) The process movie
Pilger mill Stress distribution Components stress: - Mandrels: Compression, Tensile, Bending, Torsion, Fatigue. - Dies (Rolls): Compression, Fatigue. Cross section trough the forming zone with stress distribution. ( Finite Element Method ) Main concept: To produce small stainless steel tubes we need high quality tools such as UDDEHOLM GRADES to prevent failure mechanism.
Pilger mill Failure mechanisms Typical failure: - Mandrels: Wear, Plastic deformation, Cracking, Galling. - Dies (Rolls): Wear, Chipping, Cracking, Galling. Cross section of tube pilgering process.
Pilger mill Dies/Rolls Failure mechanisms Dies/Rolls : Chipping, Galling, Cracking.
Pilger mill Mandrels Failure mechanisms Mandrels: Adhesive wear (galling), Abrasive wear, Chipping, Plastic deformation
Pilger mill Dies/(Rolls) Case Study Application: Customer: Worked material: Notes: Stainless steel tubes for Automotive DMV Austenitic stainless steel (DMV 304L 6 up to 16 mm O.D.) Dies dimensions: diam 202-212 mm 1.2344 standard ORVAR SUPREME CALDIE HARDNESS >54 HRC >56 HRC requested HEAT TREATMENT FAILURE MECHANISM PRODUCED PARTS (meters) HEAVY CHIPPING Average 30 000 mt No standard high aust temp CHIPPING Average 40 000 mt >57HRC CHIPPING Test in progress Actually 40 000 mt Better toughness at high hardness
Pilger mill Mandrels Case Study Application: Stainless steel tubes for Automotive Customer: DMV Worked material: Austenitic stainless steel (DMV 304L 6 up to 16 mm O.D.) Notes: Mandrel dimension: 3.5 mm up to 20 mm ~1.2380/VANADIS 4 VANADIS 4EXTRA VANCRON 40 HARDNESS 61 63 HRC 61 63 HRC HEAT TREATMENT FAILURE MECHANISM PRODUCED PARTS (meters) Standard Chipping and breackage Average 12 000 mt Standard Wear and breakage Average 15 000 mt Next Future
Obtained benefits - Dies: Tool life increased by ~ 30% Material cost difference: + ~ 11% (Orvar Supreme compared with Orvar 2) - Mandrels: Tool life increased by ~ 20-25% Material cost: about the same (Vanadis 4Extra compared with Vanadis 4) DMV production advantages: Pilger mill parameters : increased number of strokes per min. Production stops and set-up : reduced number of tool changes. Surface quality : better quality of the finished tubes, less galling. Pilger process lubrication : chlorine free. Reduced production costs.
Future The DMV target is to use high performance steel tools to achieve: efficiency, quality, cost saving & production reliability. How? Reliable supplier continuous technical support optimised processes high performance materials.