Technology without frontiers
From Sugar Loaf Mountain to the German Alps and back
Over 9,000 kilometers apart - yet closely connected: ThyssenKrupp Metalúrgica Campo Limpo in Brazil and ThyssenKrupp Gerlach in Germany Deutschland work together on efficient crankshafts designed to help vehicle and engine manufacturers reduce fuel consumption and CO2 emissions. This international transfer of technology competency made it possible to develop optimized lightweight crankshafts using new materials. The intensive collaboration is also reaping benefits for production processes: In response to increasing demand for diesel engines over recent years, production capacities for forged crankshafts had to be increased. To secure technology leadership, ThyssenKrupp Gerlach developed a fully automated production line. With a cycle time of 7.5 seconds and a lead time of 4.5 hours from starting material to finished product, capacity was increased to over two million crankshafts per year. The high degree of automation not only reduces production costs by 35% but also guarantees consistently high product quality. So it was little wonder that the judges in the "International Engine of the Year 2005" competition awarded first prize in the 1.0 to 1.4 liter category to the 1.3 liter turbo diesel engine of Fiat / General Motors. At the heart of this engine is a 4-cylinder crankshaft forged by ThyssenKrupp Gerlach and featuring in the Fiat Panda and Punto, Lancia Ypsilon and Opel Astra, Tigra and Corsa models. A success story, and one of the reasons ThyssenKrupp is world market leader for car and truck crankshafts.
