Innovations

2008 Innovation Contest launched

Our annual Innovation Contest helps further improve the climate for innovation in the Group and promote the translation of ideas into promising products and services. Launched in July 2007, this year's contest – the ninth – once again invites employees at all Group companies to submit their ideas and suggestions. In recognition of the importance of environment and climate protection, resource conservation, energy efficiency and lower CO₂ emissions, a special innovation prize will be awarded this year to the best project from these areas.

ThyssenKrupp involved in ICAMS

In the reporting quarter, our scientists and engineers once again worked hard to further develop our products and services, frequently in collaboration with customers and external partners. ThyssenKrupp attaches great importance to these partnerships. Worthy of particular note in this respect is our involvement in the establishment of the Interdisciplinary Centre for Advanced Materials Simulation (ICAMS) at the Ruhr University Bochum. A total of €24 million is being raised as starting capital for ICAMS. Half of this amount is being contributed by the state of North Rhine-Westphalia, the other half by industrial partners. ThyssenKrupp is providing €8 million. The institute will drive the development of the materials of tomorrow using innovative multiscale simulation techniques to predict the behavior of metallic materials at different levels of scale, from atomic to macroscopic component level. This provides a deeper understanding of material properties and enables new types of materials to be developed, from which Steel in particular will benefit.

Innovations in the segments

The Steel segment is working to develop advanced steels combining high strength and formability, as well as manufacturing processes optimized for these steels. One example is the unique T³ profile pilot plant which went into operation recently. Using this line, various forming processes can be combined with an integrated laser welding process, allowing the manufacture of light, low-cost tubular profiles for use in auto manufacture in particular. Initial forming and welding tests have confirmed the capabilities and versatility of the line. In parallel, projects are being carried out with customers to demonstrate the potential of the steel profiles in auto body structures. In one project for a Japanese customer a 25% weight saving was achieved with no reduction in the body's structural properties.

Driven by high prices for alloying elements, one key area of innovation at Stainless is the production of low-nickel and low-molybdenum materials with marketable properties. In close collaboration with our customers, we developed a ready-for-market nickel-free material for drinking water pipes to replace a nickel-bearing material. The new material has met with a very positive reception from customers.

Technologies is continuing to develop innovative ways of reducing weight, fuel consumption and emissions for cars and trucks. The results are being offered to automotive OEMs in the form of an integrated concept as an "automotive component kit to reduce CO₂ and NO_x emissions". This includes lightweighting through the use of high-strength materials, alternative manufacturing processes and optimized design. Weight savings of 10%–30% are achieved for crankshafts, camshafts, differential gears and dampers. Another key area addresses ways of lowering fuel consumption by using new bearing concepts and designs to reduce friction in the engine. Additional CO₂ reduction effects are expected from the use of electric steering components and the associated elimination of permanently needed hydraulic assistance.

Elevator launched several system innovations aimed at reducing installation cost and time. Further advances were also made in the area of standard cabs. These include design modifications which reduce weight and thus cut energy requirements during operation.

The Services segment achieved success with projects in the area of railway equipment and civil engineering. In early May 2007, GfT Gleistechnik started laboratory trials of its new slab track system "Neue Feste Fahrbahn – NFF". This system combines the advantages of a prefabricated concrete frame with mounting on injected piles, eliminating most of the costly and time-consuming work otherwise required for ground improvement. At the Bauma exhibition in Munich in April 2007, ThyssenKrupp Tiefbautechnik presented a so-called swiveling vibrator for pile-driving applications. Its advantage lies in the simplified handling of the piling. The response to the vibrator was positive; inquiries were received from Germany and abroad and initial sales were made.