Innovations
Innovations play a central role in ThyssenKrupp's strategy – including in times of global economic crisis. Our researchers and developers continued their work in the reporting period, developing numerous new and improved products and processes in close cooperation with our customers and also with external partners. In addition to high customer value, many new developments offer enhanced resource and energy efficiency.
Steel: New tailored plates
As part of our cooperation with the Japanese steel producer JFE we are working on globally available high-strength steels in the 800 – 1,200 megapascal range. Combining outstanding strength with good forming properties, these materials contribute to further weight savings in auto construction which helps reduce fuel consumption and lower CO2 emissions. One new hot-rolled variant is almost production-ready, while another is currently undergoing testing.
The laser-welded tailored product family developed by the Steel segment has now been extended to include heavy plate. As with tailored blanks, which have been used successfully in auto construction for some time, the new tailored plates are made of individual plates of different grades and thickness to match the stresses in the finished component. This not only reduces component weight but also lowers manufacturing costs for our customers. At present prototype lightweight dumper bodies are being tested by our customer. ThyssenKrupp Steel is currently the only producer offering tailored plates of this kind.
Stainless: Innovative material for high-voltage power lines
Innovative nickel alloys are opening the way to enhanced products for the energy sector. An attractive material innovation currently under development is Pernifer 36 MoW. With its low thermal expansion, this material is highly resistant to sagging. Designed for use in overhead power lines, it could permit the distance between pylons to be doubled. Alternatively, if the pylon arrangement remains unchanged, significantly higher voltages can be transmitted.
Important progress has been made in the development and implementation of stainless steel structural automotive components under a joint R&D project of the major European stainless and auto manufacturers. Successes include the development of virtual components by simulation, an analysis of the material formability required in auto construction, and the development of tools suitable for manufacturing stainless steel structural components.
Technologies: Active steering systems made quieter
To meet the growing requirements for vehicle interior noise control, the reduction of vibrations in innovative active steering systems fitted in modern vehicles is of central importance. With a new housing design featuring the composite material Bondal® developed by the Steel segment, the engineers from Technologies succeeded in damping the vibrations of the servo motor and gearbox much more efficiently than is possible with conventional steel designs. With the composite material permitting reduced wall thickness, these housings help lower component weight. Initial prototypes have met with keen interest from our customers.
Elevator: Eco-friendly elevators with regenerative drive system
ThyssenKrupp Elevator is constantly working to reduce the energy requirements of its products. An outstanding example are the eco-friendly passenger elevators for Deutsche Börse's new headquarters in Eschborn near Frankfurt/Main. In keeping with the ecological design of the building, most of the elevators are fitted with regenerative drives. Energy generated when braking the cabs is converted into electricity and fed back to the power supply system. This lowers energy consumption by more than 30% compared with conventional designs. In addition, some of the elevator cabs are fitted with energy-efficient LED lighting. Compared with conventional light bulbs, these lights use up to 90% less energy and last considerably longer.
Services: Maintenance of roll stands improved
Engineers and technicians in the Services segment have developed a process for roll stand maintenance which permits longer intervals between repairs and reduces repair time. A common cause of wear in roll stands is the vibration of the bolted fastenings on the wear plates. The new process, in which a two-component material is injected in the cavity between roll stand and wear plate, significantly dampens these vibrations.