Knowledge for the materials of tomorrow: Our ... - ThyssenKrupp AG
Knowledge for the materials of tomorrow: Our ... - ThyssenKrupp AG
Knowledge for the materials of tomorrow: Our ... - ThyssenKrupp AG
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<strong>Knowledge</strong><br />
<strong>for</strong> <strong>the</strong> <strong>materials</strong> <strong>of</strong> <strong>tomorrow</strong>:<br />
<strong>Our</strong> technologies, processes<br />
and employees<br />
<strong>ThyssenKrupp</strong> Stainless
2<br />
Contents<br />
03-07<br />
03-05<br />
06<br />
07<br />
08-37<br />
08-23<br />
08<br />
10<br />
10<br />
17<br />
24-31<br />
24<br />
24<br />
26<br />
<strong>ThyssenKrupp</strong> Stainless –<br />
an overview<br />
Companies<br />
Production sites &<br />
service centers<br />
Materials<br />
Business fields<br />
Corrosion-, acid- and<br />
heat-resistant steels:<br />
Stainless steel<br />
Schematic <strong>of</strong> <strong>the</strong><br />
production process<br />
Definition<br />
Manufacturing process<br />
Applications<br />
High-per<strong>for</strong>mance alloys:<br />
Nickel alloys<br />
Definition<br />
Manufacturing process<br />
Applications<br />
32-35<br />
32<br />
32<br />
34<br />
36-37<br />
38-39<br />
40<br />
41<br />
42-45<br />
46<br />
High-per<strong>for</strong>mance alloys:<br />
Titanium<br />
Definition<br />
Manufacturing process<br />
Applications<br />
Processing:<br />
Open-die <strong>for</strong>ge<br />
Distribution network &<br />
service centers<br />
Research and development<br />
Environmental protection<br />
Employees<br />
Glossary<br />
47<br />
Contacts
Stainless steel<br />
High-per<strong>for</strong>mance<br />
alloys<br />
Processing<br />
<strong>ThyssenKrupp</strong> Nirosta<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
<strong>ThyssenKrupp</strong> Mexinox<br />
<strong>ThyssenKrupp</strong> Stainless USA<br />
(under construction)<br />
Shanghai Krupp Stainless<br />
<strong>ThyssenKrupp</strong> Stainless International<br />
(Sales company with own service centers)<br />
<strong>ThyssenKrupp</strong> VDM<br />
<strong>ThyssenKrupp</strong> Titanium<br />
Tubificio di Terni<br />
Società delle Fucine<br />
<strong>ThyssenKrupp</strong> Stainless – an overview<br />
Companies<br />
<strong>ThyssenKrupp</strong> Stainless<br />
<strong>ThyssenKrupp</strong> Stainless is an independent<br />
segment within <strong>the</strong> <strong>ThyssenKrupp</strong><br />
Group. <strong>ThyssenKrupp</strong> Stainless <strong>AG</strong>, as<br />
<strong>the</strong> segment holding company, combines<br />
all <strong>of</strong> <strong>ThyssenKrupp</strong>’s activities<br />
in stainless steel flat products and <strong>the</strong><br />
high-per<strong>for</strong>mance <strong>materials</strong> nickel alloys<br />
and titanium. It manages and coordinates<br />
its associated business units,<br />
which have operations worldwide.<br />
Stainless steel & High-per<strong>for</strong>mance alloys<br />
Product portfolio <strong>of</strong> <strong>the</strong> <strong>ThyssenKrupp</strong> Stainless group<br />
Slab Hot band<br />
black<br />
Hot band<br />
white<br />
With plants in Germany, Italy, Mexico,<br />
China and <strong>the</strong> USA, it employs around<br />
12,000 people. The Stainless group is<br />
<strong>the</strong> world’s number one manufacturer <strong>of</strong><br />
stainless flat products and holds leading<br />
positions in high-per<strong>for</strong>mance <strong>materials</strong>.<br />
Cold-rolled<br />
strip<br />
Precision<br />
strip<br />
Nickel<br />
alloys<br />
Titanium Pipes Forging<br />
products<br />
3
4<br />
<strong>ThyssenKrupp</strong> Nirosta<br />
<strong>ThyssenKrupp</strong> Nirosta GmbH is one <strong>of</strong><br />
<strong>the</strong> world’s leading manufacturers <strong>of</strong><br />
stainless steel flat products. The company<br />
has several sites in Germany,<br />
<strong>the</strong> largest stainless market in Europe.<br />
Crude steel is produced at <strong>the</strong> sites<br />
in Bochum and Krefeld. The slabs<br />
manufactured <strong>the</strong>re are rolled into<br />
hot band at <strong>the</strong> hot strip mill <strong>of</strong> sister<br />
company <strong>ThyssenKrupp</strong> Steel in<br />
Bochum. From this, <strong>ThyssenKrupp</strong><br />
Nirosta produces treated (pickled)<br />
hot band as well as cold-rolled strip<br />
in various finished, delivery <strong>for</strong>ms<br />
and sizes at its plants in Dillenburg,<br />
Düsseldorf-Benrath and Krefeld.<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni,<br />
Italy’s only manufacturer <strong>of</strong> stainless<br />
flat steels, is located in Europe’s second<br />
largest stainless market. The Terni plant<br />
is a fully integrated mill and has a steel<br />
melt shop with a stainless capacity <strong>of</strong><br />
around 1.5 million tons per year. The<br />
slabs produced <strong>the</strong>re are rolled into hot<br />
band black on a hot strip mill and finished<br />
in a cold rolling mill. Some <strong>of</strong> <strong>the</strong><br />
hot band black is currently still supplied<br />
to <strong>the</strong> cold rolling mills <strong>of</strong> <strong>the</strong> Stainless<br />
group in Mexico and China. In addition,<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
has several producing subsidiaries.<br />
<strong>ThyssenKrupp</strong> Titanium, with its sites<br />
in Terni, Italy and Essen, Germany,<br />
is <strong>the</strong> largest titanium producer in<br />
Western Europe. In <strong>the</strong> processing<br />
area, Tubificio di Terni is engaged in <strong>the</strong><br />
manufacture <strong>of</strong> welded pipes made <strong>of</strong><br />
stainless steels. Ano<strong>the</strong>r company is<br />
<strong>the</strong> Società delle Fucine open-die <strong>for</strong>ge,<br />
which operates <strong>the</strong> largest <strong>for</strong>ging<br />
press in Europe and specializes in <strong>the</strong><br />
production <strong>of</strong> large and heavy components,<br />
primarily <strong>for</strong> <strong>the</strong> energy sector.<br />
<strong>ThyssenKrupp</strong> Mexinox<br />
The <strong>ThyssenKrupp</strong> Mexinox cold rol-<br />
ling mill in San Luis Potosí is <strong>the</strong> only<br />
manufacturer <strong>of</strong> stainless flat products<br />
in Mexico. <strong>ThyssenKrupp</strong> Mexinox<br />
has a cold-rolled strip capacity <strong>of</strong><br />
more than 250,000 tons a year. For<br />
<strong>the</strong> most part, <strong>the</strong> mill is currenly<br />
still supplied with hot band black and<br />
white from <strong>the</strong> group’s European<br />
plants. After <strong>the</strong> launch <strong>of</strong> <strong>the</strong> new<br />
mill in <strong>the</strong> USA, hot band will be supplied<br />
from <strong>the</strong>re. The mill primarily<br />
serves <strong>the</strong> North American market.
<strong>ThyssenKrupp</strong> Stainless USA<br />
<strong>ThyssenKrupp</strong> Stainless USA is currently<br />
building a new integrated mill <strong>for</strong> stainless<br />
flat products in Calvert, Alabama.<br />
The project in <strong>the</strong> USA is an important<br />
element <strong>of</strong> <strong>the</strong> growth strategy <strong>of</strong><br />
<strong>ThyssenKrupp</strong> Stainless. The Stainless<br />
group’s direct entry into <strong>the</strong> USA will<br />
significantly expand our business in <strong>the</strong><br />
NAFTA market. After <strong>the</strong> new mill’s projected<br />
start <strong>of</strong> production at <strong>the</strong> end <strong>of</strong><br />
2009, <strong>ThyssenKrupp</strong> Stainless USA will<br />
begin delivery to direct clients in North<br />
America toge<strong>the</strong>r with <strong>ThyssenKrupp</strong><br />
Mexinox, which will also be supplied<br />
with hot band from <strong>the</strong> new mill in<br />
<strong>the</strong> USA, beginning in mid-2011.<br />
Shanghai Krupp Stainless<br />
The Shanghai Krupp Stainless plant<br />
in China at <strong>the</strong> Shanghai site is a joint<br />
venture with <strong>the</strong> Chinese steel group<br />
Baosteel and produces stainless<br />
cold-rolled flat products. With its high<br />
growth rates, China is <strong>the</strong> largest national<br />
market <strong>for</strong> stainless flat products.<br />
Hot band is supplied to <strong>the</strong> mill both<br />
from <strong>the</strong> group’s European stainless<br />
plants and from local manufacturers.<br />
<strong>ThyssenKrupp</strong> Stainless International<br />
<strong>ThyssenKrupp</strong> Stainless International<br />
is primarily responsible <strong>for</strong> sales <strong>of</strong> <strong>the</strong><br />
Stainless group’s stainless flat products<br />
in all markets where <strong>ThyssenKrupp</strong><br />
Stainless is not represented by its own<br />
manufacturing companies. It operates<br />
service centers in Spain, <strong>the</strong> UK,<br />
France, Poland, Hungary, Turkey and<br />
China. In addition, sales companies,<br />
some holding inventories, are located<br />
at many locations worldwide.<br />
<strong>ThyssenKrupp</strong> VDM<br />
<strong>ThyssenKrupp</strong> VDM, with its main<br />
<strong>of</strong>fice in Germany, is one <strong>of</strong> <strong>the</strong> world’s<br />
leading suppliers <strong>of</strong> high-per<strong>for</strong>mance<br />
nickel alloys and special stainless<br />
steels. In Germany, <strong>ThyssenKrupp</strong> VDM<br />
has production sites in Unna, Werdohl,<br />
Siegen and Altena. American subsidiary<br />
<strong>ThyssenKrupp</strong> VDM USA has plants in<br />
Florham Park, New Jersey and Reno,<br />
Nevada.<br />
5
6<br />
Stainless steel<br />
Germany<br />
1: <strong>ThyssenKrupp</strong> Nirosta GmbH,<br />
plant Krefeld<br />
2: <strong>ThyssenKrupp</strong> Nirosta GmbH,<br />
plant Düsseldorf-Benrath<br />
3: <strong>ThyssenKrupp</strong> Nirosta GmbH,<br />
plant Bochum<br />
4: <strong>ThyssenKrupp</strong> Nirosta GmbH,<br />
plant Dillenburg<br />
5: <strong>ThyssenKrupp</strong> Nirosta Präzisionsband<br />
GmbH, plant Schalksmühle<br />
Europe<br />
6: <strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
S.p.A., plant Terni/Italy<br />
America<br />
7: <strong>ThyssenKrupp</strong> Mexinox S.A. de C.V.,<br />
plant San Luis Potosí/Mexico<br />
8: <strong>ThyssenKrupp</strong> Stainless USA,<br />
plant Calvert/Alabama, USA<br />
(under construction)<br />
Asia<br />
9: Shanghai Krupp Stainless Co. Ltd.,<br />
plant Pudong New Area/Shanghai,<br />
P.R.China<br />
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Production sites & service centers<br />
Germany Europe<br />
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America<br />
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Nickel alloys<br />
Germany<br />
10: <strong>ThyssenKrupp</strong> VDM GmbH,<br />
plant Unna<br />
11: <strong>ThyssenKrupp</strong> VDM GmbH,<br />
plant Altena<br />
12: <strong>ThyssenKrupp</strong> VDM GmbH,<br />
plant Werdohl<br />
13: <strong>ThyssenKrupp</strong> VDM GmbH,<br />
plant Siegen<br />
America<br />
14: <strong>ThyssenKrupp</strong> VDM USA, Inc.,<br />
plant Reno/Nevada, USA<br />
15: <strong>ThyssenKrupp</strong> VDM USA, Inc.,<br />
plant Florham Park/New Jersey, USA<br />
Legend<br />
Titanium<br />
Germany<br />
16: <strong>ThyssenKrupp</strong> Titanium GmbH,<br />
plant Essen<br />
Europe<br />
17: <strong>ThyssenKrupp</strong> Titanium S.p.A,<br />
plant Terni/Italy<br />
Processing<br />
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Europe<br />
18: Tubificio di Terni S.p.A.,<br />
plant Terni/Italy<br />
19: Società delle Fucine S.p.A.,<br />
plant Terni/Italy<br />
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Asia<br />
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Stainless steel<br />
service center<br />
Germany<br />
20: smbChromstahl GmbH,<br />
Langenhagen<br />
21: <strong>ThyssenKrupp</strong> Nirosta Service-Center<br />
GmbH, Wilnsdorf-Anzhausen<br />
22: EBOR Edelstahl GmbH,<br />
Sachsenheim<br />
Europe<br />
23: <strong>ThyssenKrupp</strong> Stainless UK Ltd.,<br />
Birmingham/Great Britain<br />
24: <strong>ThyssenKrupp</strong> Stainless Benelux B.V.,<br />
Rotterdam/Ne<strong>the</strong>rlands<br />
25: <strong>ThyssenKrupp</strong> Stainless France S.A.,<br />
Paris/France<br />
26: <strong>ThyssenKrupp</strong> Stainless DVP, S.A.,<br />
Barcelona/Spain<br />
27: Terninox S.p.A., Ceriano Laghetto,<br />
Mailand/Italy<br />
28: <strong>ThyssenKrupp</strong> Stainless Polska,<br />
Katovice/Poland<br />
29: <strong>ThyssenKrupp</strong> Silco Inox Kft.,<br />
Bátonyterenye/Hungary<br />
30: <strong>ThyssenKrupp</strong> Eurinox Paslanmaz Celik<br />
Servis Merkezi A.S., Istanbul/Turkey<br />
Asia<br />
31: <strong>ThyssenKrupp</strong> Stainless International<br />
(Guangzhou) Ltd., P.R.China<br />
��
Requirements <strong>for</strong> material properties<br />
Materials<br />
<strong>ThyssenKrupp</strong> Stainless is a major supplier<br />
<strong>of</strong> a wide range <strong>of</strong> metallic <strong>materials</strong>.<br />
Its stainless steel, nickel alloy and<br />
titanium products are at <strong>the</strong> top <strong>of</strong> <strong>the</strong><br />
pyramid in terms <strong>of</strong> material properties.<br />
The range <strong>of</strong> stainless steels is so extensive<br />
that <strong>the</strong>y are used in almost<br />
every aspect <strong>of</strong> daily life. In comparison<br />
with conventional unalloyed steels,<br />
<strong>the</strong>y display significantly better resistance<br />
to corrosion. The reason <strong>for</strong><br />
this is a protective passive coating <strong>of</strong><br />
chromium oxide. In addition to corrosion<br />
resistance, stainless steel is<br />
also acid- and heat-resistant, which<br />
extends its range <strong>of</strong> applications<br />
fur<strong>the</strong>r. In addition, stainless steels<br />
are easy to clean, hygienic, <strong>for</strong>mable,<br />
durable and environmentally friendly.<br />
Nickel is an extremely corrosion-resistant<br />
metal. In addition to its function<br />
as an alloying component <strong>of</strong> stainless<br />
steel, it is melted with o<strong>the</strong>r metals<br />
to create nickel alloys that have considerably<br />
higher corrosion resistance and<br />
strength than pure nickel. Depending<br />
on alloy content, <strong>the</strong>y are individually<br />
tailored <strong>for</strong> different applications.<br />
Titanium is <strong>the</strong> material <strong>of</strong> choice<br />
when low weight, high strength and<br />
<strong>the</strong> highest level <strong>of</strong> corrosion resistance<br />
are called <strong>for</strong>. Ano<strong>the</strong>r special characteristic<br />
is its low specific density.<br />
Titanium<br />
Nickel alloys<br />
Stainless steel<br />
7
8<br />
Business fields<br />
Corrosion-, acid- and heat-resistant steels:<br />
Stainless steel<br />
Schematic <strong>of</strong> <strong>the</strong> production process
10<br />
Definition<br />
Stainless steels are defined as iron<br />
alloys with a minimum content <strong>of</strong><br />
10.5 % chromium and a maximum <strong>of</strong><br />
1.2 % carbon. One <strong>of</strong> <strong>the</strong> most important<br />
properties <strong>of</strong> stainless steels is <strong>the</strong>ir<br />
resistance to corrosion. The reason <strong>for</strong><br />
this is a passive coating that acts as a<br />
barrier between <strong>the</strong> alloy and <strong>the</strong> media<br />
surrounding it. The passive coating<br />
is impermeable and insoluble. When<br />
damaged, it repairs itself using oxygen.<br />
Chromium plays an important role in<br />
creating and maintaining <strong>the</strong> passive<br />
coating. O<strong>the</strong>r elements can support<br />
<strong>the</strong> passive coating. However, no o<strong>the</strong>r<br />
element by itself can recreate <strong>the</strong><br />
special properties <strong>of</strong> rustpro<strong>of</strong> steels.<br />
Production process<br />
Stainless steels pass through <strong>the</strong> production<br />
steps: steel melt shop (melting<br />
stage), hot rolling mill (hot shaping),<br />
cold rolling mill (cold shaping). In <strong>the</strong><br />
stainless steel manufacturing process,<br />
a distinction is made between hot<br />
band and cold-rolled strip (cold strip).
Slab<br />
The slab is a compact block <strong>of</strong> crude<br />
steel, usually a product <strong>of</strong> <strong>the</strong> continuous<br />
casting process in <strong>the</strong> steel melt<br />
shop, which is used as <strong>the</strong> feedstock<br />
<strong>for</strong> <strong>the</strong> hot rolling mills to produce<br />
rolled hot band. Its width generally<br />
corresponds to <strong>the</strong> width <strong>of</strong> <strong>the</strong> subsequent<br />
hot band and cold-rolled strip<br />
and measures 1,000 – 1,600 mm;<br />
in some cases it may even measure<br />
2,100 mm. The length <strong>of</strong> <strong>the</strong> slab can<br />
be up to 12 meters, while its thickness<br />
is around 200 to 250 mm.<br />
Hot band<br />
Stainless steel hot band is hot-rolled<br />
strip with a width <strong>of</strong> more than 600<br />
mm. The a<strong>for</strong>ementioned slabs serve<br />
as <strong>the</strong> feedstock, which is run through<br />
a hot rolling mill and shaped into a<br />
much thinner and longer strip and<br />
subsequently wound into coils.<br />
Cold-rolled strip<br />
Stainless steel cold-rolled strip is a coldreduced<br />
flat product in widths <strong>of</strong> up to<br />
about 2,000 mm and thicknesses <strong>of</strong><br />
0.2 to 8 mm which is wound into a coil.<br />
The cold-rolling <strong>of</strong> a strip is a shaping<br />
process that follows hot rolling. The<br />
advantages <strong>of</strong> cold-rolled strip over hot<br />
band lie in better surface quality, narrower<br />
tolerances and thinner dimensions.<br />
11
12<br />
Steel melt shop<br />
The steel melt shop represents <strong>the</strong> first<br />
step in <strong>the</strong> production <strong>of</strong> cold-rolled<br />
strip. The raw <strong>materials</strong>, scrap (alloyed<br />
and unalloyed) and ferro alloys,<br />
are melted toge<strong>the</strong>r in an electric arc<br />
furnace.The lid <strong>of</strong> <strong>the</strong> furnace is lifted<br />
and swung to <strong>the</strong> side in order to load<br />
it. The scrap is lifted over <strong>the</strong> furnace<br />
in large baskets and charged into <strong>the</strong><br />
furnace. The lid is replaced, electrodes<br />
are lowered, and <strong>the</strong>y ignite an electrical<br />
arc with <strong>the</strong> scrap. With a high<br />
degree <strong>of</strong> efficiency, <strong>the</strong> arc trans<strong>for</strong>ms<br />
<strong>the</strong> electrical energy into melting heat.<br />
During <strong>the</strong> melting process, <strong>the</strong> arc<br />
reaches temperatures <strong>of</strong> up to 3,500 °C,<br />
and <strong>the</strong> molten steel can reach up to<br />
1,800 °C. The high temperatures also<br />
allow <strong>the</strong> disintegration <strong>of</strong> hard-to-melt<br />
alloys in <strong>the</strong> scrap metal. The additional<br />
injection <strong>of</strong> oxygen or fuel gas mixtures<br />
speeds up <strong>the</strong> melting process. After<br />
that, <strong>the</strong> molten material is fur<strong>the</strong>r<br />
processed in an AOD converter (AOD<br />
= Argon Oxygen Decarburization).<br />
The main objective <strong>of</strong> this is to reduce<br />
<strong>the</strong> carbon to a target amount by<br />
injecting an oxygen-argon mixture.<br />
After AOD treatment, <strong>the</strong> molten material<br />
is poured into a ladle. The rigorous<br />
quality requirements placed on <strong>the</strong>se<br />
steels make secondary treatment necessary.<br />
This is done through secondary<br />
steelmaking, ladle or vacuum treatment<br />
<strong>of</strong> liquid steel. The goal <strong>of</strong> this processing<br />
step, in addition to homogenizing<br />
<strong>the</strong> molten material and maintaining<br />
close and/or exact temperature limits, is<br />
primarily to establish as low as possible<br />
a concentration <strong>of</strong> carbon, nitrogen,<br />
hydrogen and phosphorus as well as<br />
various trace elements in <strong>the</strong> steel.<br />
The liquid steel is <strong>the</strong>n fur<strong>the</strong>r processed.<br />
Steel intended <strong>for</strong> hot rolling<br />
is cast by <strong>the</strong> continuous casting process.<br />
A cooled bottomless ingot mold<br />
is used <strong>for</strong> this purpose, into which<br />
<strong>the</strong> liquid metal is poured. Inside <strong>the</strong><br />
mold, <strong>the</strong> outer shell <strong>of</strong> <strong>the</strong> strand<br />
solidifies and is drawn out in casting<br />
direction, encasing <strong>the</strong> liquid core. After<br />
leaving <strong>the</strong> mold, <strong>the</strong> strand’s shell is<br />
fur<strong>the</strong>r cooled with water until it has<br />
completely solidified. After it solidifies,<br />
<strong>the</strong> strand is cut into lengths by torch<br />
burners to obtain <strong>the</strong> semi-finished<br />
product, <strong>the</strong> slab. Slabs serve as <strong>the</strong><br />
feedstock <strong>for</strong> <strong>the</strong> hot rolling mills.
Hot rolling mill<br />
In <strong>the</strong> hot rolling mill, <strong>the</strong> slabs are<br />
normally rolled out on a continuous<br />
hot strip mill. In this process, <strong>the</strong> slabs<br />
from <strong>the</strong> continuous caster are heated<br />
to <strong>the</strong> required rolling temperature in<br />
reheating furnaces and <strong>the</strong>n reduced to<br />
<strong>the</strong> dimensions needed <strong>for</strong> hot rolling by<br />
reversing breakdown and edging mills.<br />
The finishing train is <strong>the</strong> last step in <strong>the</strong><br />
hot strip mill. It generally consists <strong>of</strong><br />
five to seven four-high stands lined up<br />
one after <strong>the</strong> o<strong>the</strong>r. The finishing train<br />
rolls <strong>the</strong> strip in a single pass to <strong>the</strong><br />
required final thickness <strong>of</strong> <strong>the</strong> hot strip.<br />
Downstream <strong>of</strong> <strong>the</strong> finishing train is an<br />
exit roller table with cooling devices and<br />
a coiler. The hot band black is used<br />
as feedstock <strong>for</strong> <strong>the</strong> cold rolling mill.<br />
Strip caster<br />
A pre-industrial strip caster was set<br />
up at <strong>the</strong> <strong>ThyssenKrupp</strong> Nirosta plant<br />
in Krefeld at <strong>the</strong> end <strong>of</strong> 1999. Stripcasting<br />
technology makes it possible<br />
to cast hot band black directly from<br />
molten steel. This hot band can be<br />
used in <strong>the</strong> cold rolling mill without any<br />
fur<strong>the</strong>r processing, or it can simply<br />
be sold as hot band. The high energy<br />
requirements <strong>for</strong> slab reheating and<br />
hot rolling are eliminated. After years<br />
<strong>of</strong> development, <strong>the</strong> caster is now suitable<br />
<strong>for</strong> industrial use. It will primarily<br />
be used in <strong>the</strong> production <strong>of</strong> hot band<br />
<strong>materials</strong> that cannot be manufactured<br />
using conventional technology.<br />
13
14<br />
Cold rolling mill<br />
In cold rolling, hot band white is<br />
fur<strong>the</strong>r reduced in thickness at room<br />
temperature; in subsequent strip processing,<br />
it is adjusted to meet <strong>the</strong><br />
customer’s processing requirements.<br />
Hot band preparation<br />
Hot band is first prepared <strong>for</strong> cold rolling<br />
in <strong>the</strong> stainless-steel treatment facilities.<br />
The hot band black is heat treated<br />
(annealed). For some chromium steels<br />
this takes place in batch furnaces,<br />
while chromium-nickel steels in particular<br />
are subjected to continuous heat<br />
treatment in an annealing and pickling<br />
line. In subsequent pickling, <strong>the</strong> scale,<br />
or oxide coating, is removed from <strong>the</strong><br />
surface <strong>of</strong> <strong>the</strong> hot band black. After a<br />
mechanical descaling process, pickling<br />
liquors remove <strong>the</strong> remaining scale<br />
from <strong>the</strong> metallic surface <strong>of</strong> <strong>the</strong> hotrolled<br />
strip. The annealed and pickled<br />
hot band white is <strong>the</strong>n wound into coils<br />
and is now ready <strong>for</strong> cold rolling.<br />
Cold rolling<br />
The process <strong>of</strong> cold rolling, in which<br />
<strong>the</strong> thickness <strong>of</strong> <strong>the</strong> hot band white is<br />
reduced to <strong>the</strong> desired final thickness<br />
without prior heating, is generally<br />
carried out on 20-high cold rolling<br />
stands. This type <strong>of</strong> cold-rolling stand<br />
produces <strong>the</strong> high rolling <strong>for</strong>ces necessary<br />
<strong>for</strong> stainless steels, and at <strong>the</strong><br />
same time it guarantees compliance<br />
with <strong>the</strong> finish and dimensional tolerances<br />
required by <strong>the</strong> customer.
Finish annealing<br />
The material hardened in <strong>the</strong> cold rolling<br />
process must be reheated and recrystallized<br />
in order to restore its <strong>for</strong>ming<br />
properties <strong>for</strong> fur<strong>the</strong>r processing. In <strong>the</strong><br />
next step, <strong>the</strong>re<strong>for</strong>e, <strong>the</strong> cold-rolled strip<br />
is once more subjected to annealing.<br />
This is per<strong>for</strong>med ei<strong>the</strong>r on annealing<br />
and pickling lines, where <strong>the</strong> cold-rolled<br />
strip is heat treated in an open atmosphere<br />
and <strong>the</strong>n again descaled in <strong>the</strong><br />
pickling line, or – <strong>for</strong> particularly high<br />
surface requirements – in <strong>the</strong> inert gas<br />
atmosphere <strong>of</strong> a bright annealing line.<br />
Final heat treatment in an inert gas<br />
atmosphere retains and enhances <strong>the</strong><br />
shiny metallic surface <strong>of</strong> <strong>the</strong> cold strip.<br />
Final processing<br />
In <strong>the</strong> following processing stages <strong>the</strong><br />
strip is gently re-rolled (skin passed),<br />
and if necessary it is tension leveled<br />
and trimmed. These finishing steps<br />
are generally carried out separately.<br />
For <strong>the</strong> final adjustments to meet <strong>the</strong><br />
mechanical properties, flatness, finish<br />
and brightness specified by <strong>the</strong> customer,<br />
<strong>the</strong> heat-treated cold-rolled strip is<br />
gently re-rolled (skin passed). This takes<br />
place on two-high or four-high skin-pass<br />
mills with polished work rolls. Where<br />
necessary, grinding lines create various<br />
ground finishes on <strong>the</strong> strip surfaces.<br />
For very high flatness requirements in<br />
stainless-steel sheet, skin-passed even<br />
non-skin-passed material is processed<br />
on tension-leveling equipment. This<br />
removes any residual stresses that<br />
could lead to unevenness in <strong>the</strong> strip.<br />
Finishing shop<br />
Finishing is <strong>the</strong> final operation in a cold<br />
rolling mill. This is where coils are tailored<br />
to customer requirements. Slitting<br />
and cut-to-length lines slice <strong>the</strong> coils<br />
into narrower strips or sheets. Strips<br />
and sheets can be given a plastic film<br />
coating to provide surface protection<br />
<strong>for</strong> fur<strong>the</strong>r processing by <strong>the</strong> customer.<br />
15
16<br />
Precision strip<br />
Precision strip is defined as cold-rolled<br />
strip made <strong>of</strong> stainless steels with a<br />
maximum width <strong>of</strong> 650 mm and gauges<br />
between 0.05 and 1.5 mm. At gauges<br />
between 0.4 and 1.5 mm, <strong>the</strong>re are<br />
overlaps with cold-rolled wide strip,<br />
but only with regard to physical size.<br />
Only a specially rolled and cut product<br />
can meet <strong>the</strong> specific demands made<br />
<strong>of</strong> precision strip, such as minimal<br />
dimensional tolerances, special strip<br />
edge conditions, maximum flatness<br />
and strengths <strong>of</strong> 2000 N/mm 2 and<br />
higher. Some examples <strong>of</strong> <strong>the</strong>se<br />
applications are surgical instruments,<br />
hypodermic needles, seals, valves and<br />
watch springs. Pickling and annealing<br />
lines condition <strong>the</strong> hot band black<br />
<strong>for</strong> <strong>the</strong> cold-rolling process or impart<br />
required mechanical and technological<br />
properties after cold rolling. Tension<br />
leveling equipment optimizes flatness.<br />
Welded pipes<br />
Welded pipes made <strong>of</strong> stainless steel<br />
are manufactured by Tubificio di<br />
Terni, a subsidiary <strong>of</strong> <strong>ThyssenKrupp</strong><br />
Acciai Speciali Terni. The automotive<br />
industry is a principal customer.<br />
In this process, stainless-steel strips<br />
are cut to corresponding widths<br />
and <strong>for</strong>med into longitudinally welded<br />
pipes using special welding<br />
equipment. Cutting machines <strong>the</strong>n cut<br />
<strong>the</strong> pipes to specific lengths according<br />
to <strong>the</strong> customer’s requirements.
Applications<br />
A wide variety <strong>of</strong> microstructures can be<br />
created in stainless steels through control<br />
<strong>of</strong> alloy composition and heat treatment.<br />
These microstructures determine<br />
material properties within broad limits.<br />
Based on microstructure, stainless<br />
steels are broken down into rough categories.<br />
The following types are differentiated:<br />
austenitic steels, ferritic steels,<br />
martensitic steels and ferritic-austenitic<br />
(duplex) steels. In terms <strong>of</strong> production<br />
volume, <strong>the</strong> austenitic and ferritic steels<br />
are <strong>the</strong> most significant. However, <strong>the</strong><br />
o<strong>the</strong>r types are essential <strong>for</strong> a variety<br />
<strong>of</strong> highly exacting applications.<br />
The numerous fields <strong>of</strong> application <strong>for</strong><br />
stainless steels include architecture,<br />
household goods, food manufacture,<br />
<strong>the</strong> automotive industry, transportation<br />
and <strong>the</strong> chemical and energy industries.<br />
17
18<br />
Facilities in <strong>the</strong> business field stainless steel<br />
Steel melt shop<br />
Arc furnace<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Krefeld Terni Calvert, AL<br />
Type AC AC AC AC<br />
Number <strong>of</strong> units [no.] 1 1 2 1<br />
Nominal rating [MVA] 135 80 110/120 150<br />
Average tap weight [t] 150 80 150/125 160<br />
AC = Alternating Current<br />
Converter<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Krefeld Terni Calvert, AL<br />
Type KCB-S AOD-L AOD-L AOD-L<br />
Number <strong>of</strong> units [no.] 2 2 2 1<br />
Average heat weight [t ] 80 90 140 180<br />
KCB-S = Krupp combined blowing - Stainless AOD-L = Argon Oxygen Decarburization-Lance<br />
Continuous caster<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Krefeld Terni Calvert, AL<br />
Number <strong>of</strong> units [no.] 1 1 1 2 1<br />
Radius [m] 10.5 10.8 — 8.0/8.5 —<br />
Number <strong>of</strong> strands [no.] 1 1 2 1 1<br />
Min./max. slab width [mm] 865-1,650 600-1,600 600-1,300 700-1,600 —<br />
Thickness [mm] 240 240 222 215 230<br />
Max. slab length [m] 9.6 12 12 11 11.5<br />
Slab grinding shop<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Krefeld Terni Calvert, AL<br />
Number <strong>of</strong> grinders [no.] 4 3 4 2<br />
Hot strip mills<br />
Products<br />
Company <strong>ThyssenKrupp</strong> Steel <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Terni Calvert, AL<br />
Min./max strip width [mm] 600-1,630 600-1,560 800-1,870<br />
Min./max strip thickness [mm] 1.5-20.0 1.5-13.0 1.5-25.4<br />
Coil weight [kg/mm] 20.5 18 23<br />
Max. coil weight [t] 32.5 28 36<br />
Reheating furnaces<br />
Company <strong>ThyssenKrupp</strong> Steel <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Terni Calvert, AL<br />
Type Pusher type furnace Walking beam furnace Walking beam furnace Walking beam furnace<br />
Number <strong>of</strong> units [no.] 1 3 1 3<br />
Capacity [t/h] 220 250 225 380<br />
Roughing stands<br />
* under construction<br />
* under construction<br />
* under construction<br />
Company <strong>ThyssenKrupp</strong> Steel <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Terni Calvert, AL<br />
Driving rate [kW] 4 x 4,860 2 x 5,000 2 x 4,250/2 x 8,500<br />
* under construction
Finishing stands<br />
Company <strong>ThyssenKrupp</strong> Steel <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Stainless USA *<br />
Site Bochum Terni Calvert, AL<br />
Type 4 high 4 high 4 high<br />
Number <strong>of</strong> units [no.] 7 7 7<br />
Installed drive rating [MW] 62.5 32.4 84<br />
Work roll diameter [mm] 775/675 760/680 850/700<br />
Min./max. Back-up roll<br />
diameter<br />
[mm] 1,530/1,360 1,500/1,460 1,600<br />
Max. final rolling speed [m/s] 15.6 16.0 21<br />
O<strong>the</strong>r features coil box heat-insulated roller table —<br />
Cold rolling mill<br />
Batch Annealing Furnaces Passive Annealing Furnaces<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
<strong>ThyssenKrupp</strong><br />
Acciai Speciali Terni<br />
<strong>ThyssenKrupp</strong><br />
Mexinox<br />
Company<br />
19<br />
<strong>ThyssenKrupp</strong><br />
Acciai Speciali Terni<br />
Site Düsseldorf-Benrath Terni San Luis Potosí Site Terni<br />
Max. coil outside<br />
diameter<br />
[mm] 1,960 1,940 1,960 1,900 1,900 1,900 1,900<br />
Max. coil outside<br />
diameter<br />
[mm]<br />
1,900 1,900<br />
Max. stack height [mm] 4,000 3,825 4,000 4,170 4,040 2,750 4,160 Max. coil width [mm] 1,750 1,750<br />
Max. charge on base [t] 80 75 80 60 60 46 69 Max. coil weight [mm] 28 28<br />
Number <strong>of</strong> furnaces [no.] 11 7 1 4 2 11 1 Number <strong>of</strong> cells [no.] 6 6<br />
Number <strong>of</strong> bases [no.] 18 14 2 7 3 12 2<br />
Number <strong>of</strong> cooling<br />
bells<br />
Annealing and Pickling Lines<br />
[no.] 0 0 0 4 1 3 1<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
Number <strong>of</strong> coils<br />
per cell<br />
Site Krefeld Dillenburg Düsseldorf-Benrath<br />
Min./max. thickness [mm] 2.0-8.0 0.5-6.0 0.4-6.0 0.2-2.0 0.7-6.0 0.3-3.5 1.5-5.5 0.7-8.0<br />
Max. width [mm] 1,570 1,320 1,850 1,380 1,550 1,360 1,350 1,600<br />
Max. coil weight [t] 22 28 29 30 28 23 25 26<br />
Type HAPL HAPL & CAPL CAPL CAPL HAPL & CAPL CAPL HAPL HAPL & CAPL<br />
Max. line speed [m/min] 24 72 80 100 36 42 30 50<br />
Furnace length [m] 35 70 35 62 28 28 no 41<br />
Scale breaker no no no no no no yes no<br />
Number <strong>of</strong> shot blaster<br />
wheels<br />
[no.] 4 8 no no 8 no 8 8<br />
Pickling tanks length [m] 40 67 48 103 45 60 44 42<br />
In-line mill/skin-pass no no no 2 high no no no no<br />
Company <strong>ThyssenKrupp</strong> Acciai Speciali Terni <strong>ThyssenKrupp</strong> Mexinox<br />
[no.]<br />
5 5<br />
Shanghai Krupp<br />
Stainless<br />
Site Terni San Luis Potosí Shanghai<br />
Min./max. thickness [mm] 1.8-7.0 1.5-6.5 1.5-6.5 0.3-3.0 0.3-4.0 0.8-4.0 1.8-6.7 0.3-4.0 1.5-6.0 0.3-3.0<br />
Max. width [mm] 1,550 1,570 1,570 1,570 1,540 1,350 1,350 1,350 1,350 1,340<br />
Max. coil weight [t] 30 30 28 30 28 30 30 30 30 28<br />
Type HAPL HAPL HAPL & CAPL CAPL CAPL HAPL & CAPL HAPL CAPL HAPL CAPL<br />
Max. line speed [m/min] 40 80 25 90 60 30 20 65 80 120<br />
Furnace length [m] 29 86 32 81 47 34 no 34 85 74<br />
Scale breaker no yes no no no no no no yes no<br />
Number <strong>of</strong> shot blaster<br />
wheels<br />
[no.] 8 16 8 no no 8 12 no 12 no<br />
Pickling tanks length [m] 35 132 42 102 51 45 30 50 110 150<br />
In-line mill/skin-pass no 2×6 high no 4 high no no no no no 2 high<br />
HAPL = Hot Annealing and Pickling Line CAPL = Cold Annealing and Pickling Line<br />
* under construction
20<br />
Cold-rolling mills<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Nirosta<br />
Site Krefeld Dillenburg Düsseldorf-Benrath<br />
Min./max. thickness [mm] 0.4-5.0 0.4-7.0 0.6-8.0 0.2-6.0 0.2-6.0 0.2-3.8 0.2-4.0 0.5-6.5 0.4-4.5 0.3-4.0 0.6-10.0<br />
Max. width [mm] 1,030 1,320 1,570 1,350 1,350 1,320 1,350 1,525 1,300 1,300 1,600<br />
Max. coil weight [t] 20 24 22 28 34 23 30 25 23 23 29<br />
Max. speed [m/min] 300 400 500 1,000 800 450 880 540 240/400 450 500<br />
Max. strip tension [kN] 270 400 600 500 500 350 400 450 240 400 600<br />
Max. roll <strong>for</strong>ce [kN] 6,000 8,000 14,000 12,000 8,000 8,000 13,000 13,000 8,000 8,000 16,000<br />
Pay-<strong>of</strong>f reel yes yes yes no no no no no no no yes<br />
AFC no no yes yes yes no yes yes yes yes yes<br />
Company <strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
Site Terni<br />
Min./max. thickness [mm] 1.0-5.0 0.4-6.0 0.2-6.4 0.7-6.5 0.2-6.3 0.2-6.3 0.4-5.0<br />
Max. width [mm] 1,270 1,300 1,370 1,575 1,370 1,370 1,570<br />
Max. coil weight [t] 21 22 27 30 30 27 28<br />
Max. speed [m/min] 235 300 600 800 800 700 600<br />
Max. strip tension [kN] 350 368 500 600 500 500 500<br />
Max. roll <strong>for</strong>ce [kN] 6,000 6,500 8,000 16,000 8,000 7,800 14,000<br />
Pay-<strong>of</strong>f reel yes yes yes no yes yes yes<br />
AFC no yes yes yes yes yes yes<br />
Company <strong>ThyssenKrupp</strong> Mexinox Shanghai Krupp Stainless <strong>ThyssenKrupp</strong> Stainless USA*<br />
Site San Luis Potosí Shanghai Calvert, AL<br />
Min./max. thickness [mm] 0.3-4.0 0.3-4.0 0.3-4.0 0.2-5.0 0.2-6.0 0.2-6.0 0.2-3.0 0.2-5.0 0.2-5.0<br />
Max. width [mm] 1,340 1,340 1,340 1,340 1,340 1,340 1,350 1,625 1,880<br />
Max. coil weight [t] 25 25 25 27 28 28 35 35 35<br />
Max. speed [m/min] 540 590 800 800 800 800 800 800 800<br />
Max. strip tension [kN] 450 450 470 500 500 500 500 200 200<br />
Max. roll <strong>for</strong>ce [kN] 7,800 7,800 9,300 7,850 8,000 8,000 7,850 16,000 16,000<br />
Pay-<strong>of</strong>f reel yes yes yes yes no no no yes yes<br />
AFC no yes yes yes yes yes yes yes yes<br />
Bright Annealing Lines<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
<strong>ThyssenKrupp</strong> Acciai<br />
Speciali Terni<br />
Site Krefeld Dillenburg Düsseldorf-Benrath Terni<br />
Thyssen<br />
Krupp<br />
Mexinox<br />
San Luis<br />
Potosí<br />
Shanghai<br />
Krupp<br />
Stainless<br />
Shanghai<br />
Min./max. thickness [mm] 0.4-3.0 0.3-3.5 0.15-1.2 0.3-3.0 0.2-1.0 0.3-1.5 0.35-2.0 0.3-1.3 0.25-2.0<br />
Max. width [mm] 1,270 1,550 1,350 1,300 1,320 1,550 1,320 1,320 1,340<br />
Max. coil weight [t] 24 25 30 26 26 30 25 22 28<br />
Type electric muffle<br />
muffle +<br />
electric<br />
electric electric<br />
muffle +<br />
electric<br />
muffle muffle muffle<br />
Max. line speed [m/min] 35 50 70 40 70 70 45 45 60<br />
Furnace length [m] 10 24 32 10 21 35 24 24 31<br />
Cooling zones length [m] 10 13 16 7 13 22 15 16 14<br />
In-line/skin-pass no no<br />
2 high +<br />
stretch<br />
leveler<br />
* under construction<br />
no no 4 high no no no
Skin-pass mills<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
Site Krefeld Dillenburg Düsseldorf-Benrath Terni<br />
Min./max. thickness [mm] 0.4-6.0 0.4-6.0 0.2-2.0 0.2-3.5 0.2-1.2 0.3-2.0 0.5-6.0 0.3-3.0 0.3-1.5 0.3-3.0 0.3-5.0<br />
Max. width [mm] 1,350 1,570 1,380 1,550 1,350 1,320 1,550 1,320 1,550 1,570 1,540<br />
Max. coil weight [t] 24 22 — 25 — 25 28 21 — — 25<br />
Type 2 high 2 high<br />
2 high<br />
CAPL<br />
In-line<br />
2 high<br />
2 high<br />
BAL<br />
In-line<br />
2 high 2 high 2 high<br />
Max. speed [m/min] 600 500 120 300 70 370 240 300 70 130 400<br />
Max. strip tension [kN] 300 200 110 140 — 300 140 110 120 200 120<br />
AFC no no no no yes no no no no no no<br />
Company <strong>ThyssenKrupp</strong> Mexinox Shanghai Krupp Stainless <strong>ThyssenKrupp</strong> Stainless USA*<br />
Site San Luis Potosí Shanghai Calvert, AL<br />
Min./max. thickness [mm] 0.3-4.0 0.3-4.0 0.25-2.0 0.3-3.0 0.30-6.50 0.35-3.50<br />
Max. width [mm] 1,340 1,600 1,340 1,340 1,880 1,880<br />
Max. coil weight [t] 25 25 27 28 35 35<br />
Type 2 high 2 high 2 high<br />
2 high<br />
CAPL In-line<br />
4 high<br />
BAL<br />
In-line<br />
2 high<br />
4 high<br />
CAPL<br />
In-line<br />
2 high<br />
2 high<br />
CAPL In-line<br />
Max. speed [m/min] 500 800 600 120 600 140<br />
Max. strip tension [kN] 120 160 300 — 300 —<br />
AFC no yes yes — yes —<br />
BAL = Bright Annealing Line<br />
CAPL = Cold Annealing and Pickling Line<br />
Stretcher Levelling Lines<br />
Company <strong>ThyssenKrupp</strong> Nirosta <strong>ThyssenKrupp</strong> Nirosta<br />
<strong>ThyssenKrupp</strong> Acciai<br />
Speciali Terni<br />
Shanghai Krupp<br />
Stainless<br />
Site Krefeld Dillenburg Terni Shanghai<br />
Min./max. thickness [mm] 0.3-1.2 0.2-2.0 0.15-1.2 0.3-6.0 0.2-2.0<br />
Max. width [mm] 1,550 1,550 1,350 1,570 1,320<br />
Max. coil weight [t] 28 — — 30 27<br />
Type continuous continuous continuous BAL In-line discontinuous continuous<br />
Max. strip tension [kN] 230 640 — 5,000 550<br />
Max. speed [m/min] 250 220 70 100 150<br />
BAL = Bright Annealing Line<br />
* under construction<br />
21
22<br />
Grinding lines<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
Site Krefeld Dillenburg<br />
Düsseldorf-<br />
Benrath<br />
<strong>ThyssenKrupp</strong><br />
Acciai Speciali<br />
Terni<br />
<strong>ThyssenKrupp</strong><br />
Mexinox<br />
Shanghai Krupp<br />
Stainless<br />
<strong>ThyssenKrupp</strong><br />
Stainless USA*<br />
Terni San Luis Potosí Shanghai Calvert, AL<br />
Number <strong>of</strong> units [no.] 1 1 1 3 3 1 2<br />
Min./max. thickness [mm] 0.3-3.0 0.3-6.0 0.5-8.0 0.4-3.0 0.4-4.0 0.3-6.0 0.3-6.0<br />
Max. width [mm] 1,550 1,350 1,560 1,550 1,560 1,550 1,550<br />
Min./max. coil weight [t] 30 — — 23-30 23 30 35<br />
Type dry wet wet dry<br />
Number <strong>of</strong> top grinding<br />
heads<br />
Number <strong>of</strong> bottom grinding<br />
heads<br />
1x dry and<br />
2x wet<br />
wet wet<br />
[no.] 4 4 4 2-4 2 2 3<br />
[no.] 1 no no 0-1 1 0 1<br />
Min./max. speed [m/min] 4-40 25 40 30-40 22-35 30 —<br />
Grinding type polishing<br />
Coating line<br />
grinding and<br />
polishing<br />
Company <strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
Site Terni<br />
Min./max. thickness [mm] 0.2-1.2<br />
Max. width [mm] 1,550<br />
Max. coil weight [t] 20<br />
Max. speed [m/min] 25<br />
Slitting lines<br />
grinding and<br />
polishing<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
polishing polishing<br />
grinding and<br />
polishing<br />
—<br />
<strong>ThyssenKrupp</strong><br />
Acciai Speciali Terni<br />
Site Krefeld Dillenburg Düsseldorf-Benrath Terni<br />
Number <strong>of</strong> units [no.] 8 5 4 11<br />
Min./max. thickness [mm] 0.3-6.0 0.2-5.5 0.2-6.0 0.3-4.0<br />
Min./max. entry width [mm] 1,350-1,580 400-1,550 1,350-1,640 750-1,550<br />
Min./max. slit width [mm] 30-200 10-50 20-50 10-150<br />
Min./max. coil weight [t] 22-30 4-30 26-30 10-30<br />
Min./max. speed [m/min] 90-300 120-250 200-250 100-200<br />
Company <strong>ThyssenKrupp</strong> Mexinox Shanghai Krupp Stainless <strong>ThyssenKrupp</strong> Stainless USA*<br />
Site San Luis Potosí Shanghai Calvert, AL<br />
Number <strong>of</strong> units [no.] 7 3 4**<br />
Min./max. thickness [mm] 0.3-4.0 0.25-3.0 0.3-10.0<br />
Min./max. entry width [mm] 1,300-1,524 1,350 1,550-1,880<br />
Min./max. slit width [mm] 18-50 50 25-160<br />
Min./max. coil weight [t] 10-25 29 35<br />
Min./max. speed [m/min] 50-250 200 60-250<br />
** one <strong>of</strong> <strong>the</strong>m is a combined line<br />
* under construction<br />
* under construction
Cut-to-length lines<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
23<br />
<strong>ThyssenKrupp</strong> Acciai Speciali<br />
Terni<br />
Site Krefeld Dillenburg Düsseldorf-Benrath Terni<br />
Number <strong>of</strong> units [no.] 3 2 1 6<br />
Min./max. thickness [mm] 0.3-8.5 0.15-2.0 0.3-2.0 0.4-3.2<br />
Min./max. width [mm] 1,580 750-1,550 690 750-1,550<br />
Min./max. coil weight [t] 24-30 14-32 13 12-30<br />
Min./max. sheet length [mm] 6,000-12,000 4,000-9,000 4,000 3,000-8,000<br />
Min./max. speed [m/min] 50-100 60-100 60 12-30<br />
Company <strong>ThyssenKrupp</strong> Mexinox Shanghai Krupp Stainless <strong>ThyssenKrupp</strong> Stainless USA*<br />
Site San Luis Potosí Shanghai Calvert, AL<br />
Number <strong>of</strong> units [no.] 6 1 3**<br />
Min./max. thickness [mm] 0.3-3.4 0.25-2.0 0.3-10.0<br />
Min./max. width [mm] 1,270-1,524 1,340 1,550-1,880<br />
Max. coil weight [t] 4 29 35<br />
Min./max. sheet length [mm] 2,438-6,500 4,000 3,050-9,150<br />
Min./max. speed [m/min] 35-60 90 60<br />
Precision Strip<br />
Company <strong>ThyssenKrupp</strong> Nirosta<br />
Site Dahlerbrück<br />
Facility<br />
Pickling<br />
Line<br />
Cold Rolling<br />
Mills<br />
Bright Annealing<br />
Lines<br />
Skin-pass<br />
Mills<br />
Flattener<br />
Slitting<br />
Lines<br />
Edges Rounding<br />
Lines<br />
Number <strong>of</strong> units [no.] 1 3 9 2 1 4 2<br />
Min./max. thickness [mm] 0.1-1.50 0.05-1.50 0.04-1.50 0.05-1.50 0.05-0.80 0.04-1.50 0.10-0.60<br />
Min./max. width [mm] 650 255-650 12-650 300-650 650 350-650 25-100<br />
Min./max. coil weight [t] 10 1.25-10 4-10 1.25-10 10 3-10 1.0<br />
Max. speed [m/min] 15 750 30 200 200 200 200<br />
Max. strip tension [kN] — 200 — 27 — — —<br />
Max. roll <strong>for</strong>ce [kN] — 2,400 — 4,000 — — —<br />
Pipe Production<br />
Company Tubificio di Terni<br />
Site Terni<br />
Facility Tube welding line<br />
Number <strong>of</strong> units [no.] 3 2 2<br />
Min./max. strip thickness [mm] 0.8-3.0 0.6-3.0 1.0-5.0<br />
Min./max. strip width [mm] 75-280 75-450 180-530<br />
Welding type high frequency laser TIG<br />
Pipe shapes round, square, rectangular round round, square, rectangular<br />
Min./max. outside diameter [mm] 25-89 25-126 57-168<br />
Max. speed [m/min] 120 18 2/5<br />
One slitting line also belongs to <strong>the</strong> pipe production.<br />
** one <strong>of</strong> <strong>the</strong>m is a combined line<br />
* under construction
24<br />
High-per<strong>for</strong>mance alloys:<br />
Nickel alloys<br />
Definition<br />
Nickel alloys are <strong>materials</strong> containing<br />
at least 30 % nickel. Combined with<br />
o<strong>the</strong>r metallic and nonmetallic elements,<br />
a wide variety <strong>of</strong> properties<br />
can be achieved in <strong>the</strong> final product.<br />
In addition to excellent corrosion<br />
resistance and heat resistance, <strong>the</strong>se<br />
include special physical properties like<br />
electrical resistance, controlled <strong>the</strong>rmal<br />
expansion and special magnetic<br />
properties. Depending on <strong>the</strong> product<br />
properties required, multiple-element<br />
alloys such as nickel-copper, nickel-iron,<br />
nickel-iron-chromium, nickel-chromium,<br />
nickel-molybdenum-chromium and<br />
nickel-chromium-cobalt are used.<br />
Manufacturing process<br />
The <strong>ThyssenKrupp</strong> VDM product<br />
portfolio includes sheet, strip, wire,<br />
bar and <strong>for</strong>gings made <strong>of</strong> nickel<br />
alloys and special stainless steels.<br />
Melting and casting<br />
<strong>ThyssenKrupp</strong> VDM’s melt shop is<br />
located in Unna. It is geared toward<br />
producing high-nickel alloys, highalloy<br />
specialty steels and copper-nickel<br />
alloys. The <strong>materials</strong> are melted in an<br />
electric arc furnace and <strong>the</strong>n undergo<br />
vacuum treatment. A ladle furnace is<br />
used <strong>for</strong> secondary metallurgical treatment.<br />
Casting takes place in a vertical<br />
continuous caster or by ingot casting.<br />
The homogeneity and purity <strong>of</strong> <strong>the</strong><br />
<strong>materials</strong> can be enhanced by remelting<br />
in electroslag remelting (ESR) or<br />
in <strong>the</strong> vacuum arc remelting (VAR)<br />
furnaces. The cast and/or remelted<br />
slabs/ingots serve <strong>ThyssenKrupp</strong><br />
VDM as feedstock <strong>for</strong> <strong>the</strong> production<br />
<strong>of</strong> sheet, strip, bar and wire.<br />
In addition to <strong>the</strong> conventional<br />
technology <strong>of</strong> open steel melting,<br />
<strong>ThyssenKrupp</strong> VDM also uses a newgeneration<br />
vacuum induction melting<br />
furnace (VIM furnace) at <strong>the</strong> site in<br />
Unna <strong>for</strong> <strong>the</strong> production <strong>of</strong> high-alloy<br />
specialty stainless steels, nickel alloys<br />
and super alloys. These withstand<br />
extreme mechanical and <strong>the</strong>rmal stresses<br />
in applications in <strong>the</strong> aerospace,<br />
energy, oil and gas industries, as well<br />
as in specialized applications in electrical<br />
engineering and electronics.
Fur<strong>the</strong>r processing<br />
Sheet and plate in thicknesses <strong>of</strong><br />
2 to 100 mm are hot-rolled on a<br />
four-high mill at <strong>the</strong> Siegen site <strong>of</strong><br />
<strong>ThyssenKrupp</strong> VDM. Finishing steps<br />
such as annealing, blasting, pickling,<br />
grinding and cutting take place at<br />
<strong>the</strong> Altena plant. <strong>ThyssenKrupp</strong> VDM<br />
also has a Sendzimir reversing mill<br />
that can process hot-rolled sheets<br />
into individual cold-rolled sheets<br />
with a width <strong>of</strong> up to 2,500 mm.<br />
At <strong>the</strong> Werdohl plant, strips are cold<br />
rolled on four-high and Sendzimir<br />
mills. Foil can be rolled to a thickness<br />
<strong>of</strong> 0.025 mm on a special 20-high mill.<br />
Annealing, leveling and cutting equip-<br />
ment is available to make adjustments<br />
according to customer specifications.<br />
In 2008, <strong>the</strong> Unna plant began operation<br />
<strong>of</strong> one <strong>of</strong> <strong>the</strong> most modern <strong>for</strong>ging<br />
lines <strong>for</strong> high-per<strong>for</strong>mance alloys. The<br />
<strong>for</strong>ging press operates with two manipulators.<br />
Forging material is supplied<br />
from certified heating and reheating<br />
furnaces. Following precisely specified<br />
procedures, this equipment will produce<br />
rods and semi-finished products <strong>for</strong><br />
<strong>the</strong> high demands <strong>of</strong> <strong>the</strong> aerospace,<br />
chemical and <strong>of</strong>fshore industries.<br />
Hot-rolled and <strong>for</strong>ged rods and semifinished<br />
products are also finished<br />
at <strong>the</strong> Altena plant. Heat-treatment<br />
furnaces, turning, bar peeling and<br />
grinding machines are available to<br />
per<strong>for</strong>m <strong>the</strong> necessary finishing work.<br />
A 60-ton draw bench is available <strong>for</strong><br />
<strong>the</strong> production <strong>of</strong> cold-drawn precision<br />
bar. Fur<strong>the</strong>rmore, wire in fine and<br />
ultra-fine gauges down to a diameter<br />
<strong>of</strong> 0.01 mm, heavy-gauge and shaped<br />
wire as well as welding filler <strong>materials</strong><br />
are all produced at <strong>the</strong> Werdohl plant.<br />
25
26<br />
Applications<br />
In many key technologies, high-per<strong>for</strong>mance<br />
nickel alloys are essential <strong>for</strong> <strong>the</strong><br />
large-scale implementation and safe<br />
control <strong>of</strong> corrosive processes taking<br />
place at high temperatures. They are<br />
used in <strong>the</strong> energy, environmental, electronics,<br />
electrical engineering, automotive,<br />
aerospace, chemical, petrochemical,<br />
<strong>of</strong>fshore and industrial furnace sectors.<br />
Heat exchangers and housings <strong>for</strong><br />
gas turbines are examples <strong>of</strong> uses <strong>for</strong><br />
high-per<strong>for</strong>mance nickel alloys, which<br />
<strong>of</strong>fer excellent elevated-temperature<br />
strength and chemical stability in<br />
corrosive media. The auto industry<br />
uses exhaust catalytic converters in<br />
which <strong>the</strong> substrates <strong>of</strong> metallic catalytic<br />
converters and <strong>the</strong> wire mesh<br />
<strong>of</strong> ceramic catalytic converters are<br />
made <strong>of</strong> Nicr<strong>of</strong>er or Aluchrom alloys.<br />
In addition, nickel alloys are used in<br />
exhaust manifolds, while high-nickel<br />
wires can be found in spark plugs <strong>for</strong><br />
gasoline engines. Wires and strips<br />
made <strong>of</strong> resistance alloys are needed<br />
<strong>for</strong> <strong>the</strong> starting and braking resistors<br />
in electric rail vehicles. Fuel cells,<br />
too, make use <strong>of</strong> nickel alloys. In <strong>the</strong><br />
aerospace sector, high-per<strong>for</strong>mance<br />
nickel alloys are used <strong>for</strong> combustion<br />
chambers in modern airplane gas<br />
turbines, as well as <strong>for</strong> <strong>the</strong> liquid-fuel<br />
tank in <strong>the</strong> European rocket “Ariane”.
Facilities in <strong>the</strong> business field nickel alloys<br />
Melting and Casting<br />
Primary melting facilities Treatment facilities<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Unna Site Unna<br />
Type Arc furnace Induction furnace Type VOD VLF<br />
Number <strong>of</strong> units [no.] 1 3 Number <strong>of</strong> units [no.] 1 1<br />
Charge weight [t] 30 16 Charge weight [t] 20/30 20/30<br />
Rated capacity - trans<strong>for</strong>mer [MVA] 15 3.8 Rated capacity - trans<strong>for</strong>mer [MVA] — 4.5<br />
Furnace vessel diameter [m] 3.5 1.3 Vacuum system [mbar] 1 1<br />
Casting facilities<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Unna<br />
Type Slab caster Ingot<br />
Number <strong>of</strong> units [no.] 1 strand<br />
26 sites/2-12<br />
moulds<br />
Radius [m] none –<br />
Min./max. mould width [mm] 600-1,200 300-1,600<br />
Min./max. mould thickness [mm] 200-350 300-900<br />
Max. length [m] 8.6 4<br />
Vacuum melting facilities Remelting furnaces<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Unna Site Unna<br />
Type VIDP Type ESR VAR<br />
Number <strong>of</strong> units [no.] 1 Number <strong>of</strong> units [no.] 3 2<br />
Charge weight [t] 20 (30) Min./max. charge weight [t] 7-22 10-30<br />
Rated capacity - trans<strong>for</strong>mer [MVA] 7 Min./max. ingot diameter [mm] 400-1,000 400-1,000<br />
Furnace vessel diameter [m] 1.4 Slab thickness [mm] 930-1,200 —<br />
Vacuum system [mbar] 0.15 Min./max. width [mm] 320 —<br />
Electrode dimensions<br />
Min./max. ingot weight [t] 2-17 2-17<br />
[mm] 330-980<br />
Min./max. diameter Slab weight [t] 6-7 —<br />
Rectangular [mm] 390-1,485 I 390-770 Vacuum system [t] — 0.001<br />
Electrode weight round [t] 2.9-20 Rated capacity - trans<strong>for</strong>mer [mbar] 2.1-3.5 2-2.5<br />
Rectangular [t] 1.5-14<br />
Annealing facilities<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Unna<br />
Type Annealing trolley furnace<br />
Number <strong>of</strong> units [no.] 3<br />
Charge weight [t] 20<br />
Heating power (gas) [MW] 2.4<br />
Max. temperature [°C] 1,220<br />
Max. length [mm] 9,500<br />
VOD = Vacuum Oxygen Decarburization<br />
VLF = Vacuum Laddle Furnace<br />
VIDP = Vacuum Induction Degassing and Pouring Furnace<br />
ESR = Electro Slag Remelting<br />
VAR = Vacuum Arc Remelting<br />
27
28<br />
Subsequent processing<br />
Strip Production<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl<br />
Type 4 high 6 high CVC 20 high 4 high<br />
Number <strong>of</strong> units [no.] 1 1 1 1<br />
Min./max. strip width [mm] 400-800 400-800 350-750 80-350<br />
Min./max. strip thickness [mm] 0.2-5.0 0.1-5.0 0.02-1.0 0.04-3.17<br />
Max. coil weight [t] 9 9 9 3<br />
Max. roll speed [m/min] 240 450 600 250<br />
Max. strip tension [kN] 100 100 150 60<br />
Max. roll <strong>for</strong>ce [kN] 13,000 6,500 2,100 3,500<br />
Heat treatment facilities<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl<br />
Type Bright-annealing furnace Cover-tpe annealing furnace Electro puller furnace<br />
Number <strong>of</strong> units [no.] 2 1 3<br />
Min./max. strip width [mm] 400-800 2,100 70-450<br />
Min./max. strip thickness [mm] 0.1-4.0 1.50-5.00 0.04-3.0<br />
Min./max. coil weight [t] 9 4 2-6<br />
Min./max. annealing speed [m/min] 12-26 non-applicable 12-30<br />
Min./max. annealing<br />
temperature<br />
[0C] 800-1,230 400-1,050 850-1,150<br />
Annealing atmosphere H2 Ar H2 Min./max. furnace length [m] 8-13 1.31 Ø 4-6<br />
Min./max. cooling zone<br />
length<br />
[m] 6 non-applicable 4-5<br />
In-Line/skin-pass mill no non-applicable no<br />
Straightening facilities<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl<br />
Type Stretching, straightening and slitting facilities Straightening and cut-to-length facilities, degreaser<br />
Number <strong>of</strong> units [no.] 2 3<br />
Min./max. strip width [mm] 30-765 8.0-764<br />
Min./max. strip thickness [mm] 0.03-0.8 0.03-3.5<br />
Max. straightening speed [m/min] 180-200 25-40<br />
Max. coil weight [t] 1.5-6.0 0.5-6<br />
Max. stretching <strong>for</strong>ce [kN] 20-80 non-applicable
Strip grinding units Slitting lines<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl Site Werdohl<br />
Min./max. strip width [mm] 550-825 600-1,050 Type<br />
thin strip, foil, wide strip, narrow strip,<br />
strip- and circular shear<br />
Min./max. strip thickness 1.40-4.90 1.4-4.8 Number <strong>of</strong> units [no.] 6<br />
Number <strong>of</strong> cabins [no.] 6 3 Min./max. strip width [mm] 3.0-800<br />
Min./max. coil weight [t] 9 20 Min./max. strip thickness [mm] 0.025-4.8<br />
Min./max. grinding speed [m/min] 10 40 Min./max. slit strip width [mm] 3-100<br />
Number <strong>of</strong> top grinding<br />
heads<br />
Number <strong>of</strong> bottom grinding<br />
heads<br />
Pickling lines<br />
[no.] 6 3 Min./max. slitting speed [m/min] 30-460<br />
[no.] 0 3 Min./max. coil weight [t] 2-9<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl<br />
Type Hot strip pickling unit Cold strip pickling unit<br />
Number <strong>of</strong> units [no.] 1 1<br />
Min./max. strip width [mm] 280-800 60-800<br />
Min./max. strip thickness [mm] 1.70-4.80 0.1-2.0<br />
Max. coil weight [t] 9 9<br />
Max. pickling rate [m/min] 10 30<br />
Pickling length [m] 20 15<br />
In-line/skin-pass mill no no<br />
Wire<br />
Heat treatment facilities<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl<br />
Type Batch furnace Continuous annealing furnace<br />
Number <strong>of</strong> units [no.] 3 14<br />
Min./max. wire diameter [mm] 2.0-25.0 0.1-5.0<br />
Drawing equipment<br />
Company <strong>ThyssenKrupp</strong> VDM<br />
Site Werdohl<br />
Type Dry drawing machine Wet drawing machine<br />
Number <strong>of</strong> units [no.] 7 14<br />
Min./max. wire diameter [mm] 1.0-15.0 0.1-2.0<br />
Additionally diverse treatment facilities complement<br />
<strong>the</strong> wire production at <strong>the</strong> Werdohl site<br />
• one flat rolling machine<br />
• one drawing and shaving machine<br />
• two shot blasting machines<br />
• two streng<strong>the</strong>ning and cutting machines.<br />
29
30<br />
Sheet production<br />
Rolling Mills Slab heating/reheating furnace<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Siegen Site Siegen<br />
Type 4 high Type Roller hearth<br />
Number <strong>of</strong> units [no.] 1 Number <strong>of</strong> units [no.] 2<br />
Max. sheet width [mm] 2,500 Min./max. slab width [mm] 320-2,650<br />
Min./max. sheet thickness [mm] 2-100 Min./max. slab thickness [mm] 3-160<br />
Min./max. sheet length [mm] 1,000-9,000 Min./max. slab length [mm] 600-9,000<br />
Max. unit weight [t] 2.8 Max. unit weight [t] 2.8<br />
Max. roll <strong>for</strong>ce [kN] 40,000 Min./max. temperature [°C] 770-1,200<br />
Max. roll speed [m/min.] —<br />
Heat treatment furnaces Descaling facilities<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Altena Siegen Site Altena<br />
Type Roller hearth Batch annealing furnace Type Shot blaster<br />
Number <strong>of</strong> units [no.] 1 1 Number <strong>of</strong> units [no.] 2<br />
Min./max. sheet width [mm] 300-3,200 100-2,160 Min./max. sheet width [mm] 500-3,200<br />
Min./max. sheeet thickness [mm] 1.0-42.0 2-140 Min./max. sheet thickness [mm] 0.7-180<br />
Min./max. sheet length [mm] — 100-6,000 Min./max. sheet length [mm] 1,000-12,000<br />
Max. unit weight [t] 4.5 9 Max. unit weight [t] 5<br />
Min./max. temperature [°C] 500-1,180 300-900 Min./max. speed [m/min] 1-10<br />
Pickling facilities Cold rolling mill<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Altena Altena Siegen Site Altena<br />
Type Spray pickling Tank pickling Tank pickling Type Sendzimir<br />
Number <strong>of</strong> units [no.] 1 3 1 Number <strong>of</strong> units [no.] 1<br />
Min./max. sheet width [mm] 760-3,200 8-2,500 8-2,500 Min./max. sheet width [mm] 1,000-2,600<br />
Min./max. sheet thickness [mm] 1.0-40.0 1.0-150.0 2-100 Min./max. sheet thickness [mm] 1.0-10.0<br />
Min./max. sheet length [mm] 1,300-10,000 150-8,000 1,000-9,500 Min./max. sheet length [mm] 2,000-10,000<br />
Max. unit weight [t] 4.5 8 2.8 Max. unit weight [t] 1.5<br />
Pickling length [m] 10 8 9.5 Max. roll <strong>for</strong>ce [kN] 25,000<br />
Pickling media HNO3/HF, 40°C HNO3/HF, RT HF&H2SO4,40°C Speed [m/min] 5-60<br />
The finishing department also has available:<br />
• four roller straighteners<br />
• two dry grinding machines, one wet grinding machine<br />
• two shears, one saw, two plasma cutters.<br />
Cooling media oil
Rod production<br />
Heat treatment facilities Straig<strong>the</strong>ning<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Altena Site Altena<br />
Type Car-bottom furnace Type Press straightener Roller straightener<br />
Number <strong>of</strong> units 4 Number <strong>of</strong> units [no.] 1 5<br />
Min./max. furnace height [mm] 500-700 Min./max. rod diameter [mm] 25-400 8-95<br />
Min./max. furnace width [mm] 1,000-1,200 Min./max. rod length [mm] 300-8,000 1,800-11,000<br />
Min./max. furnace length [mm] 7,000-12,500<br />
Charge weight [t] 21<br />
Min./max. temperature [°C] 500-1,240<br />
Forge<br />
Forging press Manipulators<br />
Company <strong>ThyssenKrupp</strong> VDM Company <strong>ThyssenKrupp</strong> VDM<br />
Site Unna Site Unna<br />
Type Push down press Type 2 railbound, 1 mobile<br />
Number <strong>of</strong> units [no.] 1 Number <strong>of</strong> units [no.] 3<br />
Max. press capacity [MN] 40 Carrying capacity [kN] 80-600<br />
Max. upsettung <strong>for</strong>ce [MN] 45 Load moment [kNm] 360-1,500<br />
Daylight [mm] 4,300<br />
Min./max. tongs clamping<br />
range<br />
[mm] 110-1,810<br />
Min./max. column spacing [mm] 3,125 Travel distance [m] 16<br />
Max. stroke rate [min-1] 120<br />
The rod production has available <strong>the</strong> following machining and finishing facilities:<br />
• one peeling machine, five la<strong>the</strong>s, one circle la<strong>the</strong><br />
• one abrasive grinder<br />
• three centreless grinders<br />
• four saws, two abrasive cutters<br />
• one hydraulic bench.<br />
The <strong>for</strong>ge also has available:<br />
• three car bottom furnaces and<br />
• five batch furnaces.<br />
31
32<br />
High-per<strong>for</strong>mance alloys:<br />
Titanium<br />
Definition<br />
Titanium is <strong>the</strong> 22nd element in <strong>the</strong><br />
periodic table. It is a common element<br />
in <strong>the</strong> earth’s crust. With an incidence<br />
<strong>of</strong> 0.6 %, it is <strong>the</strong> ninth most common<br />
element and <strong>the</strong> fourth most<br />
common metal. But it is only since<br />
<strong>the</strong> introduction <strong>of</strong> an economical and<br />
reliable process <strong>for</strong> extracting titanium<br />
from ore (Kroll process) in <strong>the</strong> early<br />
1950s that various titanium-based<br />
<strong>materials</strong> have been developed to<br />
meet specialized customer needs.<br />
These can be divided roughly into<br />
two categories:<br />
• commercially pure titanium, com-<br />
posed <strong>of</strong> ≥ 99.2 % titanium, plus<br />
accompanying elements like oxygen,<br />
nitrogen, carbon, iron, etc.<br />
• titanium alloys, i.e. titanium alloyed<br />
with up to about 20 % <strong>of</strong> additi-<br />
ves such as aluminum, vanadium,<br />
tin, molybdenum and zirconium<br />
Manufacturing process<br />
From ore to rolled product, <strong>the</strong> manufacturing<br />
<strong>of</strong> titanium mill products takes<br />
place in three major steps:<br />
• reduction <strong>of</strong> titanium ore to a porous<br />
<strong>for</strong>m <strong>of</strong> titanium metal called<br />
“sponge”<br />
• remelting <strong>of</strong> <strong>the</strong> sponge and/or<br />
titanium scrap – toge<strong>the</strong>r with alloying<br />
elements in <strong>the</strong> case <strong>of</strong> alloys –<br />
to produce an ingot or slab<br />
• reshaping <strong>of</strong> <strong>the</strong> ingots and/or slabs<br />
into general mill products, or via<br />
intermediate sizes into bar or open-<br />
die <strong>for</strong>gings
Melting process<br />
Titanium and titanium blocks are generally<br />
melted twice in an electric arc<br />
furnace under a vacuum. For some<br />
“critical” applications, <strong>for</strong> instance aircraft<br />
engine components, a third melting<br />
phase is used to increase <strong>the</strong> purity<br />
and homogeneity <strong>of</strong> <strong>the</strong> final ingot.<br />
In addition to <strong>the</strong> three VAR furnaces,<br />
an advanced electron beam (EB) furnace<br />
<strong>for</strong> <strong>the</strong> production <strong>of</strong> titanium<br />
ingots and slabs began operation in<br />
Essen at <strong>the</strong> beginning <strong>of</strong> 2008. This<br />
is <strong>the</strong> first and so far only EB furnace<br />
in Europe. It <strong>of</strong>fers high melting and<br />
recycling rates and allows <strong>the</strong> charging<br />
<strong>of</strong> scrap and titanium sponge thanks to<br />
an integrated weighing and mixing unit.<br />
Ano<strong>the</strong>r innovative technology <strong>for</strong> using<br />
titanium scrap as raw material is <strong>the</strong><br />
skull melting process that has been<br />
fur<strong>the</strong>r developed at <strong>the</strong> Terni plant.<br />
This melting unit is distinguished by its<br />
high flexibility <strong>for</strong> use with various scrap<br />
types and weights, as well as by its<br />
ability to produce ei<strong>the</strong>r ingots or slabs.<br />
Fur<strong>the</strong>r processing<br />
The fur<strong>the</strong>r processing <strong>of</strong> blocks and<br />
slabs into semi-finished titanium<br />
and titanium-alloy products takes<br />
place both on our own equipment<br />
and on <strong>the</strong> equipment <strong>of</strong> o<strong>the</strong>r segments<br />
<strong>of</strong> <strong>the</strong> <strong>ThyssenKrupp</strong> Group.<br />
The production <strong>of</strong> flat products is<br />
concentrated at <strong>the</strong> <strong>ThyssenKrupp</strong><br />
Titanium plant in Terni. The hot- and<br />
cold-rolling and processing lines <strong>of</strong><br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
are used to manufacture strip and<br />
sheet <strong>of</strong> commercial-purity titanium.<br />
The strip rolled in this way is used<br />
at <strong>ThyssenKrupp</strong> Titanium in Terni<br />
to make longitudinally welded pipe<br />
in lengths <strong>of</strong> up to 25 meters (e.g.<br />
<strong>for</strong> seawater desalination plants).<br />
This plant also has a production line<br />
dedicated to hot-rolled titanium and<br />
titanium-alloy plate, with a four-high<br />
hot-rolling mill and downstream finishing<br />
shop. To enhance flatness and<br />
remove stress, titanium-alloy plate can<br />
be flattened and stress-relieved in a<br />
VCF (Vacuum-Creep Flattener) at <strong>the</strong><br />
Essen plant. This system is currently<br />
<strong>the</strong> only one <strong>of</strong> its kind in Europe.<br />
Long products <strong>for</strong> <strong>the</strong> aerospace industry<br />
are <strong>for</strong>ged or rolled under our own<br />
strict controls both within <strong>the</strong> Group<br />
and by audited contract processors.<br />
Machining, finishing, testing and certification<br />
take place at <strong>the</strong> Essen plant.<br />
33
34<br />
Applications<br />
Because <strong>of</strong> its positive properties in<br />
terms <strong>of</strong> strength, density and corrosion<br />
resistance, titanium is ideal <strong>for</strong> <strong>the</strong><br />
manufacture <strong>of</strong> components <strong>for</strong> <strong>the</strong><br />
aerospace industry. Titanium alloys are<br />
increasingly found in structural components<br />
<strong>of</strong> new-generation airplanes as<br />
well as in engine components <strong>for</strong> temperatures<br />
below 550 °C. In <strong>the</strong> chemical<br />
industry, titanium is <strong>of</strong>ten <strong>the</strong> construction<br />
material <strong>of</strong> choice because <strong>of</strong> its<br />
outstanding resistance to corrosion.<br />
On <strong>of</strong>fshore plat<strong>for</strong>ms, titanium is used<br />
in pipes <strong>for</strong> fire protection, in tube and<br />
plate heat exchangers, and in valves.<br />
Titanium has become irreplaceable<br />
in <strong>the</strong> marine industry. All <strong>the</strong> world’s<br />
tankers and cruise ships run on diesel<br />
engines, which are cooled with sea<br />
water by plate-type heat exchangers<br />
made <strong>of</strong> titanium. Welded titanium pipes<br />
are used worldwide in power plants<br />
and seawater desalination systems.<br />
Even <strong>the</strong> medical industry is dependent<br />
on titanium. Because <strong>of</strong> its excellent<br />
biocompatibility, it is <strong>of</strong>ten used as an<br />
implant material: <strong>for</strong> pros<strong>the</strong>tic joints,<br />
as a fixative <strong>for</strong> bones, tooth implants,<br />
artificial heart valves and pacemakers.<br />
The automotive industry, architecture<br />
and sports equipment as well as <strong>the</strong><br />
watch and jewelry industry are among<br />
<strong>the</strong> new markets in which titanium is<br />
being used more and more <strong>of</strong>ten.
Facilities in <strong>the</strong> business field titanium<br />
Remelting furnaces<br />
Company <strong>ThyssenKrupp</strong> Titanium<br />
Site Terni Essen<br />
Type skull melter VAR VAR EB<br />
Number <strong>of</strong> units [no.] 1 1 3 1<br />
Min./max. charge weight [t] 1.6 0.1 3-13 15<br />
Min./max. rated capacity [MVA] 3 0.18 0.855-2.5 3.6<br />
Min./max. vessel diameter [m]<br />
ingots 0.45 Ø<br />
slabs 0.2 x 0.9<br />
0.2 ingot 0.6-1.05 Ø<br />
Min./max. vacuum system [mbar] 10 -3 10 -3 10 -3 -10 -2<br />
VAR = Vaccum Arc Remelting EB = Electron Beam<br />
Sheet production<br />
Heat treatment facilities Heat treatment furnaces<br />
ingot 0.84 Ø or<br />
slab 0.5 x 1.3 x 5<br />
Company <strong>ThyssenKrupp</strong> Titanium Company <strong>ThyssenKrupp</strong> Titanium<br />
Site Essen Site Terni<br />
Type Vacuum creep flattener Number <strong>of</strong> units [no.] 2<br />
Number <strong>of</strong> units [no.] 1 Min./max. plate width [mm] 2,100<br />
Bed size [m] 6.3 x 3.1 Min./max. plate thickness [mm] 60<br />
Max. material depth [m] 0.15 Min./max. plate length [mm] 12,000<br />
Max. charge weight [t] 13 Max. unit weight [t] 3.6<br />
Max. furnace temperature [°C] 980 Min./max. temperature [°C] 800; 1,100<br />
Heating furnaces Rolling mill<br />
Company <strong>ThyssenKrupp</strong> Titanium Company <strong>ThyssenKrupp</strong> Titanium<br />
Site Terni Site Terni<br />
Number <strong>of</strong> units [no.] 1 Number <strong>of</strong> units [no.] 1<br />
Min./max. slab width [mm] 1,500 Max. plate width [mm] 2,100<br />
Min./max. slab thickness [mm] 170 Min./max. plate thickness [mm] 170<br />
Min./max. slab length [mm] 2,000 Min./max. plate length [mm] 8,000<br />
Max. unit weight [t] 3.6 Max. unit weight [t] 2<br />
Min./max. temperature [°C] 800; 1,250 Max. roll <strong>for</strong>ce [kN] 28<br />
Blasting plants Pickling lines<br />
Max. roll speed [m/min.] 60<br />
Company <strong>ThyssenKrupp</strong> Titanium Company <strong>ThyssenKrupp</strong> Titanium<br />
Site Terni Essen Site Terni Essen<br />
Number <strong>of</strong> units [no.] 1 1 Number <strong>of</strong> units [no.] 2 1<br />
Min./max. plate width [mm] 2,100 1,300 Min./max. plate width [mm] 2,100 950<br />
Min./max. plate thickness [mm] 170 500 Min./max. plate thickness [mm] 170 1,000<br />
Min./max. plate length [mm] 12,000 8,000 Min./max. plate length [mm] 12,000 5,000<br />
Max. unit weight [t] 3.6 5 Max. unit weight [t] 3.6 3<br />
Min./max. speed [m/min.] 1; 6 0.5-2 Pickling length [m] 13 4.5<br />
Pipe Production<br />
Welded tube mills<br />
Company <strong>ThyssenKrupp</strong> Titanium<br />
Site Terni<br />
Number <strong>of</strong> units [no.] 3<br />
Min./max. diameter [mm] 15-65<br />
Min./max. thickness [mm] 0.5-2.5<br />
Min./max. length [mm] 2,000-25,000<br />
An ultrasonic, eddy-current and pneumatic test is also carried out.<br />
10 -4<br />
Pickling media HF, H2SO4, H2O2 HF/HNO3<br />
Rod production<br />
The rod production also has available:<br />
• four saws<br />
• two la<strong>the</strong>s<br />
• one pickling line<br />
• one blasting plant<br />
• fur<strong>the</strong>rmore a US-test bath technique and within<br />
metallography a micro test are carried out<br />
35
36<br />
Processing:<br />
Open-die <strong>for</strong>ging<br />
Open-die <strong>for</strong>ge<br />
Società delle Fucine is an open-die<br />
<strong>for</strong>ge that can produce components<br />
in weights <strong>of</strong> up to 250 tons. Its products<br />
are mainly used in <strong>the</strong> energy,<br />
plant engineering, chemical, petrochemical<br />
and <strong>of</strong>fshore sectors. Typical<br />
applications <strong>for</strong> large <strong>for</strong>gings are<br />
shafts <strong>for</strong> electric generators and large<br />
backup rolls <strong>for</strong> plate rolling mills.<br />
In open-die <strong>for</strong>ging, hydraulic presses,<br />
or so-called <strong>for</strong>ging presses, are used<br />
<strong>for</strong> very large components. The pieces<br />
to be <strong>for</strong>ged are moved in <strong>the</strong> press<br />
by manipulators that hold <strong>the</strong> part with<br />
tongs. After <strong>for</strong>ging, <strong>the</strong> part has to be<br />
cooled. For larger <strong>for</strong>gings and specific<br />
qualities, an annealing treatment<br />
is necessary be<strong>for</strong>ehand in order to<br />
guarantee <strong>the</strong> absence <strong>of</strong> cracks in <strong>the</strong><br />
part. In addition, <strong>the</strong> open-die <strong>for</strong>ge has<br />
a large number <strong>of</strong> horizontal and vertical<br />
turning machines, milling machines<br />
and grinding machines at its disposal in<br />
<strong>the</strong> machine shops <strong>for</strong> final processing.
Facilities in <strong>the</strong> business field processing<br />
Forging and Machining<br />
Company Società delle Fucine Company Società delle Fucine<br />
Site Terni Site Terni<br />
Facility Forging Presses Facility Forging Manipulators<br />
Press capacity [t] 12,600 5,000 Load moment [t×m] 120 40 250<br />
Min./max. column spacing [mm] 2,200-6,200 2,000-4,250<br />
Max. openings [mm] 6,510 4,120<br />
Min./max. diameter, with<br />
gripping section<br />
Min./max. diameter, without<br />
gripping section<br />
[mm] 400-1,100 250-1,000 400-1,800<br />
[mm] 700-1,200 620-1,300 1,400-3,000<br />
Min. openings [mm] 3,300 1,920 Min./max. height [mm] 1,450-2,400 1,200-2,000 2,350-5,200<br />
Run [mm] 13,600 7,000 22,000<br />
Company Società delle Fucine Company Società delle Fucine<br />
Site Terni Site Terni<br />
Facility Forging and Treatment Furnaces Facility La<strong>the</strong>s<br />
Milling<br />
Machines<br />
Number <strong>of</strong> units [no.] 24 Number <strong>of</strong> units [no.] 18 3 2<br />
Grinding<br />
Machines<br />
Min./max. unit weight [t] 10-500 Min./max. unit weight [t] 15-220 100-400 90-100<br />
Max. diameter [mm] 1,750 Min./max. diameter [mm] 900-4,000 — 1,803<br />
Max. length [mm] 4,115 Min./max. length [mm] 1,000-4,300 — 11,590<br />
Min./max. chamber internal<br />
volume<br />
[m3] 1-471 Min./max. horizontal run [mm] —<br />
Furnace [type] 16 horizontal, 2 vertical, 1 rotating Vertical run [mm] — 3,000-5,000 5,000<br />
Min./max. temperature [°C] 1,000-1,230 Min./max. turntable diameter [mm] 5,500-7,300 — —<br />
Min./max. capacity [Gcal/h] 0.5-12.0 Min./max. height [mm] 3,200-5,700 — —<br />
Type [type]<br />
horizontal and<br />
vertical<br />
11,225-<br />
19,400<br />
16,000<br />
— —<br />
Min./max. capacity [kW] 95-544 136 82-102<br />
37
38<br />
Distribution network & service centers<br />
Distribution network<br />
<strong>ThyssenKrupp</strong> Stainless has sales<br />
companies, sales <strong>of</strong>fices, warehouses<br />
and service centers throughout <strong>the</strong><br />
world. This global market presence<br />
enables <strong>the</strong> operating companies <strong>of</strong><br />
<strong>ThyssenKrupp</strong> Stainless to quickly<br />
provide customers with <strong>the</strong> best possible<br />
services and excellent quality.<br />
Service centers <strong>for</strong> stainless steels<br />
<strong>ThyssenKrupp</strong> Nirosta has three stainless<br />
steel service centers in Germany –<br />
Nirosta Service-Center GmbH (NSC)<br />
in Wilnsdorf, EBOR Edelstahl GmbH<br />
in Sachsenheim and smbChromstahl<br />
GmbH in Langenhagen. In Italy,<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni has<br />
a highly efficient service center, Terninox<br />
S.p.A., based in Ceriano Laghetto.<br />
In addition, <strong>ThyssenKrupp</strong> Stainless<br />
International operates a series <strong>of</strong> service<br />
centers in Spain, <strong>the</strong> UK, France,<br />
Poland, Hungary, Turkey and China.
Stainless steel service center<br />
Company Stainless Steel Service Center Production site Key Facilities<br />
<strong>ThyssenKrupp</strong> Nirosta<br />
<strong>ThyssenKrupp</strong><br />
Acciai Speciali Terni<br />
<strong>ThyssenKrupp</strong> Stainless<br />
International<br />
<strong>ThyssenKrupp</strong> Nirosta<br />
Service Center GmbH<br />
smbChromstahl GmbH Langenhagen (Germany)<br />
EBOR Edelstahl GmbH Sachsenheim (Germany)<br />
Terninox S.p.A. Ceriano Laghetto (Italy)<br />
<strong>ThyssenKrupp</strong> Stainless U.K.<br />
Ltd.<br />
<strong>ThyssenKrupp</strong> Stainless France<br />
S.A.<br />
Wilnsdorf (Germany) • 5 x Slitting lines<br />
Birmingham (Great Britain)<br />
Paris, (France)<br />
<strong>ThyssenKrupp</strong> Stainless D.V.P. Barcelona (Spain)<br />
<strong>ThyssenKrupp</strong> Silco Inox Kft. Batonyterenye (Hungary)<br />
<strong>ThyssenKrupp</strong> Eurinox S.A. Istanbul (Turkey)<br />
<strong>ThyssenKrupp</strong> Stainless Polska Kattowitz (Poland))<br />
<strong>ThyssenKrupp</strong> Stainless<br />
Guangzhou<br />
• 1 x Coil polishing, brushing and cut-to-length line<br />
• 2 x Sheet polishing and brushing lines<br />
• 1 x Sheets mirror polishing line<br />
• 2 x Slitting lines<br />
• 3 x Cut-to-length lines<br />
• 1 x Coil polishing and cut-to length line<br />
• 1 x Coil polishing line<br />
• 2 x Sheet polishing lines<br />
• 5 x Cut-to-length lines<br />
• 3 x Slitting lines<br />
• 4 x Coil brushing lines<br />
• 1 x Sheet polishing and brushing lines<br />
• 2 x Shears<br />
• 1 x Cut-to-length line<br />
• 1 x Sheet polishing line<br />
• 2 x Slitting lines<br />
• 1 x Cut-to-length line<br />
• 1 x Coil polishing and brushing line<br />
• 1 x Sheet polishing line<br />
• 1 x Sheet brushing line<br />
• 2 x Slitting lines<br />
• 2 x Cut-to-length lines<br />
• 1 x Coil brushing line<br />
• 1 x Coil polishing and brushing line<br />
• 1 x Sheets mirror polishing line<br />
• 2 x Slitting lines<br />
• 1 x Cut-to-length line<br />
• 1 x Sheet polishing and sheet brushing line<br />
• 5 x Slitting lines<br />
• 2 x Cut-to-length lines<br />
• 1 x Sheet polishing and brushing line<br />
• 1 x Slitting line<br />
• 1 x Cut-to-length line<br />
• 1 x Sheet polishing line<br />
Guangzhou (China) • 1 x Slitting line<br />
39
40<br />
Research & development<br />
In order to meet <strong>the</strong> challenges <strong>of</strong><br />
<strong>tomorrow</strong>, <strong>the</strong> operating companies <strong>of</strong><br />
<strong>ThyssenKrupp</strong> Stainless are focused<br />
on strategic innovations in <strong>the</strong> fields<br />
<strong>of</strong> applications, <strong>materials</strong>, processes<br />
and products. Ambitious, innovative<br />
and close to customers, we are pursuing<br />
new approaches to increase <strong>the</strong><br />
per<strong>for</strong>mance potential <strong>of</strong> our <strong>materials</strong><br />
while at <strong>the</strong> same time optimizing<br />
possible applications <strong>for</strong> <strong>the</strong> customer.<br />
Computer-assisted simulations play<br />
an increasingly important role here.<br />
For this reason, we have increased<br />
our collaboration with various universities<br />
and institutes in this field.<br />
Current R&D activities <strong>of</strong> <strong>ThyssenKrupp</strong><br />
Stainless include <strong>the</strong> development <strong>of</strong><br />
finishes with improved appearance and<br />
functionality, and <strong>the</strong> development <strong>of</strong><br />
new alloys that will set new standards<br />
<strong>of</strong> heat- and corrosion resistance<br />
and open up additional areas <strong>of</strong> use.<br />
Against <strong>the</strong> background <strong>of</strong> significantly<br />
increased raw-material prices, particularly<br />
<strong>for</strong> nickel, and <strong>the</strong> current tendency<br />
<strong>of</strong> <strong>the</strong> final consumer to replace<br />
chromium-nickel-steel products with<br />
more cost-effective low-nickel products,<br />
<strong>the</strong> group’s research and development<br />
departments have developed alternative<br />
<strong>materials</strong> and optimized <strong>the</strong> production<br />
and processing steps so that appropriate,<br />
cost-effective solutions can be<br />
<strong>of</strong>fered <strong>for</strong> almost every customer need.
Environmental protection<br />
For <strong>ThyssenKrupp</strong> Stainless, environmental<br />
management means consistent<br />
and continuous respect <strong>for</strong> environmental<br />
aspects. The company has made it<br />
a goal to create as few emissions and<br />
waste products as possible, and to use<br />
raw <strong>materials</strong> and energy sparingly. All<br />
<strong>of</strong> <strong>the</strong> <strong>ThyssenKrupp</strong> Stainless plants<br />
use production systems that protect<br />
<strong>the</strong> environment and save resources.<br />
Potential effects on <strong>the</strong> environment<br />
are taken into account in <strong>the</strong> planning<br />
<strong>of</strong> new facilities and in expanding and<br />
updating existing plants. Environmental<br />
protection was enhanced by a variety <strong>of</strong><br />
measures adopted in <strong>the</strong> <strong>ThyssenKrupp</strong><br />
Stainless plants.<br />
The plants also have <strong>the</strong> goal to<br />
reduce water usage and to optimize<br />
wastewater processing and acid recycling.<br />
There were also noteworthy<br />
successes in recycling consumables,<br />
<strong>for</strong> instance in paper usage.<br />
Significant successes were achieved<br />
in reducing environmental impact.<br />
However, <strong>ThyssenKrupp</strong> Stainless<br />
makes an above-average contribution<br />
to global environmental protection not<br />
just through its environmentally friendly<br />
production measures. The use <strong>of</strong> our<br />
highly innovative <strong>materials</strong> also has<br />
positive effects on <strong>the</strong> environment.<br />
Stainless steel is a particularly environment-friendly<br />
material because it<br />
is nearly one hundred percent recyclable,<br />
without any appreciable loss<br />
in quality. Thus recyclability is an<br />
important property <strong>of</strong> our <strong>materials</strong>.<br />
41
42<br />
Employees<br />
The <strong>ThyssenKrupp</strong> Stainless group<br />
employs approximately 12,000 people<br />
worldwide. They are a key resource<br />
<strong>for</strong> <strong>the</strong> sustained successful development<br />
<strong>of</strong> our company, since <strong>the</strong>y<br />
provide us with <strong>the</strong>ir motivation, <strong>the</strong>ir<br />
knowledge and <strong>the</strong>ir experience. It is<br />
important to streng<strong>the</strong>n this potential<br />
through training and continuing education,<br />
human resources development<br />
and personnel marketing as well as<br />
ideas management. By doing so,<br />
<strong>ThyssenKrupp</strong> Stainless is securing its<br />
innovativeness and competitiveness<br />
and ensuring a positive response to<br />
<strong>the</strong> demographic trends, which is <strong>the</strong><br />
only way to survive in <strong>the</strong> race <strong>for</strong><br />
technological knowledge with an aging<br />
work<strong>for</strong>ce. At its sites, <strong>ThyssenKrupp</strong><br />
Stainless and its subsidiaries are known<br />
as reliable employers who create and<br />
protect jobs. <strong>ThyssenKrupp</strong> Stainless<br />
also streng<strong>the</strong>ns communities and<br />
regions through its social commitment.
Human resources development<br />
Strategic personnel management is<br />
highly valued within <strong>the</strong> <strong>ThyssenKrupp</strong><br />
Stainless segment. <strong>ThyssenKrupp</strong><br />
Stainless <strong>of</strong>fers numerous human<br />
resources development programs<br />
<strong>for</strong> its employees:<br />
Connect2TKL is <strong>the</strong> orientation course<br />
<strong>for</strong> selected graduate trainees and<br />
direct-entry employees. Its main<br />
goals are raising participants’ awareness<br />
<strong>of</strong> what it means to work in<br />
an international group, and focusing<br />
on intercultural understanding in<br />
<strong>the</strong> context <strong>of</strong> global cooperation.<br />
The GLAD@TKL (= Global Learning<br />
And Development) seminar series,<br />
in addition to teaching basic competencies<br />
according to uni<strong>for</strong>m<br />
standards, is meant to facilitate an<br />
exchange <strong>of</strong> experiences and help<br />
create networks. The target group<br />
<strong>for</strong> this is made up <strong>of</strong> domestic technical<br />
and management trainees.<br />
The Develop@TKL program is aimed<br />
at potential candidates <strong>for</strong> senior<br />
management, and senior managers<br />
with potential.<br />
On <strong>the</strong> one hand, <strong>the</strong> assessment<br />
program serves to create transparency<br />
regarding management skills in<br />
<strong>the</strong> segment. At <strong>the</strong> same time, it is<br />
intended to increase motivation and<br />
loyalty and to facilitate networking.<br />
In <strong>the</strong> context <strong>of</strong> <strong>the</strong> Group initiative<br />
”Company Goal: Zero Accidents”,<br />
employees and managers receive<br />
special training on <strong>the</strong> topic <strong>of</strong> health<br />
and safety. In this program, employees<br />
and management from all levels <strong>of</strong> <strong>the</strong><br />
domestic segment go through set training<br />
modules <strong>for</strong> health and safety that<br />
have been developed in cooperation<br />
with <strong>the</strong> Employer’s Liability Insurance<br />
Association. <strong>Our</strong> international subsidiaries<br />
also have numerous programs to<br />
help reach <strong>the</strong> goal <strong>of</strong> “Zero Accidents”.<br />
In addition, <strong>the</strong>re is an ongoing communication<br />
and training initiative in<br />
<strong>the</strong> field <strong>of</strong> value management, linking<br />
<strong>the</strong> continuous and sustained<br />
increase <strong>of</strong> <strong>the</strong> company’s value with<br />
strategic and operational decisions<br />
through <strong>the</strong> efficient use <strong>of</strong> resources.<br />
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44<br />
In our business units, <strong>the</strong>re are<br />
numerous o<strong>the</strong>r examples <strong>of</strong> successful<br />
support <strong>for</strong> employees in various fields:<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni<br />
invested about one million euros in<br />
<strong>the</strong> creation <strong>of</strong> a new training center<br />
in Terni. The training and continuing<br />
education center has an area <strong>of</strong> 800<br />
square meters and is located in a completely<br />
renovated historical building at<br />
<strong>the</strong> heart <strong>of</strong> <strong>the</strong> plant site. In addition<br />
to classroom teaching, <strong>the</strong>re are also<br />
tools <strong>for</strong> learning “on <strong>the</strong> job,” primarily<br />
<strong>for</strong> tasks with extensive technological<br />
aspects. About 1,900 employees (workers,<br />
salaried employees, senior staff<br />
and executives) complete about 5,000<br />
days <strong>of</strong> training here each year. Both inhouse<br />
and external teachers are highly<br />
specialized. As a result, <strong>the</strong> training and<br />
continuing education center is not just<br />
a tool <strong>for</strong> trainees, but also an in-house<br />
knowledge bank <strong>for</strong> <strong>the</strong> entire range <strong>of</strong><br />
all competences within <strong>the</strong> company.<br />
In keeping with <strong>the</strong> motto “health<br />
makes wealth”, each employee <strong>of</strong> VDM<br />
has <strong>the</strong> opportunity to collect points by<br />
taking part in health-related activities. A<br />
variety <strong>of</strong> activities apply: getting a flu<br />
vaccine or having a checkup; being a<br />
member <strong>of</strong> a certified gym; or having a<br />
personal absence rate <strong>of</strong> less than 4 %.<br />
This initiative is meant to increase<br />
employees’ motivation to act in a<br />
health-conscious way. In addition to this<br />
support <strong>of</strong> a “culture <strong>of</strong> good health”,<br />
illness-related costs will be reduced.<br />
Engineers, team leaders and <strong>for</strong>emen<br />
from all areas <strong>of</strong> production take part in<br />
<strong>the</strong> 5-S training program at Shanghai<br />
Krupp Stainless. The 5-S philosophy<br />
guides <strong>the</strong> organization and <strong>the</strong><br />
management, with a primary focus<br />
on orderliness, cleanliness, discipline<br />
and efficiency. Primary goals are <strong>the</strong><br />
standardization and improvement <strong>of</strong><br />
processes in <strong>the</strong> workplace in order<br />
to optimize health and safety, quality,<br />
productivity and individual attitudes.<br />
The <strong>ThyssenKrupp</strong> Academy is a<br />
Groupwide initiative to promote training<br />
<strong>of</strong> management staff. Its programs are<br />
geared toward <strong>the</strong> company’s requirements<br />
and its strategy. The Academy’s<br />
learning plat<strong>for</strong>m is <strong>the</strong> Management<br />
School. This is where managers are<br />
taught new knowledge and are able to<br />
build business-enhancing networks.<br />
Additional programs <strong>for</strong> top executives<br />
were <strong>of</strong>fered in cooperation with<br />
<strong>the</strong> Harvard Business School and<br />
<strong>the</strong> European School <strong>of</strong> Management<br />
and Technology. Fur<strong>the</strong>rmore, learning<br />
plat<strong>for</strong>ms take place at regular<br />
intervals, and <strong>the</strong>ir results are<br />
addressed by <strong>the</strong> Group in order to<br />
develop wider-reaching solutions.
Social responsibility<br />
The willingness to accept responsibility<br />
is an important aspect <strong>of</strong> pr<strong>of</strong>essional<br />
life. For this reason, young apprentices<br />
at <strong>ThyssenKrupp</strong> Nirosta work<br />
on social projects where <strong>the</strong>y can use<br />
<strong>the</strong>ir acquired skills and knowledge to<br />
provide volunteer help where it is most<br />
needed. <strong>ThyssenKrupp</strong> Nirosta supports<br />
<strong>the</strong>se projects by releasing <strong>the</strong> apprentices<br />
<strong>for</strong> <strong>the</strong>se projects. <strong>ThyssenKrupp</strong><br />
Nirosta is one <strong>of</strong> <strong>the</strong> companies taking<br />
part in “Human Capital Return”, a<br />
voluntary commitment to support<br />
employees by giving <strong>the</strong>m time <strong>of</strong>f <strong>for</strong><br />
social projects. Those involved hope<br />
to obtain certain benefits from this<br />
agreement with <strong>the</strong> apprentices. Young<br />
people are able to demonstrate reliability<br />
and to practice coordinating <strong>the</strong>ir<br />
own work. The apprentices’ teamwork<br />
is streng<strong>the</strong>ned by <strong>the</strong>ir activity outside<br />
<strong>the</strong> company and <strong>the</strong>ir mutual cooperation.<br />
This has a positive effect on<br />
<strong>the</strong>ir work in <strong>the</strong> training shops as well<br />
as on <strong>the</strong>ir later work in <strong>the</strong> company.<br />
Each year, <strong>ThyssenKrupp</strong> Mexinox<br />
in San Luis Potosí celebrates <strong>the</strong><br />
“Day <strong>of</strong> Children”. The employees<br />
along with <strong>the</strong>ir families and guests<br />
take part in numerous child-friendly<br />
activities and games. Among o<strong>the</strong>r<br />
things, <strong>the</strong> event increases children’s<br />
environmental awareness.<br />
Social values play a large role within <strong>the</strong><br />
Stainless segment as well – <strong>for</strong> example<br />
at <strong>ThyssenKrupp</strong> Nirosta: In <strong>the</strong> socalled<br />
“transfer agency” in Krefeld,<br />
<strong>the</strong>re are about 30 people working who<br />
can no longer per<strong>for</strong>m <strong>the</strong>ir <strong>for</strong>mer jobs<br />
because <strong>of</strong> physical problems. At workplaces<br />
adapted to meet <strong>the</strong>ir needs,<br />
<strong>the</strong>y per<strong>for</strong>m tasks that had temporarily<br />
been outsourced, <strong>for</strong> instance paper<br />
recycling – <strong>the</strong> employees recycle up to<br />
200 tons <strong>of</strong> paper each month, a task<br />
that helps <strong>the</strong> environment as well.<br />
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46<br />
Glossary<br />
Alloy<br />
An alloy is a steel material which as well as<br />
iron contains o<strong>the</strong>r metallic and/or nonmetallic<br />
elements (e.g. carbon, chromium, silicon).<br />
AOD converter<br />
AOD stands <strong>for</strong> Argon Oxygen Decarburization.<br />
The AOD converter reduces <strong>the</strong> carbon content<br />
<strong>of</strong> molten stainless steels to <strong>the</strong> target level<br />
by injecting argon and oxygen mixtures.<br />
Austenitic stainless steel<br />
Austenitic stainless steel is steel alloyed with chromium<br />
and nickel, and is not magnetic. It is currently<br />
<strong>the</strong> most commonly used type <strong>of</strong> stainless steel.<br />
Chromium<br />
Chromium is a metal which when used as an alloying<br />
element in steel in concentrations <strong>of</strong> more than<br />
12 % ensures <strong>the</strong> steel’s resistance to corrosion.<br />
Cold rolling<br />
Material to be rolled is reduced to a predetermined<br />
thickness in <strong>the</strong> roll gap <strong>of</strong> <strong>the</strong> cold-rolling<br />
mill by pressure applied between two rolls.<br />
Cold-rolled strip<br />
Cold-rolled strip is a cold-reduced flat product which<br />
after rolling is annealed and pickled or “bright<br />
annealed”, <strong>the</strong>reby becoming a saleable product.<br />
Continuous caster<br />
A semi-continuous process <strong>for</strong> <strong>the</strong> production<br />
<strong>of</strong> slabs from liquid steel, which is cast into a<br />
water-cooled copper mold. The cast strand leaves<br />
<strong>the</strong> mold with a just-solidified shell, is guided<br />
between rollers and cooled be<strong>for</strong>e being<br />
cut to <strong>the</strong> desired length by a torch cutter.<br />
Ferritic stainless steel<br />
Ferritic stainless steel contains >12 % <strong>of</strong> chromium;<br />
it is nickel-free and magnetic.<br />
Hot rolling<br />
A shaping process in which slabs with a thickness<br />
<strong>of</strong> 250 millimeters and a length <strong>of</strong> 10<br />
meters are rolled into 2.5-millimeter-thin<br />
strips with a length <strong>of</strong> up to 1 kilometer.<br />
Hot-rolled strip<br />
Hot-rolled steel strip with a width <strong>of</strong> >600 mm<br />
that is rolled from slabs in semi- or fully continuous<br />
hot strip mills and <strong>the</strong>n wound into coils.<br />
Nickel<br />
As an alloying element, nickel primarily<br />
increases stainless steel’s resistance<br />
to corrosion and toughness.<br />
Nickel alloy<br />
Nickel alloy is a collective name <strong>for</strong> a series <strong>of</strong> alloys<br />
which contain a very high percentage <strong>of</strong> nickel<br />
combined with o<strong>the</strong>r metals – copper, chromium,<br />
iron, molybdenum – and are distinguished by <strong>the</strong>ir<br />
very high heat- and/or corrosion resistance.<br />
Sendzimir cold-rolling mill<br />
A Sendzimir mill is a type <strong>of</strong> mill used in all <strong>the</strong><br />
<strong>ThyssenKrupp</strong> Stainless cold-rolling plants;<br />
it is <strong>of</strong> 20-high construction and is especially<br />
suitable <strong>for</strong> rolling stainless steels. The mill is<br />
named after its inventor, Tadeusz Sendzimir.<br />
Slab<br />
A compact rectangular block <strong>of</strong> steel that<br />
is produced in a continuous caster.<br />
Stainless steel<br />
Among o<strong>the</strong>r things, stainless steels are much<br />
more resistant to corrosion than conventional,<br />
unalloyed steels. Fur<strong>the</strong>rmore, <strong>the</strong>y are corrosion-,<br />
acid- and heat-resistant, low-maintenance, hygienic,<br />
<strong>for</strong>mable, durable and environmentally friendly.<br />
Titanium<br />
Titanium has a strength similar to that <strong>of</strong> stainless<br />
steel, but it is distinguished by especially high<br />
corrosion resistance in specific aggressive media.<br />
Fur<strong>the</strong>rmore, it displays a low specific density.
Contacts<br />
<strong>ThyssenKrupp</strong> Nirosta GmbH<br />
Oberschlesienstraße 16<br />
47807 Krefeld/Germany<br />
Phone: +49 (0) 2151 83 01<br />
marketing.nirosta@thyssenkrupp.com<br />
www.nirosta.de<br />
<strong>ThyssenKrupp</strong> Acciai Speciali Terni S.p.A.<br />
Viale B. Brin 218<br />
05100 Terni/Italy<br />
Phone: +39 (0) 7 44 490 1<br />
info@acciaiterni.it<br />
www.acciaiterni.com<br />
<strong>ThyssenKrupp</strong> Mexinox, S.A. de C.V.<br />
Av. Industrias No. 4100<br />
Zona Industrial 1a Sección<br />
78395 San Luis Potosí/S.L.P. Mexico<br />
Phone: +52 (0) 444 8 26 51 00<br />
mexinox@thyssenkrupp.com<br />
www.mexinox.com<br />
<strong>ThyssenKrupp</strong> Stainless USA, LLC.<br />
1087 Downtowner Boulevard, Suite 200<br />
Mobile, AL 36609/USA<br />
Phone: +1 251 544 3600<br />
ulrich.albrecht-frueh@thyssenkrupp.com<br />
www.thyssenkruppnewusplant.com<br />
Publisher:<br />
Shanghai Krupp Stainless Co. Ltd.<br />
101 Xueye Road West<br />
Pudong New Area<br />
Shanghai 20012/PR China<br />
Phone: +86 (0) 21 38 87 48 87<br />
customerservice@skschina.com<br />
www.skschina.com<br />
<strong>ThyssenKrupp</strong> VDM GmbH<br />
Plettenberger Straße 2<br />
58791 Werdohl/Germany<br />
Phone: +49 (0) 2392 55 0<br />
vdm@thyssenkrupp.com<br />
www.thyssenkruppvdm.com<br />
<strong>ThyssenKrupp</strong> Stainless<br />
International GmbH<br />
Oberschlesienstraße 16<br />
47807 Krefeld/Germany<br />
Phone: +49 (0) 2151 83 3503<br />
info.stainless-international@thyssenkrupp.com<br />
www.thyssenkrupp-stainlessinternational.com<br />
<strong>ThyssenKrupp</strong> Stainless <strong>AG</strong><br />
Communications/Executive Affairs<br />
Kaiser-Wilhelm-Straße 100<br />
47166 Duisburg/Germany<br />
Phone: +49 (0) 203 52-1<br />
Fax: +49 (0) 203 52-5102<br />
E-mail: stainless@thyssenkrupp.com<br />
Internet: www.thyssenkrupp-stainless.com<br />
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