Tailor-made bright steel solutions

0302 SCHMOLZ + BICKENBACH GROUPSCHMOLZ + BICKENBACH GROUP

SCHMOLZ + BICKENBACH Group: Production of specialty steel long products

About SCHMOLZ + BICKENBACH

The SCHMOLZ + BICKENBACH Group is today one of the world´s leading providers of individual solutions in the special long steel products sector. Steeltec is one of the leading manufacturers of tool steel and non-corrosive long steel on the global market and one of the two largest companies in Europe for alloyed and high-alloyed constructional steel. With around 9,000 employees and inhouse production and distribution companies in over 30 countries and on 5 continents, the company guarantees its customers a global supply and customer service, and offers them a complete production portfolio as well as sales and services around the world. They benefit from the company´s technological expertise, the consistently high product quality around the world and detailed knowledge of local markets.

04 STEELTEC GMBH

Steeltec bright steel

Special steel solutions for every field of application

Steeltec provides its customers with almost the entire range of bright steel in many qua-lities and dimensions.

Our wide product range is completedby a comprehensive array of services.From individual consulting through exten-

sive processing to logistical solutions,we offer you excellent technical know-howand a maximum of flexibility.

Our Sales & Services network ensures thatour products are available in Germany,in Europe and around the world.

0706 QUALITY AND SERVICE

Quality, service and individual processing

Steeltec offers you the complete service spectrum, from production to distribution. We obtain the steel from our own plants or external suppliers at the world‘s best conditions.

When doing so, our long-standing coopera- tion with renowned steel producers ensures constant quality standards. To permanentlyguarantee these to you, not only the pro-ducers but also the steel they produce issubject to continuous controls. These goso far that on request we also certify ourproducers jointly with you.

As a result, our bright steel fulfills the highquality requirements of the automotive andmechanical engineering industries.

Our cross-matched range of servicesbenefits you by ensuring that you alwaysreceive your steel products in tested quality from a single global source.

You also have access to our comprehen- sive array of services. These range fromtechnical advice by highly qualified teamsof engineers to a wide variety of processing possibilities. From simple saw cuts toprocessing with the tightest tolerances:from us you receive virtually everythingthat is technologically feasible in relationto short lengths and end-processing.

Our bright-steel assortment comprisesseveral thousand articles in drawn, peeledand ground finishes, which are polished asstandard.

Whether for country-specific standardqualities or customer-specific specialmaterials for sophisticated components:with Steeltec you have a service partner for every steel solution – if you wish, even for ready-to-install components.

09DRAWN BRIGHT STEEL

The drawing process results in substantially higher dimensional accuracy than with hot- formed steel products. Dimensional accu- racy itself is an important precondition forworkability on multi-spindle automatic lathes which allow the production of high-precision turned parts as specified in drawings. Thedrawing process also results in increasedstrength characteristics (tensile strengthand yield point).

In the case of steel grades with low carboncontent, the drawing process also improves their machinability. For all steel grades,the strain hardening that results from thedrawing process can be reversed in asubsequent heat-treatment process. In ourmost modern production lines, we drawbright steel with high dimensional accuracyand surface quality, as well as definedmechanical characteristics, from bar to bar,from coil to bar, and from coil to coil.

To enable large cross-sections also to bedrawn from bar with maximum precision,we employ bar-drawing benches with adrawing stress of up to 100 tons.

Thanks to the most modern interlinkingof the plant components, we can descale,draw, straighten and saw bright steelfrom rolled raw material without extensivehandling.

For efficient production, an eddy currenttesting system for surface defects as well as the end-processing systems are integrated in our production lines.

With coil-drawing we produce bright steelwith a diameter of up to 40 mm from coil.Here, too, in-line production extends frombending-up, descaling, shearing and straight- ening through eddy-current testing and end- processing to weighing and packing.

Drawn bright-steel bar is always straight- ened and polished after it has been drawn.Thinner dimensions can also be suppliedwound into coils. On request, the coils canalso be laid in layers.

We supply drawn bright steel in a wide range of cross-sectional shapes according to DINEN 10278 in tolerance class IT 11 or IT 9.

Drawn bright steel

Drawn bright steel is produced from hot-rolled steel bar or wire by chipless drawing

1110 GROUND BRIGHT STEELPEELED BRIGHT STEEL

Peeled bright steel is exclusively roundmaterial (usually 14 mm diameter andhigher). Compared to rolled steel,the material has greater dimensionalaccuracy and a bright, smooth surface.

This kind of bright steel is peeled fromrolled or forged steel bar by rough-turningand afterwards it is straightened andpolished. When peeling, the chip takeoff

is measured to such an extent thatunavoidable surface defects resultingfrom the manufacturing process, such asrolling marks, cracks, pores, splinters ordecarburisation seams are removed.

We supply peeled bright steel according toDIN EN 10278 in tolerance class IT 11 orIT 9. Other tolerances can be supplied uponrequest.

Ground bright steel is drawn or peeledround material which has been additionallyground and polished to achieve an evenbetter surface quality and an even greaterdimensional accuracy.

This surface quality is therefore particularlysuitable for surface finishing with high-glosscharacteristics.

The high dimensional accuracy of groundbright steel is of outstanding importancewherever it is used for machine partswithout further surface treatment.

We supply ground bright steel according toDIN EN 10278 to tolerance class IT 6.

General engineering steel according to DINEN 10125 and DIN EN 10277-2 stands forunalloyed steel grades which are mainlyused in steel construction and mechanicalengineering.

These steel grades can be given specialmechanical-technological characteristics.

The following engineering steel gradesare standardized in DIN EN 10277-2:» S235JRC +C and +SH [FN]» E295GC +C and +SH [FN]» E335GC +C and +SH [FN]» S355J2C +C and +SH [FF]

Strength-controlled steel grades:FN = rimming steel not permittedFF = fully killed, with sufficient contentof nitrogen-binding elements, normalizedon request.

Peeled bright steel

We supply peeled round material according to DIN EN 10278

Ground bright steel

Steel for general applications

1312 FREE CUTTING STEELCASE HARDENING STEEL

Case hardening steel according toDIN EN 10084 and DIN EN 10277-4 aresteel grades with a relatively low carboncontent, which are used for workpieceswhose surface layers are normally car- burized or carbonitrided before they arehardened. This gives them substantiallygreater hardness in the surface layer whilemaintaining the better toughness of thecore zone.

Unalloyed case hardening steel is usedfor low-stressed parts such as hubs, shaftsand levers for vehicle and general mecha-nical engineering.

Depending on the alloy, alloyed case hard- ening steel is used for parts with mediumto high core-strength and toughness. Suchparts include highly stressed gearwheelsand control components in vehicles andaircraft construction and others.

Unalloyed steel grades:e.g. C10E, C10R, C15E, C15R

Alloyed steel grades:e.g. 16MnCr5, 20MnCr5, 20MoCr4.Other steel grades on request.

Alloyed steel grades with controlledsulphur content:e.g. 16MnCrS5, 20MnCrS5, 20MoCrS4,20NiCrMoS2-2

The standard conditions are as follows:+C = cold drawn+SH = peeled, from 14 mm round+A = soft annealed+TH = treated on hardening strain+FP = treated on ferrite-perlite material structures

In some cases, these grades can also besupplied with an additional lead content(0.15 - 0.30 %).

Compared to sulphurized steel grades,free cutting steel (DIN EN 10087 andDIN EN 10277-3) shows a substantiallyimproved machinability and surface fi nishwhich allow shorter production times.

Soft free cutting steel:e.g. 11SMn30, 11SMnPb30, 11SMn37,11SMnPb37

These grades can also be supplied withadded tellurium and/or bismuth. Heat-treat- ment for special magnetic properties canbe agreed upon request.

Free cutting case hardening steel:e.g. 10S20, 10SPb20, 15SMn13

Free cutting heat-treatable steel:e.g. 35S20, 36SMn14, 38SMn28, 44SMn28,46S20

These steel grades are normally supplied incold-drawn condition.

Other conditions can be agreed upon request:+SH = peeledAdditionally heat-treated conditions:+A = soft annealed+SR = stress-relieved+QT = quenched and tempered

Case hardening steel

Steel according to DIN EN 10084 and DIN EN 10277-4 for case hardening

Free cutting steel

Steel according to DIN EN 10087 and DIN EN 10277-3 for high-speed machining

1514 OTHER STEEL GRADESHEAT-TREATABLE STEEL

Heat-treatable steel according toDIN EN 10083 and DIN EN 10277-5 aresteel grades that are intended for quen-ching and tempering.

In addition, through inductive surfacehardening, they can also be given maximum wear resistance. They are used for highlystressed screws, springs and piston rods,where especially the combination of highstrength, wear-resistance and toughness isvery important.

Unalloyed steel:e.g. C22 to C60, C22E to C60E, C22R toC60R

E = high-grade steelR = high-grade steel with a controlledsulphur content of 0.020 to 0.040 %

Other conditions:+C = cold drawn+SH = peeled, from 14 mm round+A = soft annealed+SR = stress-relieved+N = normalized+QT = quenched and tempered

For improved machinability, these steelgrades can also be supplied with addedlead of 0.15 to 0.30 %.

Alloyed steel:e.g. 38Cr2, 46Cr2, 34Cr4, 37Cr4, 41Cr4,25CrMo4, 42CrMo4, 50CrMo4, 36CrNiMo4, 34CrNiMo6, 30CrNiMo8, 51CrV4.

Grades 38Cr2 to 42CrMo4 can also besupplied in sulphurized condition withS = 0.020 to 0.040 %. We supply othersteel grades on request.

Wind energy: We produce the basic material for up to

per rotor blade

After heat treatment, this steel is characte-rized by good cold formability.

The following conditions are available:+C = cold drawn+SH = peeled, from 14 mm round+A = soft annealed+FP = treated on ferrite-perlite material structures

Additional surface treatments such as phos- phating or polymer coating are possible onrequest.

We issue material testing certificatesaccording to DIN EN 10204. The contentsand tests to be certified must be agreedupon when ordering.

Heat-treatable steel

Steel according to DIN EN 10083 and DIN EN 10277-5 quenched and tempered to be high-strength

Other steel grades

Cold heading and cold extrusion steel according to DIN EN 10263

1716 DIMENSIONSDIMENSIONS

Dimensions

Lengths according to DIN standard or standard commercial lengths

Our bright steel assortment comprisesmore than 5,000 articles with approximately 400 material variants in drawn, peeled andground finishes.

Dimensional ranges for our bright steel:» Drawn from 6 to 80 mm round» Peeled from 14 to 125 mm round» Ground from 6 to 125 mm round» Squares, hexagons and octagons up to 80 mm» Dimensional limits are dependent on the quality.

We produce steel in lengths according toDIN standard or in standard commerciallengths.

More than

with approximately

We supply special fixed lengths, shortlengths, and specially processed endexecutions on request.

Our steel shows permissible deviationsfrom nominal dimensions according to DINand ISO standard tolerances for brightsteel.

If requested, all tolerances can be suppliedup to ISO tolerance class IT 6.

We also supply special sections in barsor coils in all executions in order to matchdrawings or samples upon request.

1918 PRODUCTION PROGRAMME SPECIAL SHAPED SECTIONSTOLERANCE FIELDS

Production programme for specialshaped sections

Cost-efficient alternative for a large variety of applications

Our hot rolled or bright drawn specialsections are a cost-efficient alternative forconstruction in many fields of application.

For the production of customer-specificspecial sections, high-performance facilities are available at our premises.

The possible shapes are extremely diverseand adapted as far as possible to the indi- vidual requirements of our customers.

Except for air hardening steel, all kinds ofsteel can be delivered.

Weights per meter from 0.22 to 3.5 kg/mare possible, and up to 4.10 kg/m forparticularly suitable cross-sections.

On several winders, we draw not onlyspecial sections but also standard cross-sections from coil to coil, which are pre- rolled in our own conductive hot-rolling mill.

We can also supply special shaped sec-tions only pre-rolled to bar or coil.

In addition to our comprehensive technicalpossibilities, a team of experienced engi- neers is at your disposal for the develop-ment of individual shapes. They canprovide you with solutions for almost everyfield of application.

18

Nominal dimen-sion (mm)

h6 h7 h8 h9 h10 h11 h12

> 1 to ≤ 3 0.006 0.010 0.014 0.025 0.040 0.060 0.100

> 3 to ≤ 6 0.008 0.012 0.018 0.030 0.048 0.075 0.120

> 6 to ≤ 10 0.009 0.015 0.022 0.036 0.058 0.090 0.150

> 10 to ≤ 18 0.011 0.018 0.027 0.043 0.070 0.110 0.180

> 18 to ≤ 30 0.013 0.022 0.033 0.052 0.084 0.130 0.210

> 30 to ≤ 50 0.016 0.025 0.039 0.062 0.100 0.160 0.250

> 50 to ≤ 80 0.019 0.030 0.046 0.074 0.120 0.190 0.300

> 80 to ≤ 120 0.022 0.035 0.054 0.087 0.140 0.220 0.350

> 120 to ≤ 180 0.025 0.040 0.063 0.100 0.160 0.250 0.400

> 180 bis ≤ 200 0.029 0.046 0.072 0.115 0.185 0.290 0.460

Tolerance fields (example: h tolerance)

The above dimensional limits are negative deviations from nominal dimension. For example, for a nominal diameter

of 20 mm with tolerance field h9, valid dimension is 20 mm +0 / -0.052 mm, i. e. 19.948 mm to 20.000 mm.

R = round bar S = square bar H = hexagonal bar

Tolerance fields (example: h tolerance)

Finished state h6 h7 h8 h9 h10 h11 h12

Drawn R R R, S, H R, S, H

Peeled R R R R

Ground R R R R R R R

Polished R R R R R R R

TOLERANCE FIELDS

S+Bi Blankstahl_EN_04-2014_06.indd 18 04.11.14 16:52

21PRODUCTION PROGRAMME SPECIAL SHAPED SECTIONS 21PRODUCTION PROGRAMME SPECIAL SHAPED SECTIONS

Section Sectional shapeWidth

max. mmCross section

min. mm2

Cross section max. mm2

Flat sections Sharp edges or withmill edges

30 30 200

Rounded edgesR approx. 1/3 thickness

33 30 220

Round side surfacesR approx. 1/2 thickness

35 30 340

Round, both sides flattened

35 30 340

Bevelled edges,bevel approx. 1/3 thickness

33 30 340

Square sections

Sharp edges or with mill edges

14 30 200

One side bevelled, sharp edges or mill edges

14 30 200

All sides bevelled or rounded

15 30 230

Production programme for special shaped sections

S+Bi Blankstahl_EN_04-2014_06.indd 21 04.11.14 16:52

Weights per meter from

to

possible

23END PROCESSING

End processing

For efficient production, end-processing system are integrated in our production lines

23END PROCESSING

+C (K), +SH (SH), +SL (SL)Roundin mm

Squarein mm

Hexagonalin mm

Chamfer Standard length

in mm

Chamfer + face 6 - 75 6 - 40 6 - 70 30°, 45°, 60° 2000 - 6000

Chamfer + face + centre 10 - 70 8 - 36 10 - 70 30°, 45°, 60° 2000 - 6000

Tap max. 30 mm on request on request 2000 - 6000

Standard for commercial lengths

For efficient production, end-processing system are integrated in our production lines

End processing

S+Bi Blankstahl_EN_04-2014_06.indd 23 04.11.14 16:52

2524 HEAT TREATMENTSHORT LENGTH PRODUCTION

In our short length production plant, brightsteel is manufactured for further processing purposes in accordance with customerrequirements in diameters of 8 to 80 mm,in lengths of between 25 to 2000 mm, andup to a maximum piece weight of25 kg. Depending on the machinery used,processing lengths (turning) are 10, 50 or120 mm. Depending on the machine anddiameter, length tolerances range between± 0.05 mm and ± 0.10 mm. On high-perfor-mance automatic machinery we can saw,deburr, turn, plan, chamfer, center anddegrease. Furthermore, end processingaccording to drawing can also be providedon request. Respective combinations canbe freely selected.

For special customer requirements andtargeted applications, our bright steelproducts can be heat treated.

Under an inert gas atmosphere, we can per- form stress-relieved, soft and spheroidisedannealing as well as normalisation in thetemperature range from 560 °C to 900 °C.

In addition to that, features relating toprocess safeguarding can also be checked.

Over and beyond the above-mentioned,we can offer further services such aswashing, length measurement, straightness testing, demagnetisation, weight recording,stamping and packaging.

By means of fully automatic packagingsystems, the finished short pieces can becustomer-specifically packed either asbulk freight or in layers in customer ownedcontainers. The packing units can be smallor large, as per customer request.

For highest strength requirements, we cananneal round and hexagonal cross sectionsand tubes in our single-bar quenching andtempering plants. In these facilities we areable to adjust mechanical-technologicalproperties which cannot be achieved byconventional means.

Short length production Heat treatment

Approximately

short pieces per year

Normalisation from

to

26 EDDY CURRENT TESTING

To detect surface defects, depending on the cross-sectional shape and given recordinglimits, either the feed-through coil methodor the rotating system method is used.

For round material cross sections, the twomethods can be used alternatively ortogether. For non-round cross sections,only shape-adapted feed-through coilscan be used.

To achieve the required high defect reso- lution, in most cases differential coils areused for the eddy current surface test.

The differential connection is invariablyaligned with the scan direction of the coil

or rotating probe, i.e. in the case of thefeed-through coil, in longitudinal directionof material, and in the case of the rotatingprobe, in circumferential direction. Thisresults in a specific sensitivity to differenttypes of defect.

Specifically, the encircling feed-through coil is particularly sensitive to short longitudinaland transverse-oriented defects as well asto local flaws such as holes, breakages andpeeling shells.

On the other hand, the rotating probe isparticularly sensitive to detect open lon- gitudinal surface defects, such as overlaps,seams and tension cracks.

Eddy current testing

Differential coils achieve the required high defect resolution

29ULTRASONIC TESTING

When steel is produced, a sporadic occurring of internal material discontinuities cannot becompletely avoided. To ensure that highestrequirements for the internal quality of thebright steel are achieved, we can performultrasonic testing. This method of testing isa so-called non-destructive impulse-echoprocess.

Depending on the application, with theultrasonic method that we use, we can testfor inclusions up to a maximum circular discreflector – also known as flat bottom hole –size of 0.7 mm.

In case of round cross sections, the testingmethod we use also enables us to detect

internal faults in the full volume or full crosssection with a length of 5 mm or more up to0.10 mm below the surface.

This test is currently one of the most rigo- rous checks that can be applied technicallyand economically to bright steel bars and iseven below the limit value of the applicableDIN EN standards.

Typical components that place maximumdemands on the internal quality of brightsteel are, for example, individual parts of thecommon-rail diesel fuel-injection system aswell as engine and gearbox componentsthat are designed for high fatigue strength.

Ultrasonic testing

Our most rigorous test that can be technically and economically performed

30 MATERIALS TECHNOLOGY

Materials technology

Quality ManagementExcellent technical Know-how for the very best steel solutions

Awarded with the Ford Q1 Preferred Quality Award

Steeltec materials technology offers our customers the reliable basis for receiving individual and high-quality steel and alu- minium solutions.

Our technicians’ know-how ensures thatwe understand our customers’ specificrequirements and provide you with theoptimal steel.

Our materials technology is supported bythe latest testing equipment. This enablesus to perform all chemical, physical andmechanical-technological tests that arenecessary to determine the characteristicproperties of the following steel grades:

» Free cutting, case hardening and cold heading steel» General engineering and heat-treatable steel» Stainless, acid- and heat-resistant steel» Tool and high-speed steel

In order to fulfill the highest requirements – such as those of the automotive industries,the automotive supply industries and the mechanical engineering industries – we target at azero-error policy whose main focus is on preventing production errors. In meeting this aim over the long term, we rely on the permanent optimisation of our processes and employ the follow- ing tools and/or methods:

» Project planning/advance quality planning» Statistical process control (SPC)» Process and machine capability analysis» Measuring system analysis (MSA)» Failure Mode and Effects Analysis (FMEA)» Audits (product, process and system audits)» Benchmarking» 8-D reporting» Initial sample routine (PPAP/VDA/IMDS record)

In addition, we have been certified by TÜV Nord in accordance with DIN EN ISO 9001:2008 orISO TS 16949:2009 and by TÜV Rheinland in accordance with AD 2000-Merkblatt WO(Pressure Equipment Directive) and awarded by Ford with the Q1 Preferred Quality Award.

We use the following methods and equip-ment for determination:

» carbon/sulphur (C/S) analyser» chemical analysis by emissions spectro- meter, stationary/mobile» strength and toughness testing by tensile and notched bar impact tests at high and low temperatures» Vickers, Brinell and Rockwell hardness testing and microhardness testing» testing of magnetic properties including hysteresis» determination of microstructure, purity degree and grain size by microsections» detection of internal material flaws by ultrasonic testing» detection of external material flaws by magnetic particle inspection testing and eddy current testing» roughness measurements

3332 DISTRIBUTIONDISTRIBUTION

Steeltec GmbH

Locations

Steeltec GmbHEupener Straße 70D-40549 DüsseldorfTel. +49 (0)211 5 09 2205Fax +49 (0)211 5 09 2314

Steeltec GmbHTrossingenGottlieb-Daimler-Straße 2 - 4D-78647 TrossingenTel. +49 (0)7425 22 03 31Fax +49 (0)7425 22 03 4731

From several locations in Germany we deliver oursteel throughout Europe and around the world.

34 ENVIRONMENTAL AND ENERGY MANAGEMENT SYSTEM

Environmental and Energy Management Systemof Steeltec GmbH

At Steeltec GmbH the responsible hand-ling of resources and protection of the environment are of paramount importance. Alreadyin 2003 we started to build up a comprehensive environmental manage-ment system according to the ISO 14001 international standard.

Steeltec GmbH is certified to ISO 14001:2009. This is subject to regular inter-nal monitoring.

According to the guidelines of the ISO14001 Environmental Management stan-dard, all of the company‘s processes areanalyzed and classified for their environ-mental compatibility. Wherever necessary,optimisation measures are continuouslydefined and implemented.

An effective organisational structure,defined processing methods and operat- ing procedures ensure that the sustainable

corporate goals for responsible handling ofresources and protection of the environment are constantly pursued.

In 2012, Steeltec GmbH, supplemented its environmental management system by adding an energy management system in accordance with ISO 50001:2011.

In line with the specifications of this stan-dard, all energetic processes are firstchecked with regard to their energy effi-ciency and then integrated into strategicand operational energy targets. The assess- ment of these energetic processes involvesdifferentiated acquisition and evaluationof energy data, which creates a basis foridentifying approaches that will facilitatethe long-term improvement of the energybalance. For this reason, the planning stage of new projects already includes an energyanalysis to ensure that energy issues can be taken into account at implementation stage.

Comprehensive environmental management system since

STEELTEC GROUPwww.steeltec-group.comTechnical inquiries: technical.support@steeltec-group.comCommercial inquiries: commercial@steeltec-group.com

Steeltec GmbHEupener Strasse 70D - 40549 DüsseldorfPhone +49 211 509 2315Fax +49 211 509 1315

Steeltec AGEmmenweidstrasse 72CH - 6020 EmmenbrückePhone +41 41 209 6363Fax +41 41 209 5294

Steeltec Praezisa GmbHGewerbestrasse 1D - 78078 NiedereschachPhone +49 7728 6490Fax +49 7728 825 | 1781

Steeltec A/SKystvejen 52, BouetDK - 9400 NørresundbyPhone +45 9817 1211Fax +45 9817 5954

Steeltec Boxholm ABNordenstens väg 2S - 59012 BoxholmPhone +46 142 55 100Fax +46 142 51 968

Steeltec Celik A.S.Pelitli Köyü Pelitli Yolu Cad. No 197TR - 41400 Gebze - KOCAELÍPhone +90 2626 783 800Fax +90 2626 783 899

Find your local contact www.schmolz-bickenbach.com