STEEL

STEEL TRAINING

OEMs are currently faced with a wide range of requirements. While lightweight automotive construction must increase energy efficiency to reduce both fuel consumption and CO2, it must also provide the crash performance needed to save lives. Both are essential, and both contribute to the constant movement that can be seen in the automotive market.

Today, technological changes have both accelerated and become more versatile.  These changes have resulted in shorter and more multifaceted development cycles. As a result, it is essential for all those involved in the automotive market to not to rest on their achievements and prior experience. Instead, they must continuously question and enhance their performance.

Presently, the use of ultra-high strength steel (UHSS) for typical components such as A and B pillars, beams and panels has led to the evolution of Press Hardened Steel (PHS) technology. The percentage of hot-formed parts is rapidly increasing, as still more production lines are put into operation worldwide.

Our training is not only effective, but is distinguished within this field. Training modules are offered for materials, heating methods, forming, process know-how, tooling and measurement, as well for testing technologies. Our innovative and dedicated partners can provide expanded content and in-depth courses.

Customized competence development creates the foundation for "Sustainable Business Success".

Level 1 - BASIC TRAINING

Description

The overall performance, the variety of methods and the high number of practical examples of the seminar are designed in a most helpful way for efficient learning. You will have the opportunity to experiment with various parameter and experience Hot Sheet Metal Forming in a daily basis and acquire a deep insight and an efficient method of operating for this technology.

A detailed view about the topics will be given below. Although the range of the course is going from the state-of-the-art press hardening process to solution-based problem solving approaches and finishes with new innovative ideas in the hot forming sector.

Audience

Engineers, technicians and foremen in the fields of production, assembly, process planning QM & QS and technical sales.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will have the opportunity to experiment with various parameters and experience Hot Sheet Metal Forming in the field and acquire a deep insight into the most efficient skills in technology.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

T1 – Fundamentals

As the topic header already suggests this chapter is all about the fundamentals for press hardening. It aims at creating a basic understanding what press hardening is and what the big advantages behind this technology are. The focus goes towards the automobile industry. Moreover, into the direction of crash performance and the usefulness of press hardened products in this field.

Crash performance

  • Steel banana
  • Specification of material strength classes
  • IIHS tests
  • UHSS product examples in the automobile industry

Press hardening methods

  • Direct press hardening
  • Indirect press hardening

T2 – Semi-finished Products (press hardenable materials)

This unit is all about the materials and coatings that can be effectively used for hot forming of steels. It gives a short overview about the material structures and alloy contents that need to be insured. The state-of-the-art material, the 22MnB5 is discussed and compared to new innovative ideas generated from the material- and coating point of view.

Fundamentals for press hardenable materials

  • Overview of the needed material structure – ZTU
  • Carbon content
  • Alloys

Boron alloyed steel – 22MnB5

  • Uncoated
  • Al-SI coated USIBOR1500P
  • Zinc coated
  • Diffusion and austenitisation

Non-corrosive stainless steel

Material combinations – tailor made materials (HSLA)

Further materials

T3 – Measurement Systems

Before going into the first practical unit of this seminar a knowledge about the current needed measurement systems in a hot forming process need to be discussed. Measurement systems are needed to guarantee a specific heating rate in the oven but also need to monitor the cooling rates during the forming process.

Overview of state of the art temperature measurement systems

  • Thermocouples
  • Pyrometer
  • Thermo camera

P1 – Laboratory heating fundamentals

Based on the knowledge gathered in the previous units this practice aims on getting a feeling about the material heating and cooling. Experiments are made with different test parameters concerning, material thicknesses, cooling media and transport times. This will give a comprehensive understanding were temperature losses can potentially occur during the press hardening process.

Working with the roller hearth furnace

Heating and cooling of press hardenable materials under different conditions

  • Metal sheet thickness
  • Transport times
  • Cooling on air
  • Temperature losses
  • Measurement system (Thermocouples, Thermo camera, Pyrometer)

T4 – Heating Technologies

There are various different heating possibilities for press hardening. Still, state of the art tells another story. Roller hearth furnaces are primarily used in the process chain of press hardening. A close look into this technology will be given in this unit. What is the operating principle? What is the efficiency of this technology? How can you calculate the needed energy for your products? Just to name some of the question that will be answered in this unit. Nevertheless also other heating technologies are discussed and compared to roller hearth furnace technology.

Fundamentals

  • Radiation
  • Convection
  • Heat transfer

State of the art roller hearth furnaces

  • Operating principle
  • Efficiency level
  • Energy recuperation
  • Advantages and disadvantages of this technology

Alternative heating concepts

  • Induction
  • Conduction
  • Indirect induction (flat iron principle)
  • Infrared

T5 – Tool- and Plant Technologies

Tool design plays a big role for hot forming because the cooling of the material during the forming process is the main reason for achieving a high strength product. The unit provides information about overall tool setup and design, different cooling strategies and materials and coatings used tool manufacturing. Furthermore, knowledge of a hot forming serial production line is provided. This includes the different units needed within the press hardening process, handling in-between the units and measurement systems which provide the quality of the process. Also a fundamental knowledge of different press designs is created within this unit.

Usefulness of cooled tools

Construction of a cooled tool

  • Monocoque construction
  • Segmented construction
  • Rapid-Tooling
  • Casted construction

Tool raw materials & surface treatments (overview)

Structure of a serial production plant

  • Handling
  • Oven
  • Press
  • Interface analysis
  • Sequences in-between the single components & their linking

Inline measurement

Structure of a press

  • Necessary equipment
  • Velocities
  • Forces

Cooling aggregates

P2 – Laboratory test tool

First press hardening experiments with a simple flat tools are made and investigated. The focus hereby lies on the cooling of the material. Different cooling media are compared and the difference in hardness of the products are measured. Also, the influences of different heating curves in the furnace is considered within this unit.

Micro hardness measurement

  • Air cooled part
  • Tool cooled part
  • Temperature variations

T6 – Simulation for hot forming

The unit aims at creating a comprehensive understanding of simulation as tool for supporting the hot forming process. The unit is not designed for simulation engineers but for forming engineers and technicians to get a better feeling of the importance of simulation as a tool to increase overall development efficiency for a product.

Fundamentals

  • Influence parameters
  • Interaction of mechanical and thermal properties
  • Failure criteria

Outlook tool calculation

P3 – PHS Laboratory

This practical block aims towards the manufacturing of industrial realistic geometries. In detail a sample automotive part is manufactured. The whole process chain, starting from the semi-finished sheet metal, through part heating, direct press hardening with included measurement systems towards product final inspection is shown.

Press hardening of a PHS-part

  • Temperature measurement during the forming process
  • Temperature measurement after the forming process

Validation of Hot spots

P4 – Follow-up Operations

Follow-up operations are normally the last finishing step in a standard press hardening process chain. This part focuses on the part measurements in terms of quality control and the differences in trimming operations with high- and ultra-high strength steels to normal steels.

Trimming

  • Laser trimming (practical)
  • Hard trimming (lecture)

Part measurements

  • 3MA System (practical)

T7 – Summarization & exam

  • Summary of the training
  • FAQ
  • Feedback

Price on request

>>> PDF download 1000-L1-01

REGISTRATION

Level 2 - ADVANCED TRAINING

Description

The steel microstructure defines the final mechanical properties of the formed parts. The evolution of the microstructure characteristics, such as phase composition and grain size will be defined in theoretical units. The attendee will have an opportunity to create experimental investigations on the influence of various process parameters, for example, heating temperature, transfer time, and the cooling rate on the resulting mechanical properties. Furthermore, the influence of the process chain on the surface properties regarding coated and uncoated materials will be clearly represented. The structure and composition of the surface layers of press hardened materials will be investigated and analysed. The scheduled material investigations and analysis will be built on widely used press hardenable materials such as 22MnB5 and 34MnB5.
This course combines theoretical explanation of materials phenomena with experimental internship in laboratory and final analytical examination of generated press hardened parts.

Audience

Engineers and technicians in the fields of production, tooling, material testing and QM & QS.

Prerequisites

Successful completion of the Principles of PHS „Heat Treatment & Hot Forming of Steel“.

Benefits

This Advanced Training is aimed at the development of deepening each participant’s present knowledge in material behaviour during the complete press hardening process. This knowledge creates a solid foundation in understanding the influence of the process parameters on the press hardened components.

Methods

To achieve the objectives listed in the content, digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key-players in this market.

Content

Theoretical units aim at creating a deep understanding of material transformations during heating, cooling and forming.

T1: Introduction

  • Light weight design with steel
  • Press hardening process

T2: Steel structure and properties

  • Crystal structure
  • Phases in steel
  • Influence of time, temperature and alloying elements on phase composition
  • Phase diagrams: equilibrium, time-temperature-austenitisation (TTA), time-temperature-transformation (TTT), continuous-cooling-transformation (CCT)

T3: Basic properties of press hardenable steels

  • Chemical composition and mechanical properties
  • TTA, TTT and CCT diagrams
  • Coatings

T4: Phase transformations during press hardening and mechanical properties

  • Austenitisation
  • Formation of martensite, bainite and ferrite
  • Adjusting of mechanical properties

T5: Surface properties

  • Scaling of uncoated materials
  • Evolution of AlSI-coating
  • Surface roughness in dependence from the heating rate

T6: Materials Characterization

  • Destructive and non-destructive material testing
  • Tensile and hardness testing
  • Metallography, optical and laser microscopy
  • Scanning electron microscopy

The main goal of the practical units is to obtain a practical experience of the influence of process parameters on the properties of press hardened components. The first part of the internship contains the production of small-scale components on the laboratory equipment simulating the whole press-hardening process chain. The second part of the practical training includes testing and analysis of the produced components.

P1: Press hardening in laboratory

Experiments to investigate the influence of

  • Heating parameters on austenitisation
  • Transport time on mechanical properties
  • Cooling conditions on mechanical properties
  • Heating time on surface properties

P2: Analysis of press hardened components

  • Hardness measurement
  • Tensile testing
  • Metallography and optical microscopy
  • Surface properties with laser microscopy
  • Scanning electron microscope

T7: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

>>> PDF download 1000-L2-01

REGISTRATION

Description

The main goal of this Advanced Training is the explanation of the process monitoring requirements and the quality control methods of press hardened components. The attendee will get a theoretical knowledge about the possible sources of production defects and their dependence on the process parameters. Furthermore, the background information about the principles of the process monitoring and the components inspection methods like thermography, non-destructive mechanical testing and 3D optical measurement. The practical internship contains the production of press hardened components on the automated pilot plant with variation of the process parameters. The influence of the parameter variation on the temperature distribution in steel blanks and pressed components will be obtained using thermography measurements. The effect of the thermal history on the components quality will be investigated making use of the non-destructive mechanical testing and the 3D optical measurement.

Audience

Engineers and technicians in the fields of production, tooling, material testing and QM & QS.

Prerequisites

Successful completion of the Principles of PHS „Heat Treatment & Hot Forming of Steel“.

Benefits

The attendee will get a theoretical knowledge about the possible sources of production defects and their dependence on the process parameters. Furthermore, the background information about the principles of the process monitoring and the components inspection methods like thermography, non-destructive mechanical testing and 3D optical measurement.

Methods

To achieve the objectives listed in the content, digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key-players in this market.

Content

Theoretical units aim at creating a deep understanding of material transformations during heating, cooling and forming.

T1: Process monitoring

  • Sources of manufacturing defects
  • Requirements to process monitoring

T2: Selected quality control methods

  • Temperature measurements
  • Mechanical properties measurements
  • 3D optical measurements

P1: Press hardening on pilot plant and thermography

Temperature distribution in steel blanks in dependence on

  • Heating parameters
  • Transport parameters
  • Forming parameters

P2: Analysis of press hardened components

  • Distribution of mechanical properties
  • 3D geometrical measurements

T3: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

Nowadays energy efficiency and crash performance bring a lot of requirements within the material or the material selection. Anyone who wants to successfully manage automotive lightweight construction today must understand the principles of tailored part properties. Therefore, essential knowledge is crucial. The TPP training will give the participants the opportunity to take over a leading role in utilizing this technology on a practical level according to OEMs standards.

Audience

Engineers and technicians in the fields of production, material testing and QM & QS.

Prerequisites

Successful completion of the Principles of PHS „Heat Treatment & Hot Forming of Steel“.

Benefits

Leading engineers in the field of press hardening with the key aspect on TTP will introduce new engineers and technicians into the comprehensive field of TTP. The participants will experience the different challenges in this field as well different design concepts by detecting the problems outlined in previous tests. Leading engineers in the field of press hardening with the key aspect on TTP will introduce new engineers and technicians into the comprehensive field of TTP. The participants will experience the different challenges in this field as well different design concepts by detecting the problems outlined in previous tests.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

Theoretical units aim at creating a deep understanding of TWB- and TRB- material transformations during heating, cooling and forming.

T1: The following questions will be answered

  • How can tailored part properties be achieved?
  • What are the advantages for locally different material properties regarding safety, weight and costs?
  • What needs to be considered for the PH process when working with TWB/TRB?
  • What are the possibilities to produce partial heat treated or tempered stamping parts?
  • How does tailored parts influence the tool design?
  • How and where can it be used in serial production?

T2: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

The advanced training in the field of tooling is based on the learned in basic training bases. There are taught vocational skills in the area of tool design. Beginning from an existing component geometry our trainers show the different work steps to create the geometry and function of a PHS-tool.

We consider together virtual engineering approaches like FEM and CAD. In particular the cooling of PHS-Tools is demonstrated because it is essentially important.

Design philosophies, possible errors and the selection of proper tool materials are also included in this seminar. It is completed by real case studies of PHS- tools from Schuler. Additionally, you have the possibility to get insights in Try- out, Tool setting and an operating PHS-line by guided tours.

Audience

Engineers, technicians and foremen in the fields of tooling, production, quality assurance, assembly and process planning.

Prerequisites

Successful completion of the Principles of PHS „Heat Treatment & Hot Forming of Steel“.

Benefits

In cooperation with leading engineers and technicians in the field of press hardening and the key aspect on tooling, a training concept will be developed. The aim is to introduce new engineers and technicians into the special field of tool design in hot sheet metal forming and press hardening, to show the different challenges in this field and different design concepts.

By this training a fast and coordinated know-how transfer should be established in order to reduce the amount of trial and errors of beginners in this new technology.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

The main focus of this training is the following key aspects and their sub items.

T1: Introduction and fundamentals in Press Hardening of Steel (PHS)

  • Recapitulation Process fundamentals - Direct Press Hardening Process Chart, Overview of the needed material structure – ZTU, UHSS product examples
  • Which quality characteristics have to be fulfilled? - Critical quenching rate, Interface between tool/press/cooling, Thermal expansion, Form- ability of 22MnB5, Product Warping, Cooling media mass flow, etc...
  • PHS product design, most important process parameters, tool concepts, thermal   treatment

T2: Process Parameters for Tools

  • Cooling approaches, handling of problem areas
  • Segmented construction
  • Tool design
  • Failure possibilities (drawing clearance, wear, blank holder, positioning ejector, etc.)
  • Failure criteria by replica or drawing clearance measuring
  • Process control by measurement system in the tool
  • OEM Parts with welding patches (Process and tool Design)
  • Presentation about different coatings (AlSi, Zinc coating, uncoating…)
  • Flow, pressure, temperature of cooling networks
  • Advantages and disadvantages of different types of design (Direct, Bridge…)
  • Type of pipes recommended (pipes material, diameter …)

T3: Virtual Engineering

  • From the component geometry to the tool
  • Interface definition and using software
  • How the product geometry has to be? Already possibilities for optimization? What is not possible (for example: undercuts)
  • Active surface construction
  • Blank shape
  • FEM Simulation (Live presentation case study AutoForm vs. Pam- Stamp vs. LS-Dyna)
  • CAD (Catia)
  • Trimming

T4: Tool Materials and Coatings

  • Hot forming tool steel (mechanical and thermal properties)
  • Tool coating
  • Laser Material Deposition (LMD)
  • Recent developments

T5: Practical Examples

  • Case Studies

P1: Practical Examples

  • Tool-Shop for Hot Forming Tools
  • Tool Setting
  • Training-Center PHS-Line

T6: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

>>> PDF download 1000-L2-04

REGISTRATION

Description

The focus of this training is clearly focused on the particulars of the micro magnetic

measurement system of Fraunhofer IZFP (3MA). 3MA is possibly the most exciting measuring principle to be applied for qualifying a process hardened steel component and this even on a non-destructive testing basis. Once calibrated the 3MA system allows a steel component to be qualified quantitatively in terms of yield and tensile strength, proportional and fracture elongation stress, hardness, coating thickness and much more. A sensor device is simply swept over the component to be inspected which allows the inspection to be performed during the manufacturing process. Consequently 100% quality control may be provided in the end. All this information is available within seconds.

Audience

Engineers and technicians in the fields of production, material testing, QM & QS and technical sales.

Benefits

Leading engineers in the field of press hardening with the key aspect on TTP will introduce new engineers and technicians into the comprehensive field of TTP. The participants will experience the different challenges in this field as well different design concepts by detecting the problems outlined in previous tests.

By this training a fast and coordinated know-how transfer should be established in order to reduce the amount of trial and errors of beginners in this new technology.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

T1: General Introduction (short introduction of IZFP and trainer)

  • Testing Procedures
  • Difference between destructive and non-destructive testing
  • Qualification of technical staff
  • Standardization of non-destructive testing methods
  • What means 3MA testing?

T2: 3MA-testing – Qualified use based on standards

  • Procedure for qualification/validation
  • Theory of 3MA-Method
  • Application range
  • Physical background
  • Functional principle
  • Testing procedure
  • 3MA software
  • 3MA-Calibration
  • Used definitions and calibration methods
  • Preparation of calibration samples
  • Recording of 3MA data
  • Determination of reference data
  • Calculation/Validation of calibration functions
  • Activation and use of calibration

P1: Calibration of 3MA unit

  • Test execution

P2: Determination of mechanical technological parameters by 3MA

  • Test execution

T3: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Level 3 - EXPERT TRAINING

Description

The training gives the opportunity to transfer the basic knowledge to the installed processes in the plant. Participants learn how to handle their own equipment within the process of hot stamping. Special attention is paid to possible sources of error, such as handling time, temperature of the sheet, the transfer time between interface furnace / press.

The definition of “process window” includes the consideration of the influencing factors e.g. component dimension, sheet geometry, coated / uncoated material, oven temperature, dew point, transfer time. The procedures in the course vary depending on the available equipment of the companies.

Audience

Engineers and technicians in the fields of production, material testing and QM & QS.

Prerequisites

Successful completion of the Principles of PHS „Heat Treatment & Hot Forming of Steel“.

Benefits

Participants learn how to handle their own equipment within the process of hot stamping. Special attention is paid to possible sources of error, such as

  • handling time
  • temperature of the sheet
  • the transfer time between interface furnace / press

Methods

To achieve the objectives listed in the content, digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key-players in this market.

Content

Theoretical unit aim at creating a deep understanding of accuracy and necessary steps to be successful.

T1: Introduction

  • Short repetition of the basics of the press hardening process
  • Assessment of the on-site work piece spectrum
  • Calculation of transfer times, furnace time
  • Definition of process parameters of the hydraulic press
  • Further Topics in coordination with customers

T2 – Summarization & exam

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

The basic knowledge gained from the Principles of PHS Training and the Advanced Level Trainings must be purposefully used for the company. The on-site trainings give the opportunity to transfer the basic knowledge to the installed processes in the companies. Participants learn how to handle their own equipment within the process of hot stamping. Special attention is paid to possible sources of error, such as handling time, temperature of the sheet, the transfer time between interface furnace / press.

The definition of “process window” includes the consideration of the influencing factors e.g. component dimension, sheet geometry, coated / uncoated material, oven temperature, dew point, transfer time. The procedures in the course vary depending on the available equipment of the companies.

Audience

Engineers and technicians in the fields of production, material testing and QM & QS.

Prerequisites

Successful completion of the Principles of PHS „Heat Treatment & Hot Forming of Steel“.

Benefits

With this approach it can be insured that the specific issues of the companies’ press hardening process can be addressed.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

Theoretical unit aim at creating a deep understanding of accuracy and necessary steps to be successful.

T1: Introduction

Short repetition of basics of measurement systems and quality control. The following questions will be discussed and answered.

  • What should be measured?
  • How and when should it be measured?
  • At which positions should what be measured?
  • What is the profit gained out of these measurements and what are the necessary follow-up steps?
  • Further Topics in coordination with customers

T2 – Summarization & exam

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

In this training the operator learns in his own workplace everything worth knowing about the press hardening equipment and how it can be used optimally in everyday life.

Audience

This training is aimed at groups of people responsible for operating the running PHS production line.

Benefits

The participants will be sensitized to recognize and evaluate relevant product-quality indicators during the process and, therefore, to take proper decisions during PHS line operation.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

Basic understanding on various effects of adjustment of process parameters on relevant material processing properties (e.g. tool life, roller pollution, etc.) and final product properties (e.g. surface properties, coating consistency, mechanical properties, etc.) will be gained. The focus of this training is the key process parameters and controls. The objective here is as fast as possible to get to a safe and stable process.

Price on request

REGISTRATION

Description

This specific training in the field of Press Hardening Technology (PHT) is based on the recent developments. This “update training” has been developed in cooperation with leading engineers and technicians. While it is an update training, it still keeps the total picture of PHT.

The aim of this training is to introduce engineers and technicians to the state of the art and how these could be translated into new opportunities for the team.

We discuss different opportunities as well as challenges that could occur during this relatively new PHS-processes, as well as their approach and methods of resolution.

The seminar is completed by real case studies of digicon Academy and its partners.

Audience

Engineers, technicians and foremen in the fields of tooling, production, quality assurance, assembly and process planning.

Prerequisites

Understanding the PHS-Process and experience in PHT.

Benefits

The participant will be required to think outside the box and think about new ways to rise efficiency which the company benefits from. Attendees get essential market updates and a comprehensive know-how upgrade.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in form of seminar lectures. The involved trainer is highly qualified and an experienced key player in the PHS-market.

Content

The main focus of this training is to give the audience a total overview of the following key aspects and their sub items.

T1: Brief introduction and fundamentals in Press Hardening of Steel (PHS)

T2: Recent developments* in Press Hardening Technology (PHT)

  1. New uses by the OEM's
  • Passenger cars,
  • EV's, hybrids,
  • Light commercial vehicles,
  • Heavy commercial vehicles**
  1. New materials offered by the steelmakers
  • Servo press formable air harden able grades**
  • Available and new Zn coatings,
  • Al-Si Pro coating**
  • 2nd and 3rd generation PHS grades
    1.   -- 1.0 - 1.2 GPa grades,
    2.   -- >1.8 GPa grades,
    3.   -- ~1.5 GPa high elongation grades**
  1. Recent applications of tailored parts:
  • Part consolidation through TWB and soft zones
  • Part performance improvement
  • Potential of new grades with TWB’s**
  1. New process methods
  • Servo press forming**
  • Reducing laser trimming
  • New furnaces: walking beam furnace

5. Quality control and maintaining a line

  • 3MA nondestructive testing
  • -- Furnace maintenance: new roller with increased build-up resistance

 * recent developments mostly focus on technologies that have been used since 2015

** items marked are only available since 2018

T3: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Level 4 - PRE- & POST-PROCESSES TRAINING

Description

Friction Stir Welding (FSW) is an innovative pressure welding method, which was first developed and patented in 1991 by the TWI (The Welding Institute) in the UK. Within a short period of time it has found entrance in many distinctive ranges of application, particularly, in fields of mobility. After the original patent lost its validity, an interest to use this procedure in very diverse manufacturing areas increased. The procedure distinguishes itself by the fact that it is possible to weld materials in a ductile condition without fusion. Using this technology, it is now possible to join light alloys such as Mg, Ti- and Al-alloys with a welding speed of up to 25 m/min. In the past, these materials were hardly economically weldable by fusion methods; in addition, Mg/Al and Al/Steel combinations are now producible in high quality. Moreover, the influence on the microstructure of the materials is substantially smaller compared to fusion-welded joints.

Audience

Engineering, Management and Supervisory staff from R&D, Shop floor, Quality assurance, Design, Production Planning departments in Automotive, Aviation and Ship building industry. Additionally, employees of metalworking companies who are interested in taking this welding procedure in the portfolio, e.g., by re-equipment of existing CNC machines.

Benefits

Within this crash course the most important welding parameters and influencing variables for Friction Stir Welding (FSW) are presented, considering valid standards and directives. For example, current tooling developments and their influence on the resulting microstructure in the joining area are considered. In addition, the monotonic and cyclic properties as well as the corrosion behaviour of the produced joints are targeted. Apart from the established destroying testing methods, modern non-destructive testing methods are presented. Furthermore, the current available FSW systems are described with reference to the materials and geometries to be joined. Various variants of the FSW process, for instance, hybrid FSW, Friction Stir Spot Welding and Friction Stir Processing are also covered.

Methods

Lecture, Documentation, Video clips, FSW simulation device.

Content

Theoretical units aim at creating a deep understanding of:

T1: Friction Stir Welding Basics

This process is illustrated in detail and the fundamental parameters and influencing variables are discussed thoroughly. Additionally, aspects are approached through further details, for example, appropriate tools selection, optimized work piece clamping, adequate temperature management and the assurance of a high weld quality. Key questions, for example regarding the use of position-controlled or force-controlled FSW, are answered. Dependent from the produced compounds, the most particular FSW systems are demonstrated with reference to high manufacturing speed, either a high or low metal sheet thickness or a high design flexibility of the weld joint. A FSW simulation device serves for the practical illustration of the process.

Learning objective

Based upon provided knowledge and abilities, the participants are able to understand the fundamental principles of the Friction Stir Welding process and to narrow down the choice of appropriate FSW systems composite dependent on the given conditions.

T2: Appropriate materials as well as microstructure and properties of a friction stir weld

With regard to the weldability of similar or dissimilar materials the development in FSW is advancing quite rapidly. After initially almost exclusively non-ferrous metals and light metals were joined by means of FSW, there are now the first relevant industrial applications for joining steel. Moreover, a key topic is joining of different metal alloys. With FSW it is possible to join materials, which would form non-tolerable brittle phases by using fusion welding.

Connected closely to the production of the welded joint, the microstructure and mechanical properties of the welds have to be taken in account. For this purpose, the formation of the characteristic microstructure in Friction Stir welded joints is explained in detail and the interaction between the formed microstructure, the process temperature and the resulting mechanical properties is described.

In addition, monotonic properties, the resulting hardness profiles the cyclic fatigue behavior of the welded joints, and the appropriate use of high-resolution nondestructive test methods are in the foreground of this course. Furthermore, the corrosion behavior of the welds is considered. The participants are able to clarify themselves with the influences of different process parameters on the weld joint properties by programming the FSW simulation system.

Learning objective

The participants are enabled by the provided knowledge to understand and influence the weld joint properties. They become aware of the most important analysis and testing methods and can select and use the appropriate ones according to their own application needs.

T3: Current and future applications for friction stir welding as well as innovative modifications of the FSW process

Development in the technology of Friction Stir Welding is progressing extremely quick. Continual new relevant scientific papers and information have appeared with the advancement of FSW and related processes. In this unit, the most important industrial applications are shown and the crucial developers are mentioned. Additionally, a method by which information concerning current Friction Stir Weldings can be achieved, will be presented.

Moreover, important advancements such as hybrid FSW, specifically the inductively supported one and the ultrasonic-enhanced Friction Stir Welding are provided. Specialized modifications such as Friction Stir Spot Welding and Friction Stir Processing are demonstrated.

Finally, we discuss the economic efficiency of the FSW technology compared to conventional welding processes. When a Friction Stir Welding system is available on-site, we transfer the gained knowledge from the classroom and the simulation device into practice.

Learning objective

The participants acquire the ability to attain access to the required information regarding the high-dynamic developing FSW technology and to select by economic efficiency criteria the FSW process most appropriate to their specific need.

T4: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

The laser has become an established tool in the process chain of hot sheet metal forming, called hot stamping. While 3D laser cutting of already formed parts, is the widest spread and known application, there are a variety of other laser applications which either enable processes or help to be more efficient compared to other technologies. Focusing on the laser application of cutting in 3D, the laser has not only helped to strengthen the position of the laser as a tool, but also it revolutionized its effectiveness in the production chain of hot stamped parts. During the last decade, there has been a constant growth of this technology and has risen to a global mega trend with high volume of parts and constantly changing trends. This development certainly has accelerated the continuous technical improvements of the laser cutting machines and the changeover to new laser sources with better performance and characteristics according to these materials, to meet the special requirements and needs for the users in this application. This makes the laser to the state-of-the-art technology in this application with substantial advantages over others.

Audience

Engineers, technicians and foremen in the fields of production, quality assurance, assembly and process planning.

Benefits

The Intensive Laser Seminar is aimed at giving a detailed view about the laser as a tool in general, enlarge upon 3D laser cutting in hot forming steel including important topics like characteristics of different laser sources, laser safety, programming of cutting programs, part positioning, loading concepts, etc.

The overall performance and the practical components of the seminar are designed most helpful for efficient studying.

Methods

To achieve the objectives listed in the content, digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key-players in this market.

Content

T1: Overview of laser applications in the process chain of hot stamping

A comprehensive understanding of the principal, function and benefits of the laser technology and it´s industrial applications, with focus on cutting in sheet metal and hot forming.

  • 2D processing/laser blanking
  • AlSi ablation/preparation for TWB welding
  • TWB welding of Boron steal
  • Laser metal deposition for press tool/die repair
  • 3D cutting of hot stamping parts
  • Softening
  • Scanner welding, Marking, etc.

T2: Basics of laser technology

The focus of this unit is to develop a deeper knowledge on fundamentals in laser technology.

  • Laser principal
  • Types of lasers (CO2, Solid State, Micro, etc.)
  • Laser safety
  • Laser radiation of CO2 and solid state lasers
  • Laser classes
  • System components of a laser (chiller, power supply, beam guidance, optics, etc.)
  • Practical laboratory demos:
  • Explanation of a beam guidance with a LLK sample
  • Explanation of a CO2 Laser in the laser assembly facility
  • Explanation of a solid-state laser
  • Laser beam characteristics (beam quality, optical components, etc.)
  • Matrix of laser types and its typical use

T3: Laser Cutting in general

Gaining an overview over different actual process variations of the laser technology.

  • Principle of cutting and its characteristics
  • Materials to cut with laser
  • Cutting gases
  • Limitations of laser cutting

T4: Laser Cutting of hot formed parts

The focus of this unit is to get a comprehensive understanding of different actual laser cutting variations of hot formed parts.

  • Why using solid state lasers?
  • N2 and compressed air as cutting gas
  • Influence of material cuttings in the speed, quality, etc. of the parts
  • Technology/Cutting tables

T4: Cutting fixtures

An overview over different concept of laser cutting will be provided from a material-oriented technological point of view as well as from a process-oriented point of view.

  • Cartesian system or robot?
  • Machine components of a cutting cell
  • Special requirements to a system for the cutting of hot stamped parts
  • Practical Laboratory demos:
  • 3D laser cutting of a hot formed part
  • Cutting with different parameters (gas pressures, speed, etc.)
  • Software features for higher machine performance, process safety and quality control
  • Inline-/Connected scrap conveyors for multiple machines

T5: Available 3D Programming software tools

A deeper understanding of 3D programming tools will be presented and optimized.

  • Cycle time studies on a 3D model
  • From a 3D model to a cutting program/sequence
  • Optimization of cutting programs

T6: Different Machine concepts for 3D Laser Cutting

Target of this unit is to provide insights of current trends and advanced techniques of the various laser technologies.

  • Design concept and features
  • Requirements and safety
  • Interfaces

T7: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

During the past years, demand for hot sheet metal technology in car body design has increased dramatically due to increasing requirements in passenger safety and weight reduction of car body structures.
Hand in hand with the increasing use of hot-stamped parts in car body designs goes an increasing number of companies entering the market and getting involved with this technology. This has created a demand for staff qualification programs to shorten the ramp up times and to become a competitive player in an expanding market.
Simulation software can assist this process in various ways. First and foremost, simulation of the process is mandatory to shorten time-to-market and to avoid unexpected and costly changes late in the engineering cycle. In addition, simulation software is an excellent means to make the complex interactions between material behavior and process design transparent. This allows simulation software users to quickly and easily assess the process sensitivity with respect to process parameters and – in this way – to gain a much deeper understanding of the actual manufacturing process as it relates to the quality of the manufactured product. This training module is focusing on gaining a faster and deeper understanding of hot stamping processes by using AutoForms software simulation and visualization capabilities. The goal of this training module is to become productive faster and to take control of the process in order to produce hot stamped parts of the desired quality and mechanical behavior faster and with less cost.

Audience

Engineers and technicians in the fields of production, simulation and process planning.

Prerequisites

  • AutoForm-Essentials or equivalent knowledge
  • Previous exposure to AutoForm

Benefits

In the two days course participants will, though practical application of the principles of thermomechanical metal forming, gain a deep understanding of the Hot Stamping manufacturing process within the context of metal forming simulation. Participants will be challenged to personally setup and run a variety of Hot Stamping simulations in pursuit of applying knowledge of the engineering and design requirements of production Hot Stamping product applications.
The majority of course time will be spent operating the commercial Finite Element Analysis code AutoForm-ProcessExplorerplus and AutoForm-Thermosolverplus to simulate common advanced product feasibility, stamping process engineering and process design issues that arise in the hot stamping sheet metal product process chain. Upon completion of Module B participants possess practical skills in the creation and interpretation of Hot Stamping simulations.

Methods

To achieve the objectives listed in the content, digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key-players in this market.

Content

T/P1: Finite Element Model and Simulation Setup

An overview of important input parameters for a thermo-mechanical finite element simulation will be presented. The objective of this lecture is to provide a comprehensive understanding of a finite element model and how physical effects are considered during process simulation.

T/P2: Materials

Press hardening is much more complex than cold stamping, because of the various interactions between mechanical, thermal and metallurgical effects. During this lecture it will be explained step by step how to extend a simulation model from a conventional stamping process to the requirements for an accurate press hardening process simulation. The generation of the simulation model has three major topics:

  • Material properties (temperature and strain rate dependent),
  • Heat flux (within the blank, between blank and tools/ambient),
  • Phase transformation and final product properties.

Easy and comprehensible examples are used to explain how experimental results and physical parameter incorporate into the finite element model. Simulation based design studies will show the sensitivity of the model parameters.

T/P3: Process Simulation and Result Evaluation

Simulation of press hardening processes offers the chance to shorten development cycle times. This session provides an overview of engineering tasks that can be solved with finite element analysis in an industrial development environment. Different options for a simulation setup for industrial purposes will be introduced and discussed with respect to their strengths and limitations. In an early phase of development the main task is to quickly evaluate concepts and to ensure a feasibly part. Later in the engineering workflow, before the tools are released for milling, the focus of the simulation setup is on accuracy to finally validate the press hardening process. With respect to efficiency it is reasonable to adapt the simulation setup according to these two contrary requirements from „fast“ to „accurate“. During this workshop session typical engineering tasks will be discussed. In shop exercises simulation results are used to define the blank outline and blank position, optimize temperature control, avoid wrinkles and cracks, generate input for crash analysis (result mapping).

T/P4: Advanced Simulation Techniques

Press hardening is an innovative technology that develops fast. Aim of this seminar is to provide insights of current trends in advanced simulation techniques and the simulation of the various press hardening process strategies.

Stamping simulation and press hardening technology continuously develop innovations. During this seminar advanced simulation techniques will be introduced. Based on an example for direct press hardening of a B-pillar the simulation input definition will be modified to investigate various press hardening process strategies:

  • Direct versus indirect press hardening,
  • Tailor welded and tailor rolled blanks,
  • Tailored tempering.

Furthermore, simulation setups that address classical optimization issues are presented:

  • Minimum blank outline to save material
  • Systematic process improvement based on automatic parameter variation
  • Optimization of process window to ensure a robust production.

T5: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

The CQI-9 Heat Treat Systems Assessment is standardized in the automotive industry, published by AIAG (Automotive Industry Action Group), the North American association of leading automobile manufacturers. The CQI-9 is supposed to ensure a uniform quality standard in heat treatment.

In addition to a theoretical part in which the contents of the CQI-9 are conveyed, practical training, either directly at the furnace or in your own laboratory, is provided to specifically address the required periodic measurements (IT, SAT, TUS).

Audience

Engineers, technicians and front men from quality management, maintenance and production.

Prerequisites

Basic knowledge of heat treatment and, measurement technology.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will get an introduction to the contents of the CQI-9, optimized execution of the measurements IT, SAT, TUS.

Methods

Digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content - Theory & Practice

  • General information about the AIAG CQI-9
  • Heat Treat Systems Assessment (a catalogue of audit questions)
  • Content and application of the process tables
  • Requirements for thermocouples
  • Instrumentation requirements
  • Instrument Test (IT)
  • System Accuracy Test (SAT)
  • Temperature Uniformity Survey (TUS)
  • Application of the module SURVEYperfect (additional software module)

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION

Description

The AMS2750 is standardized in the aerospace industry, published by the SAE International Group. The AMS2750 is part of the NADCAP accreditation program and supposed to ensure a uniform quality standard in heat treatment.

In addition to a theoretical part in which the contents of the AMS2750 are conveyed, practical training, either directly at the furnace or in EBNER's own laboratory, is provided to specifically address the required periodic measurements (IT, SAT, TUS).

Audience

Engineers, technicians and front men from quality management, maintenance and production.

Prerequisites

Basic knowledge of heat treatment and, measurement technology.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will get an introduction to the contents of the CQI-9, optimized execution of the measurements IT, SAT, TUS.

Methods

digicon Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content - Theory & Practice

  • General information about the AMS2750
  • Requirements on thermocouples
  • Instrumentation requirements
  • Instrument Test (IT)
  • System Accuracy Test (SAT)
  • Temperature Uniformity Survey (TUS)
  • Application of the module SURVEYperfect (additional software module)

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Price on request

REGISTRATION