REVIEW OF ACTIVITIES 2018-2019

ocas

Cover: Electron Backscatter Diffraction (EBSD) image of Nb alloyed carbon steel grade.

TEXT OCAS team, Wright Communications

EDITOR Katrien Meseure

GRAPHIC DESIGN Filip Erkens

PHOTOGRAPHY Alain Sauvan (p. 34), Ann De Vyt (p. 159), Annick Willems (p. 144, 146), Benjamin Brolet (p. vii), Dennis Van Hoecke (p. 132), Filip Erkens (p. vii, 64, 72, 96, 126), J.J. Fitzpatrick (p. 14), Jeroen Op de Beeck (p. 40, 150), Jeroen Van Wittenberghe (p. 74, 128), Johan Deheusch (p. 70), Johan Verlee (p. 76), Katrien Meseure (p. 158), Lode Duprez (p. 68), Luc Berckmoes (p. 58), Maarten Van Poucke (p. 160, 165), Marc Vanderschueren (p. 38, 66), Michiel Corryn (p. 82), Myriam Madani (p. 18), Nuria Sanchez (p. 32), Okan Yilmaz (p. 62), Özlem Esma Ayas Güngör (p. 100), Roger Hubert (p. 42, 78, 162), Rolf Berghammer (p. 86, 88), Sofie Vanrostenberghe (p. 54), Stefaan Van Landeghem (p. 112), Steven Cooreman (p. 60, 148), Ulrike Lorenz (p. 90), with the courtesy of DEME Offshore (p. 134), with the courtesy of Endures (p. 118), with the courtesy of EUROfusion (p. 50), with the courtesy of Perfect+ Events (p. 154), with the courtesy of PowerCell (p. 122)

RESPONSIBLE PUBLISHER Sven Vandeputte, Managing Director OCAS, Pres. J.F. Kennedylaan 3, 9060 Zelzate - Belgium

DISCLAIMER Although care has been taken to ensure that the information contained in the activity report 2018-2019 is meticulous, correct and complete, OCAS nv cannot give any guarantee, either explicitly or implied, with regard to the accuracy, precision and/or the completeness of the aforementioned information. OCAS nv as well as it directors, management, employees and appointees in the broadest sense possible, therefore assume no responsibility, and shall in no event be held liable, for any direct, indirect, special or incidental damage resulting from, arising out of or in connection with the use of this information, nor for any infringement of third party intellectual property rights which may result from its use. 1 DIGITALISATION 2 ENERGY TRANSITION

Introduction...... 8 Introduction...... 36 Man versus machine challenge ...... 10 Solutions for wind power...... 38 Harnessing the power of data...... 12 How hydrogen research fuels the future...... 42 Big data analysis identifies product issues...... 16 Magnelis® protects solar structures ...... 44 Combinatorial metallurgy at work...... 18 Green solutions for tomorrow’s mobility...... 46 Improved simulation capability for ­electric motors...... 22 Cryogenic steels as short- and long-term energy solutions...... 48 Modelling welding processes...... 26 Towards fusion energy ...... 50 Optimisation of materials, processes and structures in a virtual lab . . . . 28 Numerically designed heavy-gauge plate rolling ...... 32

3 DURABILITY 4 MATERIALS & LIFETIME PREDICTION FOR THE FUTURE

Introduction...... 52 Introduction...... 84 Testing methodology boosts new ­material development...... 54 Ever stronger and longer-lasting, ever thinner or thicker ...... 86 Wear on the leg of a jack-up vessel ...... 58 Fully automated lab scale heavy gauge hot rolling and cooling ...... 90 The power to bend high strength heavy-gauge up to 25 mm thick . . . . . 60 Surfaces with impact...... 92 Lighter design without compromising on in-use safety ...... 62 New tracks for green coatings ...... 94 Metallic coatings exposed ...... 64 Heavy-duty loses weight...... 97 New saline weathering grade to ­reduce the maintenance costs Lab wire with tailored chemistry for accelerated research...... 100 of offshore structures...... 66 Failure analysis taken to sea...... 70 Larger, better, faster, stronger: accelerated fatigue testing of large-scale components...... 72 Assessing corrosion in various ­environments...... 76 Combatting sour corrosion in the oil & gas sector ...... 78 Keeping connections tight ...... 80 Measuring high-temperature hardness to save lives ...... 82 5 NANO MATTERS 6 WORKING WITH OCAS

Introduction...... 102 Introduction...... 116 How Atom Probe Tomography can ­expand your horizons...... 104 OCAS and Endures embark on joint offshore and maritime journey . . . . . 118 Zoom into the problem and see the solution...... 108 Value the future, upgrade the past...... 120 To measure is to know ...... 112 Zoom on FININDUS...... 122 The power of combining micro- and nano-analysis equipment...... 114 Ionic liquid technology – green ­alternative to hexavalent chromium . . . . 126 Teaming up to combat climate change...... 128 Optimising the design of metal-to-metal seals...... 132 Collaborative materials’ research to ­accelerate the R&D of our customers...... 134 Bringing tailored solutions to our ­customers...... 138 Facilitating companies in their R&D ­endeavours ...... 142 Front & back office model quickly meets technical support requests from ­neighbouring plants ...... 144 Bending the rules ...... 148 Expanding the product range in a cost-effective manner...... 150 Research 4 .0 – Efficient and smart, with an eye for detail ...... 152

Fact sheet...... 154 Knowledge building...... 156 OCAS provides workshops to support STEM activities...... 158 Seminars...... 160 List of publications 2018/2019...... 166

iii In 2018 and 2019, OCAS has pursued its vision with further developments and Realising our vision innovations in all areas, even within an industrial and economic environment marked by turbulence. As we embark upon in the midst of 2020, we take pride in reviewing for you the highlights of these past two years.

ENERGY TRANSITION change In the context of increasing effects of global warming and greenhouse gas emissions, the primary goal of the so-called ‘Energy Transition’ is to decarbonise our energy systems. Which is an enormous challenge. “In 2025, OCAS wants to be a top-of-mind For the time being, the core of the Energy R&D centre for ArcelorMittal and metal- Transition effort is the generation of based industries worldwide, by offering its electricity using renewable energy resources, like wind, solar and hydro power. customers highly effective alloy and coating For the renewal of gas pipelines in today’s development services and related application changing environmental conditions, testing, accelerating their R&D output an area closely associated with the energy transition, we’re investigating using OCAS’s unique testing, processing the assessment of current and future infrastructure and competencies.” infrastructure for the storage and transport TWO IMPORTANT EXPANSIONS OF EXPERTISE In the summer of 2019, we acquired a controlling stake in – Endures, experts in maritime corrosion and we partnered with Finindus and ArcelorMittal Belgium in Guaranteed, a new spin-off, providing a specialised industrial welding repair activity. Both companies are long-term additions to OCAS’s know- of hydrogen. We’ve been building (sub)nanometre. This 2018-2019 Activity how, reinforcing our areas of focus and creating new competence in hydrogen as a clean Review includes some metallurgical synergies through our collaborations. energy carrier for over 15 years now – examples that show how our high-end Endures, based in Den Helder, The Netherlands, is and today that expertise is coming into microscopic techniques lead to further a contract research company specialising in applied its own. understanding of material behaviour. research on marine corrosion and antifouling. Electrical steels are more important By joining forces with OCAS’s advanced research than ever, with the rapid rise of the Another focus these last two years has activities in metallurgy, coating and steel application e-car industry. One of our key activities been the non-standard testing and development, the two companies combine expertise is the development of electrical steel modelling of materials and components in the field of corrosion and materials science. alloys and related coatings, along with to elucidate everything that triggers This synergy extends our offshore service offer and electromagnetic application testing. damage: fatigue, wear, corrosion, provides custom-made solutions, adding value, In this regard, the development of alloys hydrogen, and combinations of these reducing costs and preventing metal structure and coatings – OCAS’s core business – factors. The strengthening with the damage for our customers. remains a key strategic objective. In the expert services of Endures in the field of last few years, we have supported – and offshore and marine corrosion as well The spin-off company, Guaranteed, operating differentiated – these developments as the industrial spin-off Guaranteed in a synergic way with and within the central with advanced combinatorial, digital contributing to material repair and maintenance department of the ArcelorMittal and nano-characterisation tools. extended lifetime is fully in line with Gent plant, was created by OCAS, Finindus and As our knowledge grows deeper in this strategy. ArcelorMittal Belgium to add value for its customers developing and deploying new steel Industrial assets reliability increase, by repairing, refurbishing and producing large grades, metal alloys and associated using all this know-how, thus is a logical metal parts using Wire Arc Additive Manufacturing coatings or surface technologies, we key working axis for the upcoming (WAAM). Using state-of-the-art advanced simulation must now control the microstructure years. tools to guarantee ‘right first time’ production, and surface conditions down to the Guaranteed works to reduce downtime and lengthen the lifetime of industrial equipment. v Finindus, being a sister company of OCAS, operating mobile units capable of producing of our customers and led to a 20 times is the investment firm of the Finocas group. tall wind turbine towers on site, thereby faster result compared to classical hydraulic The Finindus portfolio is showing a strong overcoming transport restrictions. KTS can testing. Several spin-off projects for other momentum, and OCAS is very well-placed rely on OCAS’s competencies in steel grade applications are now discussed with a to also support these companies as they selection, coating, welding and large-scale number of industrial partners. grow and mature thereby capitalising and fatigue testing. adding value to our competencies and PROGRESSIVE DIGITALISATION infrastructure. One example is Borit, which EXTREME, BUT SAFE, TESTING From the very beginning, OCAS has been is contributing significantly to the energy With regard to the OCAS operations, the a digital lab – and now, with the era of transition. Borit has successfully completed most prominent aspect in the last two years digitalisation sweeping all of industry, we are its investment program including a.o. a has been our ambitious investment plan, forging further ahead in this important area. second, optimised Hydrogate® press and has whereby we continued to make substantial In the last two years, we have extended our positioned itself as a leading independent investments in state-of-the-art equipment. operational backbone systems for managing supplier of bipolar plate assemblies for fuel During this time, OCAS has reaped benefits our R&D laboratory to ArcelorMittal Global cells. Borit delivers its products worldwide from its OCAS XT (Extreme Testing) facility R&D labs and to partners on the Technology to Tier 1 and OEM customers. in Zwijnaarde, with its testing capabilities campus in Zwijnaarde. Keystone Tower Systems (KTS) is another for large components. An example of our advanced digitalisation example of a portfolio company that has Our “Jacket Connection” project financed initiatives is our image recognition tool, successfully entered a new stage in its by the major operators of offshore windmill whereby we convert steel microstructure development. KTS is now building the infrastructure in Europe led to international images into digits, enabling classification first industrial scale production facility recognition in this booming market. In this and objective analysis of ever more complex for wind turbine towers using a patented project our patented test infrastructure microstructural products we develop. Digital automated spiral welding technology. for accelerated fatigue testing of real-size is never an end in itself but always a tool This is a first step towards the final goal: components proved to fulfil the expectations complementing and supporting all of our other tools and technologies.

CONTINUING TO REALISE OUR VISION All of these activities were conducted against the background of difficult economic times for the steel industry, compounded by the accelerating changes in all areas of industry and society. In light of this, we decided to review our vision statement, which we announced in our 2016-2017 Annual Review, to see if it was still on target, or perhaps in need of adjustment. We were gratified to find that our vision out to 2025 still holds Serge Claessens, Sven Vandeputte, true: our assets, unique equipment and Chief Technology Officer Managing Director competencies are all still very much relevant to the strategic choices that we have made. The various energy transition fields, for example, are all growing markets. In fact, our vision is becoming more sharply focused with the new evolving market conditions, and we continue to invest with confidence.

vii DIGITALISATION

As an industrial R&D centre, our primary mission is to develop new products and 1 solutions for our customers and assist them with our technical competences to help them achieve their goals. And it is our ambition to do this in the most efficient way and with the highest quality standards. In this context, our secondary objective is to continuously improve our operations – and digitalisation is a key factor in realising this. During the past two years, digitalisation of our operations has risen exponentially, allowing us to achieve another level of performance. This ongoing digital transformation is largely due to the increased computational power that OCAS has access to today, and to the enhanced performance of modern artificial intelligence (AI) tools. For this, a Digital Cell has been created in our organisational structure to gather all engineers active in this domain. This cell is in charge of piloting, consolidating and disseminating all digitalisation activity in of data with a uniform ontology, and significantly thanks to higher computational our lab with (amongst other initiatives) visualisation via state-of-the-art big-data power and better algorithms and models. multi-disciplinary cross-fertilisation as a analysis packages. These models cover the final application particular target. — In particular, huge steps have been part – e.g. simulation of electric motors A first digital pillar – which has accelerated taken on (pre)treatment of high allowing a reduction of the number enormously – is everything related to (big) complexity data such as time series and of trial prototypes at our customers, data, which concerns all stages of data images, including ‘face-recognition’ of prediction of geometrical and metallurgical management in our R&D biotope. microstructural images using Artificial evolutions in welding and wire arc additive — The first stage is data generation, Intelligence. manufacturing, modelling of the mechanics where our small-scale combinatorial — The next step is profound exploration of during forming processes or the mechanical experimentation has been expanded Process-Structure-Property correlations behaviour of final components – as well as from rapid sample synthesis to further in these extended data sets by means the steel processing part – e.g. simulations property screening and microstructural of the most recent machine learning of metallurgical evolutions during hot analysis. As such, quantities of data techniques (e.g. artificial neural network rolling. All of these capabilities enable us to are generated more quickly, and the models). further reduce expensive experimentations necessary tools have been constructed to — All these tools are also being increasingly and, ideally, they produce ‘first time right’ handle all these data efficiently. applied to data sets directly originating results. — For such a structured data capture and from an industrial production context. storage, our existing Lab Integrated As such, several successful cases of — Serge Claessens & Lode Duprez Management System (LIMS), called technical support to customers have been JobManager, has been upscaled realised. to a modern 4.0 tool that enables Next to the big data axis, our classical standardisation of activities, storage modelling activities have advanced

Digitalisation 9 Digital steel microstructure image + Deep learning (“google face recognition”) Machine based distinguishing of 20 HSLA microstructures by reducing a microscopy image to a 3-dimensional vector

Applying the Google ‘face’ recognition algorithm to a microstructural ‘phase’ is fascinating and looks highly promising for tomorrow’s product development.

Jan Rens & Arunim Ray Man versus machine challenge

The use of artificial intelligence in materials science is highly valuable in identifying Process-microStructure-Property (P-S-P) links in steel research . Finding and understanding these P-S-P links has always been of key importance for new steel product development . And modern digital tools can bring this understanding to another level .

Since 2018, OCAS has made considerable similar materials are found close to each complex martensitic microstructures. First progress in describing the microstructure of other, whereas different materials are well outcomes confirmed that the machine is steel. To obtain a compact representation of separated. extremely powerful in feature extraction microstructural images using deep learning and in differentiating microstructures, techniques, an image needs to be reduced DIGITAL PRODUCT and first attempts to make the link with to a series of values. Basically, this means DEVELOPMENT final properties were highly promising. applying the ‘Google face recognition’ The OCAS team organised a man versus The machine learning provided us with algorithm to digital microstructural images machine challenge to compare the human first indications of properties solely based of different steels. An example of the eye with artificial intelligence. The results on the microstructure – i.e. without any principle is shown in the image on the left illustrated that a machine performs better input of chemical composition or process page, which clearly illustrates a machine’s in microstructure classification than a information, but purely based on the capability to distinguish microstructures. person, i.e. the machine can see features microstructural image. Indeed, in the 3D representation, each set that a human no longer detects. Based on of three coloured dots – representing one these encouraging results, the machine microstructure – is grouped together and learning was applied to much more

Digitalisation 11 element 1 element 2 element 3 element 4

Data mining and artificial intelligence have allowed us to take the first steps towards virtual metallurgy: i.e. materials design based primarily on historical data and modelling without the need for physical experiments.

Kurt Lejaeghere Harnessing the power of data

OCAS’s activities cover a broad spectrum, ranging from metal casting and rolling to chemical, mechanical and surface testing . Data on these activities are sometimes correlated and form a rich source of information . However, access to consolidated, high-quality data is essential . We have developed a comprehensive Laboratory Integrated Management System (LIMS) to manage all activities at the lab, allowing us to control and log all process parameters .

Thanks to JobManager, our in-house permission management and controlled project follow-up, knowledge management developed LIMS, OCAS has entered the documentation. Moreover, human error is and quality control. The system also digitalisation era. Historical and new avoided as much as possible by extracting manages a comprehensive inventory, data produced in the lab are stored in a data from equipment automatically and coupled to an intelligent scanner-based standardised way, laying the foundations for performing data consistency checks. tagging system for warehousing. big data analyses and artificial intelligence. Based on repeated experiments, statistical process control provides a view on expected DATA-DRIVEN KNOWLEDGE DATA-DRIVEN QUALITY uncertainties and flags anomalies. This JobManager deposits all data into a SQL Many activities, such as vacuum casting approach has enabled us to successfully database, which includes processing and and various types of chemical analysis, are obtain ISO17025 accreditation for several testing parameters as well as metadata, available in JobManager via standardised chemical analysis techniques. such as the parent material, the scheduling procedures, ensuring the highest level Because efficiency and quality are key, of the activity, the operator and the project. of quality control. The system enforces in addition to dealing with operational Cross correlating entries on different a rigorous validation flow, supported by activities, JobManager contains tools for materials or tests may reveal hidden

Digitalisation 13 JobManager contains tools for project follow-up, knowledge management and quality control. The system also manages a comprehensive inventory, coupled to an intelligent scanner-based tagging system for warehousing.

Roger Hubert trends and identify optimal composition or A DATA-DRIVEN FUTURE These developments are being added to processing conditions. With JobManager, OCAS is decisively JobManager in a modular fashion, which The amount of information reaches playing the digitalisation card. We plan to makes the software extremely customisable. staggering proportions: 300,000 samples continue to develop tools for controlling our Thanks to this flexibility, JobManager are currently registered in JobManager. To processes and harvesting data from them. is now being deployed at several other extract insights from such ‘big data’, we On-the-fly monitoring and visualisation metallurgical labs around the world. use state-of-the-art analysis techniques. capabilities will be added too, and more Data mining and artificial intelligence have advanced database queries will be made allowed us to take the first steps towards accessible through the JobManager interface virtual metallurgy: i.e. materials design for data mining and machine learning. based primarily on historical data and Over the longer term, the software will modelling without the need for physical become web-based and accessible through a experiments. smartphone app.

Digitalisation 15 In our digital approach, modelling goes hand-in- hand with physical experiments in the lab. Managing large quantities of data and comparing these with the customer’s quality rating is a good example of how digitisation leads to knowledge that creates better products as well as better customer experiences.

Steven Cooreman and Patrick Goes Big data analysis identifies product issues

One of our customers experienced quality issues on their final product . As the customer’s production process is rather complex, it was difficult to identify the cause of the problem . It could have been anything: from the quality of the incoming supply of raw material to some processing issues .

In a first approach, a numerical model of the DIGGING THROUGH DATA the customer’s evaluation score. With customer’s production process was set up DIGITALLY this information at hand, the material to investigate the influence of the different Therefore, OCAS suggested tackling the supplier was convinced of the necessity to parameters on the final product. However, problem through statistical analysis of a improve the quality of the raw material. due to the complexity of the production sufficiently large set of experimental data. Our customer and the supplier discussed process, it was hard to reproduce the actual Measurements were conducted on the various options for resolving the issue. So boundary and loading conditions. In material at different stages of the production far, the actions that have been taken have addition, it was quite a complicated matter process. The data obtained was analysed already resulted in a significant reduction of to capture the different quality aspects of and ‘translated’ into a set of quantities scrapped material, for both the supplier and the incoming material. Consequently, it was expressing the quality of the incoming our customer. virtually impossible to discover the causes material. Thanks to this digital approach, a complex of the observed problems by means of a Statistical analysis revealed a clear problem could be addressed in a limited numerical model. correlation between those quantities and amount of time.

Digitalisation 17 The scanning flow cell is the Implementing high-throughput perfect tool for high-throughput on lab equipment pushes analysis of metallic surfaces in engineering to a higher level. order to determine both their local electrochemical and their dissolution Johan Verlee & Niels Van den Berghe properties.

Myriam Madani Combinatorial metallurgy at work

Combinatorial metallurgy allows the efficient generation of large data sets . In breakthrough or exploratory projects, decision-making becomes more effective by determining interesting hot spots or very quickly eliminating uninteresting chemistry ranges .

SMALL & FAST maraging steels, lightweight steels for also thanks to its high lateral resolution Because of the large number of samples, industry applications, fire resistant obtained by confining the measurement miniaturisation and automation are key in composites, new alloys for additive locally. experimental combinatorial work flow. In manufacturing, and coating development The OCAS scanning flow cell allows high- other words: ‘small & fast’. for better corrosion resistance. throughput screening of anti-corrosion Today, OCAS is fully equipped for small- properties to identify key parameters and scale sample production: small-scale QUICKLY SCREENING METAL limit the need for expensive, lengthy real-life casting, accelerated rolling, processing SURFACES FOR CORROSION exposure testing. The technology monitors multiple samples and thermomechanical PROTECTION the dissolved elements online using ­ processing in various atmospheres. Special To screen the corrosion protection of newly UV-VIS or ICP-MS – delivering quick insights sample holders and automated flows enable developed coatings, the OCAS scanning into the active protection mechanism. fast characterisation of properties and flow cell, with coupled electrochemical data As a result, this scanning flow micro-cell structure. collection and analytical units, is the ideal addresses several issues, making it a highly Several projects have already benefitted tool. Not only because of its multi-reservoir valuable tool. from this methodology: screening for high-throughput and full automation, but

Digitalisation 19 The use of artificial neural network models truly maximises the output of combinatorial research. It optimises the experimental work by easily spotting interesting combinations and simplifying the analysis of large databases.

Laura Moli Sanchez & Nele Van Steenberge ARTIFICIAL NEURAL NETWORK physical background of the relationships approach. By optimising composition design MODELLING’S PREDICTIVE POWER between alloy composition, processing and processing, this model is supporting Artificial neural network modelling is a parameters and the final properties. So, it’s the development of the alloys. Based on the non-linear statistical analysis technique the perfect tool for exploratory research. outcomes of the neural network, new alloys linking input data to output data using a OCAS has developed a model to predict with optimum compositions and process particular set of non-linear functions. It is the mechanical properties of new nano- routes have been generated. From here, very powerful when very little (or no) prior precipitates in order to strengthen alloys experimental work will be conducted to knowledge is available concerning the based on the artificial neural network confirm the predictions.

Digitalisation 21

Improved simulation capability for ­electric motors

One of the principal components of an electric machine is its magnetic core, which guides the magnetic flux through the machine and prevents flux from leaking out . The magnetic core is made up of stacked laminations of electrical steel, characterised by high permeability and low losses .

However, manufacturing and assembly market segments, OCAS has developed ADVANCED MATERIAL techniques for cutting and stacking the modelling techniques – which take the CHARACTERISATION CAPABILITY laminations to produce the core generally effects of the various manufacturing and OCAS has a strong track-record in the result in local material degradation and operating conditions into account – to advanced characterisation of electrical somewhat weaker magnetic properties. predict the performance of the core in the steels. Apart from the tools for magnetic Also, electric motors are usually operating final application. and electrical measurements and the under conditions that are very different Our unique strength comes from the characterisation of the insulating coatings from those in which the electrical steel was combination of our in-depth material on the as-delivered sheet material as initially characterised, which exposes the knowledge, the availability of an advanced described in the international standards, material to, for example, high temperature, laboratory that is well equipped for on the request of our customers, we have high mechanical stresses, or high-frequency magnetic and electrical characterisation of developed methodologies to obtain specific magnetisation waveforms due to harmonics electrical steel, and our strong modelling material data. For example, the effects of in the supply voltage. capability, which makes use of bespoke various cutting techniques on the magnetic Through numerous collaborations with software modules for loss calculations. properties can be determined locally. customers in both automotive and industrial We can also simulate realistic operating

Digitalisation 23 Our integrated methodology allows us to improve the simulation capability for electric motors for our customers.

Jan Rens & Ahmed Abdallh conditions – including high temperatures, derived advanced formulations for the which leads to the presence of minor mechanical stresses, and high excitation prediction of core losses in electric motors loops and skin effects that redistribute the frequencies – to which the electrical steel is under real operating conditions, taking magnetic flux throughout the thickness of subjected in an electric motor. various production processes into account. the lamination. Our integrated methodology These models are based on our advanced allows us to improve the simulation IMPROVED IRON LOSS MODELLING material characterisation capability to capability for electric motors, which enables Due to the factors mentioned above, the determine both local permeability and core more accurate designs and can reduce the magnetic core losses that are measured losses under specific conditions. number of expensive prototypes at our on an electric machine are, in general, Recently, our modelling approach has also customers. significantly higher than those that could been extended to include the effect of higher be expected from the datasheet. OCAS has harmonics due to inverter-fed operation,

Digitalisation 25 We believe modelling will considerably reduce the number of experimental welding tests that are needed.

John Vande Voorde & Patrick Goes

Simulation tools are critical to achieving the target first time right – which is crucial to establishing additive manufacturing as a viable industrial manufacturing process.

Joachim Antonissen

Metallurgical knowledge, obtained from exploring the possible causes of low Our numerical model has the potential weld toughness in HFI welded pipes, is to improve the weld quality in existing now coupled with our welding process products and speed up the introduction of modelling efforts to implement a new pipe materials. sophisticated forging control.

Jan Rens Özlem Esma Ayas Güngör Modelling welding processes

The ability to model welding processes and to predict geometrical, metallurgical and technological process results offers many advantages . The simulations allow fast and precise handling of a great variety of testing scenarios . However, in applications such as welding, the complex physics makes it very difficult to model accurately . NUMERICAL MODEL FOR OPTIMISING HFI WELDING Today, High Frequency Induction (HFI) SIGNIFICANTLY REDUCING THE to significantly reduce the number of welding is considered to be the most NUMBER OF EXPERIMENTAL experimental welding tests and still gather productive line-pipe production method. WELDING TESTS enough data to provide technical support However, HFI welded pipes suffer from a As OCAS and its customers are keen to for e.g. optimising welding parameters to bad image due to inconsistent weld quality predict and overcome the occurrence of minimise distortion due to local heat input. and poor low-temperature toughness of possible welding issues − such as residual the weld when compared to submerged arc stresses due to distortion, or the metallurgy RIGHT FIRST TIME welded (SAW) pipes. Improving existing of the heat-affected zone influencing the As speed is essential in many additive welding technology requires numerical hardness – OCAS has teamed up with manufacturing related business cases, going models to better understand the underlying different research institutions across Europe through iterative product design cycles is physical interactions, optimise process to develop the toolkit required to formulate not an option. Simulation tools can provide parameters, and improve weld properties. answers to these questions. key differentiators for achieving the target In order to enhance our understanding of Currently, OCAS has tools available to first time right. High Frequency Induction welding, OCAS predict the weld bead shape and the actual It is our goal to substantially reduce the has developed a numerical model taking welding heat input and to estimate the experimental work load and number of electromagnetic, thermal and mechanical microstructural aspects in the weld pool trial & error iterations required to obtain a effects into account. The model allows us and the heat-affected zone. This allows fully functional and large-scale component. to provide recommendations for optimising OCAS to respond to welding requests more Thereby contributing to achieving the target the process parameters and implementing efficiently and quickly. In the past, a large right first time, which is crucial for additive a sophisticated forging control, which lead number of experimental tests was needed manufacturing to establish itself as a viable to substantially improving the toughness of to adequately respond to our customers’ industrial manufacturing process. HFI welded pipes at our customers. requests. From now on, it will be possible

Digitalisation 27

Optimisation of materials, processes and structures in a virtual lab

Finite Element Analysis (FEA) modelling is used to evaluate the performance of structures and components and to optimise their design . Over the last several decades, our understanding of the mechanical behaviour of metals has significantly improved, resulting in advanced phenomenological models and more reliable simulations . Moreover, the continuous increase of computational power and the introduction of other numerical techniques – such as DEM (Discrete Element Method) and PFEM (Particle Finite Element Method) – have led to ever more realistic simulations .

Nowadays, FEA modelling is not only relation between microstructure and Computational Materials Engineering) used to assess the behaviour of single macroscopic mechanical properties, thus approach was adopted to develop steel components, but also to investigate more making it possible to optimise a material’s grades with a tailored microstructure, complex problems – e.g. to optimise metal microstructure in a virtual lab. In addition, starting from the desired component forming processes, such as roll forming efficient multi-scale material modelling behaviour. A set of simulation tools was and stamping, or to assess the structural approaches are being developed, so that developed to reproduce the complete integrity of pipelines. those physics-based models can also be chain of material processing and testing Furthermore, huge effort has been exerted applied to industrial-scale problems. in a virtual environment, starting from in the development of RVE (Representative the production of the raw material up to Volume Element) modelling approaches TOOLKIT PROJECT evaluating the performance at component and physics-based constitutive models – From July 2016 to June 2019, OCAS scale. The proposed methodology was then for example, crystal plasticity models. In participated in the European funded project used in two case studies: one to improve the such models, the material’s texture and “Toolkit for the design of damage tolerant crack arrest capabilities of modern pipeline microstructure are explicitly considered. microstructures”. Within the framework of steels, and the other to increase the energy Hence, they enable us to investigate the this project, a so-called ICME (Integrated absorption of a car crash box.

Digitalisation 29 Academics are developing and using highly advanced models and techniques. It’s important to strengthen the collaboration between industry and university, so that those advanced models are employed in industrial- scale problems.

Steven Cooreman PREDICTION OF MECHANICAL in accurately describing the hardening models. Furthermore, in collaboration with PROPERTIES OF LARGE behaviour, which can be rather complex, Katholieke Universiteit Leuven, a Postdoc DIAMETER WELDED PIPE as pipe forming involves several strain project was launched to implement a Over the past few years, OCAS has been reversals and strain path changes. multi-scale material modelling approach, in developing efficient numerical models, Therefore, an advanced phenomenological which physics-based models are considered which enable various pipe forming model was implemented, which was capable to describe the material’s anisotropy and processes to be simulated, with the overall of capturing the Bauschinger and cross- hardening behaviour. goal of predicting pipe properties from coil/ hardening phenomena and provides more plate properties. The main challenge lies accurate predictions than conventional

Digitalisation 31

Numerically designed heavy-gauge plate rolling

For steels, the most important mechanical properties are strength, ductility and toughness . The general trend in steel development is to improve all of these properties at the same time and increase the thickness at an affordable cost . In this regard, numerical simulation of steel processing is a very powerful tool for accelerating the time-to-market for new steel products .

THERMO-MECHANICAL Numerical tools allow us to follow up the INTERCRITICAL ROLLING ROLLING … RIGHT FIRST TIME metallurgical mechanisms occurring during High strength heavy gauge structural Once the tailored steel microstructure is processing as a result of the temperature steel grades are most often rolled designed at pilot scale to fulfil product variations in air or water cooling and thermo-mechanically (TM). TM-rolling specifications, the industrialisation phase deformations applied to the steel during of heavy-gauge steel plates is often is launched. In this step, the numerical rolling. Thus, the optimised processing performed intentionally in the intercritical simulation of the industrial processing conditions can be numerically derived to austenite-ferrite phase region for three allows us to define the processing window attain the specific properties. reasons: (1) to increase yield strength, (2) within the industrial production constraints to avoid the deformation gradient across to achieve the target microstructure, and The main advantage of using numerical the plate thickness from surface to core, hence the material’s specified properties. tools is that the number of trials needed for and (3) to minimise thermal gradient due Let’s visualise this with an example: the industrialisation of a new steel grade drops to the high thickness. However, intercritical thermo-mechanical processing of steel is dramatically. In most cases, numerically rolling, followed by air cooling, produces a processing route that provides the steel designed trials provide successful ‘right first a bimodal distribution of ferrite grain size, properties after hot rolling. This means time’ results, while incremental approaches which is known for its detrimental effect on that the designed microstructure needs require iterations based on experience and toughness. to be generated at the end of the process. trial-and-error.

Digitalisation 33 Numerical simulation of steel processing is a very powerful tool for accelerating the time-to-market for new steel products.

Nuria Sanchez and Ulrike Lorenz Together with the partners of the and modelling, we studied the relation set up. Furthermore, this research provides European-funded INCROHSS project, between the temperature gradient, ferrite- guidelines for a wider and more stable OCAS studied the impact of two-phase austenite balance at high temperature, processing window for steels when rolling rolling on the microstructure and the strain partitioning between phases and in the two-phase intercritical temperature distribution of properties in heavy-gauge subsequent transformation. To predict the region. steel plates. By means of improved behaviour of materials during intercritical microstructure investigation techniques rolling, a micro-mechanical model has been

Digitalisation 35 ENERGY TRANSITION

the one hand, we have to switch rigorously By end of 2018, about 600 GW installed from fossil energy carriers – counting today wind turbine capacity was reached globally, for about 80% of the global primary energy of which 23 GW are offshore. Even if the production – to renewable resources. On the installation rate is temporarily slowing other hand, global primary energy demand down in Europe, wind energy is expected to is expected to increase by more than 30% by play the dominant role in our future energy 2 mid-century. supply. Solar energy, today also representing The fading out of fossil fuel consumption around 600 GW globally installed capacity, is expected to last a long time. The current is a suitable choice, primarily in southern point of view deems it necessary to shut regions. down coal-fired power plants quickly and Steel making is strongly affected by the to replace them with higher efficiency Low-Carbon Economy and the Energy gas-fired power plants. In parallel, the Transition. After publishing its first Climate implementation of Carbon Capture and Action Report in May 2019, ArcelorMittal

Sequestration (CCS) is acknowledged to be Europe has recently released its CO2 a suitable means of counterbalancing the roadmap to reduce emissions during steel

continued CO2 emissions, at least for some production by 30% by 2030, with the further It’s probably not necessary to reiterate that decades. Fossil-free technologies do exist ambition to be carbon neutral by 2050. global warming can only be slowed down – some are mature (like nuclear fission), At the same time, the Energy Transition by a drastic reduction of greenhouse gas but cause other environmental concerns. offers new opportunities to serve a growing emissions – carbon dioxide first of all. Others, like nuclear fusion, still need a market. For example, already today, the Therefore, the general idea behind the so- number of years to develop before they can ArcelorMittal group is supplying substantial called ‘Energy Transition’ is to decarbonise contribute to our energy mix. amounts of heavy plate for the windtower our energy systems. However, with the So, for the time being, the core of the market and Magnelis® coated sheet for the objective of achieving a carbon-neutral Energy Transition remains the generation support structures of photovoltaic solar economy by 2050, as targeted in the 2015 of electricity using renewable energy power plants. The overall market outlook Paris Agreement, the challenge is huge. On resources, like wind, solar and hydro power. is promising, given that installations like ENERGY TRANSITION

concentrated solar power plants or offshore corrosion protection. Here, as in many other of renewable power or fuel-cell powered wind parks are constructed with several cases, the aim is to help customers identify cars and trucks. However, under service hundred tonnes of steel per MW installed the most cost-effective solutions for their conditions during hydrolysis or redox capacity. installations – which means, in this specific reactions, the surrounding material, usually As the research centre supporting case, reducing the total cost of electricity steel, may be stressed by highly corrosive ArcelorMittal in the energy market for many production and, eventually, accelerating the conditions. Here again, the challenge is to years now, OCAS has been playing a leading Energy Transition. Likewise, we are seeking develop cost-effective solutions for lowering role in providing information concerning cheaper cryogenic steel solutions for the the barrier to the implementation of clean technology trends and market data storage of liquefied natural gas (LNG), a energy. In collaboration with our spin-off related to the Energy Transition. We have market that is expected to grow considerably company Borit – which has direct access also identified some of the technological in the near future. to the markets as a component provider – challenges and research topics that need to OCAS has a long track record in the we believe we are perfectly positioned to be addressed to speed up the clean energy development of electrical steels for facilitate this task. economy, and we are keen to work on it. motors and generators. New steels, On many occasions, OCAS has proven its Our confidence that we can deliver is based together with our support for the design ability to provide comprehensive steel on our experience and the expertise we’ve of motors, will help to make optimum solutions, comprising the choice – if not built up in the past. Some examples are use of electrical power, in particular in the development – of steels, their corrosion mentioned in this chapter. To begin with, the transportation sector. It goes without protection, processability, weldability and the market success of Magnelis® has its saying that the automotive industry is in-use performance, often in combination roots at OCAS. We continue to support its currently in the middle of a steep transition with structural design support. We are sure application at our customers. And we’ve to electrification, with the prospect of a we can assist the energy market in making already launched the development of an booming market for OCAS. the right choices for the future. even improved version. Thanks to our We consider our expertise developed We want to contribute our part to solving network in the offshore wind industry, we in our hydrogen lab to be one of our the most important challenge facing are familiar with the concerns of the different strongest assets for future steel solutions. humankind in the 21st century. stakeholders and are closely collaborating Hydrogen is a clean energy carrier and will with them in the field of fatigue and be increasingly used for energy storage — Martin Liebeherr

Energy transition 37 Through co-engineering projects, we provide solutions on topics such as the improvement of fatigue or corrosion resistance, thus helping our customers significantly reduce the maintenance costs of offshore structures.

Philippe Thibaux Solutions for wind power

Wind energy is one of the most important sources of renewable energy . Offshore wind turbines consist of steel structures that are submitted to large and variable loads in harsh environments, such as low temperatures in the North of Europe or corrosive conditions in the sea .

Over the years, OCAS has built in-house tools for investigating the behaviour of the OFFSHORE PRE-QUALIFICATION expertise to help companies develop the material and defining safe conditions. FOR ARCELORMITTAL’S most efficient structures under the safest Variable loads due to turbulences, rotation OFFSHORE PLATE OFFER conditions. Our knowledge of physical of the rotor, or waves make fatigue the One of the key features of ArcelorMittal’s metallurgy is of particular importance critical load case in the design of wind offshore plate offer is its enhanced for the development of steel grades with turbine support structures. OCAS has weldability, which ensures the steel can adequate properties – strength, toughness, investigated ways to optimise steel be welded without deteriorating its high corrosion-resistance and weldability – for foundations in order to increase their fatigue strength or excellent toughness. This the production of wind turbine towers or resistance. Today, OCAS has unique large- is proven by performing so-called pre- offshore foundations. scale fatigue testing capabilities, operating production qualification (pre-qualification, Welding is the method of choice for many more than 20 times faster than alternative in short), which demonstrates the steel’s parts of the construction. The industry test benches in industry. OCAS also works inherent suitability for component assembly can count on OCAS’s submerged arc in close collaboration with many actors in using welding. The most common standards welding system to produce representative the wind industry – through Joint Industry for offshore pre-qualification are EN10225, components and evaluate their behaviour in Projects (JaCo, Crown), subsidised projects NORSOK M-120 and API RP2Z, and they small- or large-scale tests. (JaBaCo, Fatcor, …), and direct contacts. outline in great detail the requirements Applications for use at low temperature Thanks to the recent collaboration with that the steel has to meet, including require knowledge of fracture toughness (for Endures, OCAS has enlarged its services third-party oversight during all aspects selecting material, for example). OCAS has a in the field of corrosion protection and of the pre-qualification campaign. OCAS wide variety of experimental and modelling testing facilities for the offshore and marine has successfully performed multiple pre- environment. qualifications for a number of ArcelorMittal

Energy transition 39 Our submerged arc welder, heavy- duty fatigue set-ups, and unique metal processing equipment enable us to support new product development for the most demanding offshore applications in the energy sector.

Ulrike Lorenz & Christoph Gerritsen plants and products. This has allowed us to SALINE WEATHERING RESISTANT These structural steels are applied primarily hone and optimise the approach, fulfilling GRADE DEVELOPMENT in the construction of bridges, wind the challenging requirements. Weathering steels have grown in importance turbines, aesthetic constructions, and In addition, OCAS is involved in other in the market, as they show a significantly containers. Together with the ArcelorMittal welding-related projects, such as the higher resistance to atmospheric corrosion Gijon steel plant, OCAS is developing a investigation of high-productivity plate than regular carbon steels. The enhanced thermo-mechanically rolled steel grade welding techniques, to expand the plate corrosion resistance of weathering steel is that incorporates these new high-strength weights that can be delivered. In this light, attributed to the formation of a dense and requirements. OCAS also organised an international well-adhering patina, which effectively Current standards for offshore grades (EN seminar together with the Belgian inhibits damage to steel structures, 10225 and API 2W) focus on toughness and Welding Institute in October 2019. The prolonging their lifetime and repainting weldability, while weathering resistance seminar, on the topic of high-productivity cycle. is not addressed. In a multidisciplinary welding processes for thick section steels, In the revision of standard EN10025-5, approach, OCAS is developing an offshore brought many international speakers and describing weathering structural steels, steel grade with enhanced saline corrosion participants together, including important a high-strength variant is introduced properties that still retains good toughness ArcelorMittal plate customers. with yield strength up to 460 MPa and a and weldability. toughness requirement at low temperatures.

Energy transition 41 For 15 years OCAS has been expanding its capabilities for H-related research. As such we believe we are well armed to thoroughly tackle the technological challenges in multiple applications. The response to our “SteelyHydrogen Conference” confirms that our international recognition in this field remains top of mind.

Lode Duprez How hydrogen research fuels the future

The most abundant element in the universe, hydrogen is also a promising source of ‘clean’ fuel . However, some issues still remain to be resolved first of all .

For more than 15 years, OCAS has been as evidenced by the feedback from the various steel production steps. OCAS’s developing tools, methodologies and attendees. A selection of papers has activities in quality control testing of techniques to address the various aspects furthermore been published in a special the industrial production of advanced related to the presence of hydrogen in steel edition of the scientific journal “Corrosion” high-strength steels have enabled us to and metals in general. This has resulted in a (August 2019, Vol. 75, Issue 8 879). Taking validate an in-house model for predicting large international network and the related all these factors into consideration, the the hydrogen evolution during the steel recognition. In that context, OCAS organised conference was a real success from the process. its 3rd international ‘SteelyHydrogen’ organisational, scientific and networking — Using deuterium as hydrogen tracer conference in May 2018 – following two points of view. is a powerful technique for assessing successful SteelyHydrogen conferences in OCAS’s most recent hydrogen-related hydrogen pick-up during industrial 2011 and 2014, both of which were attended activities focus on four domains: processes. The combination of the by more than 100 participants. For this third — The launching of dedicated activities in existing metallurgical lab simulation edition, the scope was enlarged to other relation to the energy transition that is capabilities and the use of deuterium metals, such as Al, Ni and Ti. required to solve global warming, where allows OCAS to simulate multiple we focus on the assessment of actual and treatments in which deuterium (instead of AN OVERALL SUCCESS future infrastructure for the storage and hydrogen) is introduced into the material. ‘SteelyHydrogen’ – the International transport of hydrogen. This methodology has been implemented Conference on Metals and Hydrogen – — Continued competence building – tools, on several product studies to first allowed us to obtain a global view on methodologies and techniques – to analyse and then suggest production today’s international research on hydrogen address hydrogen embrittlement issues optimisations that reduce hydrogen pick- in metals. With an attendance exceeding that new metal products may encounter up on industrial process lines. 170 participants, more than 100 scientific in their in-use applications. Now, with great anticipation, OCAS has contributions on a variety of metals and — A clear effort in terms of on-line started preparing for the 4th edition of applications were displayed and presented. sampling, detection, measuring and SteelyHydrogen, scheduled in 2021. This 3rd conference was very well received, monitoring of hydrogen during the

Energy transition 43 In collaboration with ArcelorMittal, OCAS has developed Magnelis®-coated HyPer® steel grades to meet the solar market’s needs for even stronger and more ductile steel grades that are also lighter, thinner and more corrosion-resistant.

Ansbert De Cleene & Arunim Ray Magnelis® protects solar structures

With excellent in-use properties and a wide range of feasibility, Magnelis® is one of the best-in-class and most cost-effective solutions for photovoltaic solar structures . Since its launch, Magnelis® has been selected by many manufacturers around the world to provide superior protection for long-lasting that are more reliable, strong and durable, solar mounting structures, even in the harshest environments . long-lasting and affordable. In collaboration with various ArcelorMittal plants across Europe, OCAS is currently developing an extended family of Magnelis®-coated Solar photovoltaic plants are designed Our outdoor soil exposure site enables OCAS high-performance steel grades (under the to last at least 20 to 25 years. They are to compare the performance of coatings, ‘HyPer®’ brand) to meet the manufacturers’ built in various climate types (tropical, such as Magnelis®, with other hot dip ever-increasing demand. industrial, …), in different locations (deserts, galvanised or batch galvanised products. Starting from small lab-scale experiments, sea shores, islands, …) having a variety To date, Magnelis® is outperforming OCAS has developed robust and flexible of geological soils, including the most batch galvanised steel in different soils. metallurgical concepts using tightly aggressive. The supporting structures of In addition, accelerated soil corrosion lab controlled chemical compositions and these solar panels must withstand these tests are also being conducted. Conducting strengthened fine-scaled microstructure. In conditions while generating minimal these experiments in parallel gives us a recent months, successful industrialisation maintenance costs. deeper understanding of the soil corrosion of the metallurgical concepts at different Models are needed to predict the lifetime of mechanisms and enables us to make ArcelorMittal plants has led to the first the structures resisting harsh environments more accurate metallic coating lifetime commercial Magnelis®-coated high-strength for decades at a time. Therefore, in 2016, predictions in different soil environments. steel, with more than 700 MPa yield strength OCAS started field exposure in its new and showing excellent ductility and in-use excavated pits at its Zelzate site. These pits SHIFT TOWARDS HIGH- properties. have different soil compositions and are PERFORMANCE ‘HyPer®’ GRADES OCAS is currently optimising the large enough for experiments with varying The current interest in metallic-coated metallurgical routes to extend the geometries, such as poles, profiles, flat structural steel grades for solar markets is ArcelorMittal ‘HyPer’ offer for the various samples and wires. The corrosion rates are shifting towards increasingly stronger – yet strength levels at different thicknesses, monitored by weight loss, coating thickness lighter, thinner, more ductile and corrosion- combined with a range of coating weights and corrosion product analysis. resistant – steels in order to build structures for multiple Arcelor­Mittal galvanising lines.

Energy transition 45 Our multi-disciplinary team and state-of-the-art equipment give us a competitive advantage in helping our customers developing solutions for green mobility.

Wahib Saikaly, Pablo Rodriguez Calvillo & Nathalie Van den Bossche Green solutions for tomorrow’s mobility

The family of electrical steels produced by ArcelorMittal and conceptualised by OCAS is a perfect example of the innovative solutions that are essential for the preservation and well-being of our environment . These electrical steels are the back-bone of the increasingly indispensable electric vehicles that are strongly on the rise worldwide .

In electric vehicles, electrical energy is Thanks to concepts developed by OCAS, OCAS’S UNIQUE AND LONG- transformed into mechanical energy to drive ArcelorMittal offers a wide range of STANDING EXPERTISE the vehicle. Electric machines are composed electrical steel grades, which are now OCAS’s expertise in the field of modelling of several components, such as copper ramping up strongly under the name electrical steel motors is unique – windings, insulation and magnets. Acting as iCARe®. iCARe® Save grades provide combining our in-depth material an excellent magnetic path to produce the minimal iron loss, resulting in significant knowledge, the availability of an advanced required torque, electrical steel is the heart motor weight reduction. They are especially lab that is well equipped for magnetic and of electric machines. useful for reducing iron losses in high-speed electrical characterisation, and our strong hybrid and electric traction machines, and modelling capabilities. Such expertise iCARe® ELECTRICAL STEEL generators which extend the driving range enables more accurate designs and reduces GRADES of electric vehicles while keeping the same the number of prototypes required to Market requirements increasingly need battery cell size. iCARe® Torque grades industrialise a motor. traction motors that deliver high torque in provide a high polarisation capability, Coating is another field in which OCAS a wide speed range at the highest efficiency allowing the motor to develop more has long-standing expertise. The coating level. In addition, low iron-loss is crucial mechanical output and thus ensuring fast is essential to isolate the thin stacked for high-efficiency electric machines. acceleration. iCARe® Speed grades, to be electrical steel lamella. Control of the Furthermore, high-speed traction motors used in the rotor, provide an excellent composition, thickness, roughness and require electrical steel grades with high compromise between mechanical properties other aspects of such a coating is of crucial mechanical strength. Finally, traction and losses. ArcelorMittal offers all these importance for good motor assembly, and motors need to be compact in order to grades with a thin lamination to meet the thus it’s final performance. reduce weight and volume. increasing frequency levels from power electronic converters.

Energy transition 47 We will need to make a full energy transition in the coming years, and this offers very exciting opportunities for OCAS to develop new steel grades in a highly competitive market. The challenge is to combine extreme technical requirements with an affordable cost and high long-term reliability.

Elke Leunis & Elvan Ekiz Cryogenic steels as short- and long-term energy solutions

The global use of gas will increase significantly, mainly driven by higher use of liquefied natural gas (LNG) . LNG needs to be produced, stored and transported in liquid state, below -163°C . This imposes the use of special materials, with extremely good low-temperature toughness .

Advanced – but costly – steels are currently construction of large-scale LNG storage climate and the environment, significant being used throughout the entire supply tanks and large cryogenic pipes. However, greenhouse gas emissions will continue. chain, from the liquefaction plant, to vast a large part of the equipment in the A possible scenario for further reducing ocean tankers, to the final transportation LNG supply chain does not require such carbon emissions dramatically is the and storage close to the end-user. So, high thicknesses. Therefore, OCAS has use of hydrogen as a fuel. Just like LNG, improved cryogenic steels are ideally investigated the production of cryogenic the production, transport and storage of positioned to support new developments steels in thin gauges. hydrogen will likely be carried out in the in energy transition. Gas fuel sources, Production of pipes and tubes is also liquid phase – at least partially. Hydrogen’s especially LNG, are poised to enter a ‘Golden being considered. These studies include extremely low liquefaction temperature Age’ – a near future in which the global use both metallurgical concepts with a proven (-253°C) and the sensitivity of steels to of gas will increase significantly. track record (typically, high Ni steels) and hydrogen embrittlement demand special new concepts that are expected to offer steels to withstand such conditions. High GETTING READY FOR THE the optimum balance between cost and Ni steels, which are well known for LNG ‘GOLDEN AGE OF GAS’ IN THE performance. applications, are not suitable for hydrogen SHORT-TERM applications. Thus, the new metallurgical ArcelorMittal has already built a strong PREPARING FOR THE HYDROGEN concepts OCAS is developing for LNG are reputation in delivering heavy plates in ECONOMY IN THE LONG-TERM also being designed to be suitable for the the cryogenic industry, such as for the Although the use of LNG is expected to hydrogen economy. reduce the impact of fossil fuels on the

Energy transition 49 I really appreciate the openness of the OCAS As an OCAS research colleagues with whom we run joint projects. Also, engineer, it is great to be I underline their willingness to discuss problems part of the nuclear fusion openly and be ready to look for flexible solutions in community, tackling case of certain technical issues. technical issues first hand.

Dmitry Terentyev, Head of Expertise Group on Athina Puype Structural Materials and Program Manager of Fusion R&D at SCK .CEN, Belgian Institute of Nuclear Material Science Towards fusion energy

The European Climate Foundation published a study in 2010 on how to reduce greenhouse gas emissions by 2050 . The study showed that the annual power demand of 29 European countries will increase by roughly 50% from 2010 to 2050 . Primary sources of the world’s energy mix will be fossil fuels, nuclear energy, and renewables such as solar and wind energy .

The existing power installations, which are In contrast, a nuclear fusion reaction is an reactor materials are expected to face high presumed to still be operational in 2050, will inherently safe reaction, as any deviation neutron doses, high temperature and/or only be able to provide a marginal amount from the optimal reaction conditions stops corrosive attacks simultaneously. Therefore, of the future power demand. The power the fusion reaction. The additional attractive new materials need to be developed, or shortage should ideally be filled by carbon- prospects of fusion energy are underlined current structural materials need to be free energy sources – preferably, renewable by this quote from Stephen Hawking: adapted, for adequate performance in these energy sources or nuclear energy – to reduce “I would like nuclear fusion to become a severe, and largely unprecedented, working the greenhouse gas emissions resulting from practical power source. It would provide conditions. energy generated by fossil fuels. an inexhaustible supply of energy, without For several years now, together with pollution or global warming.” institutes in the nuclear sector working FROM FISSION TO FUSION towards the realisation of fusion energy, Currently, nuclear energy is generated by DESIGNING STRUCTURAL OCAS has been working on the production fission power plants that generate energy MATERIALS FOR FUSION or optimisation of several types of structural via a nuclear chain reaction in which REACTORS materials for fusion reactors. uranium nuclei split into lighter nuclei by The realisation of the first fusion reactor to We are now part of the community in which absorbing neutrons. The disadvantages of be linked to the energy grid – called DEMO all key players are represented. this fission reaction are that it produces – will be enabled by, among many other nuclear waste and nuclear accidents can things, the appropriate choice of structural occur if process control is insufficient. materials to be used in the reactor. Fusion

Energy transition 51 DURABILITY 3 & LIFETIME PREDICTION

The industrialised world is facing huge positively to resource scarcity, but also to conditions, but most importantly, to validate challenges in the coming decades – whereby extending the lifetime of the current ageing developed lifetime prediction models and the scarcity of resources and global infrastructure. tools for their reliability in real applications warming are driving us towards better OCAS continues to contribute to the search in real conditions. implementation of the circular economy for improved durability in multiple ways. In the domain of wear and abrasion, OCAS principles. Steel turns out to be an excellent First of all, by developing brand-new has continued to develop and improve candidate on this quest, as it is almost 100% steel grades, microstructures and coating relevant test methodologies and link them to recyclable and always ranks high against solutions, outperforming current solutions real wear behaviour for certain applications. competitive materials in a full Life Cycle by more than a factor of 10 in the most These tests allow us to rank a whole series Assessment. extreme cases. Secondly, by optimising the of new metallurgies and identify key Furthermore, in-use steel performance is design of applications and by developing domains for optimised use. This approach expected to reach outstanding new highs lifetime prediction tools and models that could be applied to cases of offshore wear for many future application fields – whether allow us to extend the lifetime of critical performance in jack-up legs. it be wear performance, improved fatigue structures substantially. In the same spirit, we continue to develop behaviour, corrosion performance, high In recent years, OCAS has developed an unique semi-component – and even temperature or fire resistance, or a complex impressive set of unique extreme test large-scale – test set-ups to investigate combination of these qualities. In this condition set-ups that allow us not only fatigue performance. These initiatives are way, steel innovation not only contributes to test critical designs close to real load enabling us to refine our fundamental DURABILITY & LIFETIME PREDICTION

metallurgical know-how regarding fatigue issues with sour corrosion. OCAS has On top of that, we are exploring exciting and to apply it to improving offshore continued to extend its capabilities in terms new candidates for the next-generation structures and components. Furthermore, of assessing sour corrosion behaviour, from of metallic coatings with even stronger along with new metallurgical developments an experimental as well as from a modelling protection, better appearance and/or towards stronger and thicker steels, OCAS perspective. This enables OCAS to provide reduced cost. has invested in a new powerful press to effective support to customers dealing with With Endures as a sister company, we investigate the bendability of these new sour corrosion. have fortified our experience in the field of steel grades. Our corrosion work is inspired by the very maritime corrosion, a domain that’s growing In the context of the development of gas- successful industrialisation and ramp-up in importance, because improving maritime tight pipeline connections and downhole of our Zinc-Aluminium-Magnesium coating corrosion protection is an absolute must for casing and tubing lines, OCAS has Magnelis®. We continue to answer customer many energy generation systems. Our newly developed, together with the ArcelorMittal requests and develop demonstrators developed saline weathering grade shows team in Houston, a state-of-the-art premium to highlight the coating’s outstanding more and more potential for being the next threaded pipe connection, branded performance in a variety of domains – such big thing for steel solutions in maritime AM-BLADE. as solar farms, buried soil applications, environments. Increased energy demand has compelled farms, safety barriers, lighting poles, and the oil and gas sector to shift activities to many more – which require accurate and — Tom Waterschoot & Sofie Vanrostenberghe harsher environments, leading to increasing relevant accelerated corrosion test methods.

Durability & lifetime prediction 53 Combining consistent methodologies with advanced experimental and modelling techniques helped to solve industrial wear problems efficiently.

Haithem Ben Hamouda Testing methodology boosts new ­material development

Wear occurs in almost every application where contact and friction define the main interaction mode . Lab testing methodologies generally try to isolate the tribological system from the industrial application by projecting the contact mode to smaller scale, making it easier to control .

WHEN TESTING METHODOLOGY from sliding. To illustrate: precipitate- helpful tools for qualifying wear AND MATERIAL SCOPE MEET hardened steels are grades that rely on mechanisms. Additionally, OCAS can also Sliding abrasion, as observed in agricultural hard precipitates (e.g. carbides) to resist the perform in-line monitoring of the abrasive equipment (e.g. tiller tines and ploughing scratching action of the sliding abrasives. wear using techniques such as Acoustic discs), is the main contact mode affecting However, the same precipitates, when Emission (AE), light microscopy and friction tool lifetime. OCAS provides reliable lab impacted by the abrasive particles, are sensors. These techniques have proven to testing methodologies to simulate this brittle and easily pulled out, causing more be effective in detecting the threshold forces abrasion mode under controlled parameters material to be removed. corresponding to a change in the wear such as normal load, sliding speed and Understanding these differences in wear mechanism from plastic deformation to lubrication level. Accelerated sliding performance for the same material requires cracking or delamination. abrasion tests performed at OCAS generate a consistent post-analysis of the wear valuable data to assist the user in selecting mechanism and a full understanding of PORTABLE TECHNOLOGIES READY the best material considering the in-use the material microstructural features. For FOR IN-FIELD WEAR INSPECTION properties (e.g. weldability and bendability). this purpose, OCAS provides advanced In-field wear inspection is used to study When the contact mode is impact rather characterisation techniques, such as the origin of component failure or to than sliding, as observed in mining Scanning and Transmission Electron demonstrate material performance. In applications, the abrasive wear failure Microscopy (SEM and TEM), as well as both cases, OCAS has numerous portable and the material’s ranking are different microhardness and nano-indentation, technologies (e.g. portable hardness,

Durability & lifetime prediction 55 1 µm 1 µm

1 µm 1 µm

OCAS has played a key role in the industrialisation of wear-resistant steels and the development work continues, striving for ever-increasing component lifetime.

Koenraad Theuwissen ultrasonic thickness measurement tool, The output of the advanced wear although phenomenological, differ from etc.) for monitoring the wear process. This characterisation helps OCAS’s product traditional constitutive mechanical approach combines valuable answers developers design next-generation wear- material models as knowledge of the concerning possible wear failure time resistant steels. They typically combine materials’ microstructural heterogeneity and origin with other factors such as specific chemical compositions and (such as grain size, shape, crystallographic corrosion and temperature. Based on elaborate manufacturing processes. The orientation, etc.) is also included. This this input, material selection and design resulting multiphase materials show special information is needed to predict where recommendations are given to the customer microstructural features that provide fracture will occur. and validated by a test-case demonstration. tailored combinations of wear resistance The new grades combine outstanding wear For the development of wear-resistant and in-use properties. performances, such as very high hardness grades, these test methodologies are key in and strain hardening capacity, with good identifying the wear mechanisms active in SMART VIRTUAL TOOLS FOR NEW formability. This is beneficial for customers different abrasion conditions and, thereby, MATERIALS DESIGN producing components that are subjected to in selecting the most suitable metallurgical Advanced micro-mechanical modelling heavy abrasion – such as tipping wagons, concepts for a given application. techniques allow us to deal with wear excavators and conveyors – as well as the in a virtual approach. These techniques, end-users of the machines.

Durability & lifetime prediction 57 Despite the tight time frame, we were able to resolve the wear issue successfully.

Philippe Thibaux Wear on the leg of a jack-up vessel

Jack-up vessels are self-elevating units with movable legs providing a mobile platform over the surface of the sea . These are typically used for offshore and wind farm installation and service platforms .

OCAS was contacted to investigate how to A SUCCESSFUL TEST CAMPAIGN thickness reduction measured on the tooth mitigate the effect of wear between a rack UNDER TIME PRESSURE material, the better the wear performance and a guiding plate for a jack-up vessel. The An experimental test campaign was set would be on the rack. On the other hand, guiding plate was made of wear-resistant up to investigate the metal-metal contact the very high reduction factor (104) would material. The rack, in the shape of a toothed by applying lubricants and using a set mean severe wear after only a few jacking leg, was made of a high-strength steel. The of different types of materials, under operations. contact between the teeth and the guiding various operating conditions (applied The experimental campaign was plate is characterised by a very large normal pressure). The wear on the teeth was accomplished in a tight time schedule that load applied on the reduced contact surface successfully measured based on controlled was driven by the maintenance schedule. of the teeth. Under such a high contact tribological conditions: lubrication, The experiments had to be finished on time pressure, severe plastic deformation and surface roughness, load and sliding speed, to order and install the material before the intensive wear are present. The investigation and in-line monitoring techniques for end of the ship’s repair in dry dock. The was meant to determine whether, during thickness reduction. Both the material and challenge was met successfully – and, major maintenance of the jack-up vessel, a the operating conditions proved to be of today, the ship is equipped with the new different material could be selected for the high importance in wear, with thickness guiding plates. guiding plate to reduce such heavy wear on reduction ranging between factors of 1 and the teeth. 104 for a given sliding length. The lower the

Durability & lifetime prediction 59 The instrumented bending press not only allows us to determine the minimum Acoustic emission is a powerful tool guaranteed bending ratio, but also provides for online crack detection, thanks other useful information for our customers, to the direct online availability of such as the required bending force and the frequency information up to 1 MHz. springback angle.

Maarten Van Poucke Steven Cooreman The power to bend high strength heavy-gauge up to 25 mm thick

The heavy machinery market is seeking to improve the performance and efficiency of its products . To reduce the maintenance cost and to prolong the lifetime of this equipment, heavy-gauge advanced high-strength steel grades are becoming increasingly used .

A major part of the new metallurgical As the required bending force strongly DETECTING MICRO-CRACKS developments is oriented towards the depends on the material’s strength and TO THE MICROSECOND production of ever stronger and thicker steel thickness, ever more powerful presses In addition, OCAS has purchased an grades, such as FeMn grades, maraging are required to bend those heavy-gauge, acoustic emission monitoring system, steels and martensitic steels. Those grades high-strength grades. Therefore, OCAS has which enables us to detect crack initiation are mainly, if not solely, deformed by invested in a new servo-hydraulic press with during bending tests. So, it’s possible to bending. Therefore, their bendability must a capacity of 1500 kN. The press is equipped interrupt the test once the first crack has be evaluated as part of the qualification with a fixture for 3-point air bending, been detected. That way, we can identify process. In general, the bendability of making it possible to bend samples up to which microstructural feature is causing a material is expressed by means of the 25 mm thick. The press is instrumented to crack initiation, thus improving our minimum guaranteed bending ratio – i.e. capture force, punch displacement and understanding of the relation between the smallest possible ratio of punch radius bending angle, providing useful information microstructural/metallurgical features and to sheet thickness for which no cracks can such as required bending force and bendability. be observed by visual inspection. springback angle. This technique is also used for other in-use property performance tests.

Durability & lifetime prediction 61 When designing lighter, less energy- consuming heavy-duty machinery, safety during operation remains of paramount importance – which is directly related to the fatigue resistance of the assembly and cut surfaces.

Okan Yılmaz Lighter design without compromising on in-use safety

Lately, there has been an increasing demand for ultra-high-strength steels (UHSS), as they permit weight reduction in heavy-duty applications such as trucks, trailers, cranes, and agricultural machinery, where significant fatigue resistance is important . For instance, reducing the weight allows for longer booms or more elevated loading capacity . In response, OCAS has designed the Amstrong® Ultra MCL series to meet the stringent toughness and fatigue resistance requirements for these applications .

It is commonly believed that the fatigue additional mechanisms, which are not occur predominantly in the vicinity of limit can be increased by increasing the relevant for milder structural steel grades. joints and cuts, exhibiting a tensile residual static strength of the material, either Full fatigue characterisation of UHSS stress pattern. The endurance limit of by heat treatments or by modifying its grades showed us that they can live up to UHSS is extremely sensitive to its surface chemical composition. However, the trend the constraining fatigue standards of the condition and residual stress state. Local is lost at very high tensile strength values – related applications. damaged zones can be induced by common that is, the fatigue limits attained no longer manufacturing processes such as shear give a proportional increase with the static HOW CUT-EDGE AND or laser cutting, drilling, etc. However, properties. This is generally attributed to MANUFACTURING EFFECTS in product specifications, the proper inclusions present in these grades, which IMPACT FATIGUE RESISTANCE selection of the cutting process is generally act as micro-notches that initiate cracks. Fatigue failure typically originates at stress overlooked. Therefore, at OCAS, we’re Hence, the fatigue characterisation of concentrations caused by joining (drilling focusing on quantifying the cut-edge and UHSS is not a straightforward task and a hole, in the case of a bolted joint) and manufacturing effects on UHSS grades and requires a thorough understanding of cutting procedures. Indeed, fatigue cracks how these impact endurance limits.

Durability & lifetime prediction 63 The major drivers for the future generation of metallic coatings are: ecology, durability and efficiency. At OCAS, we’re striving to combine the best of all in a single coating.

Beril Corlu

Thanks to our dedicated soil corrosion testing site, we can support the Magnelis® commercial team with comparative data on the influence of different soil parameters, such as aggressive salt content and humidity.

Philippe Verpoort produce Magnelis®, along with other hot-dip Metallic coatings exposed galvanised Zn metallic coatings. OCAS is leading and supporting these deployment Magnelis® is a metallic coating consisting of zinc, aluminium and magnesium . actions, and we’re also evaluating and Thanks to its excellent corrosion resistance in various harsh environments, validating the final product before its Magnelis® production is still enjoying a steady increase in volume . commercial launch.

PREPARING THE FUTURE By applying Magnelis® to high-strength

One of the obvious markets for this type of sand storms. So, sand abrasion needs to be steels, several markets can reduce their CO2 metallic coating is the solar panel market, taken into account. Similarly, the relative footprint due to reductions in weight. This where different Zn-based metallic coatings humidity and other weather conditions can trend is also increasing, which is reflected are used in the supporting structures of also play an active and important role in the in the transversal validation projects within solar parks. These parks are typically corrosion behaviour. OCAS, whereby the metallurgical evaluation installed in environments where conditions Therefore, several studies have been of these high-strength steels is performed can be quite harsh. Supporting poles need launched to understand and follow-up in our lab, as well as the validation of to be buried into the soil, where different the performance of Magnelis® compared the coatability with Magnelis® and the soil parameters influence soil corrosion. to other well-known Zn-based coatings in performance of this metallic coating. Another way of burying profiles in soil is by several of these harsh environments. These The breakthrough R&D program ‘IMpACT’ first embedding them in concrete – but this investigations are conducted via long-term (Innovative metallic coating platform) is can also cause corrosion, mainly triggered exposures in various outdoor conditions in preparing the future for metallic coatings during the initial drying phase after locations all over the world. Comparative primarily for demanding industrial installation. studies are launched in parallel using applications. A next generation of metallic accelerated lab tests. The influence of coatings with improved durability SUN AND SAND different soil parameters (such as aggressive (atmospheric, soil & offshore), cut-edge Depending on the location, several salt content, humidity, etc.) are being protection, and stable appearance (among corrosion mechanisms take place in the studied in specifically designed lab tests other benefits) is being targeted by this exposed part of the structures. In addition that simulate corrosion at different depths R&D program by exploring a wide range to atmospheric corrosion, desert areas into the soil. of processes and alloy compositions. The with inherently high amounts of sunshine, Since the solar market is currently booming, program has already produced promising making them a preferred location for an increasing number of ArcelorMittal lab results with good potential for installing large solar parks, also suffer from galvanising plants have been adapted to upscaling.

Durability & lifetime prediction 65 Combined expertise from different OCAS The OCAS Sampling and Mechanical teams resulted in a promising metallurgical Testing team takes pride in providing concept that entails an excellent combination top quality test samples under high of corrosion resistance, mechanical throughput conditions, even when properties and weldability. dealing with heavy gauge material.

Krista Van den Bergh Koen Van Brussel New saline weathering grade to ­reduce the maintenance costs of offshore structures

Current standards for offshore grades (EN 10225 and API 2W) focus on toughness and weldability, while weathering resistance is not mentioned . However, the offshore market is seeking such products to reduce the huge maintenance costs . A new plate steel product, with enhanced corrosion resistance to atmospheric marine/saline weathering conditions, has been developed for offshore applications . Target applications are topside painted steel structures: e .g . fixed and floating platforms, offshore wind towers, substations and water ballast tanks .

PROVING THE METALLURGICAL corrosion resistance of up to 60%, compared S420 strength level is comfortably achieved CONCEPT to the conventional S355G10 grade. The for plates of 20 mm thick, and this is within The use of corrosion-resistant steel becomes development of our metallurgical concept reach for plates of 50 mm thick as well. attractive only if its cost remains below an resulted in steel compositions with a good High Charpy V-notch impact values were extra 10% compared to standard offshore combination of corrosion-resistance, measured at -40°C, even at mid-thickness. grades. Therefore, low-cost alloying is mechanical properties and weldability. targeted in this project. A wide selection of The rolling schedules have been further FULLY COMPATIBLE FILLER WIRE chemistries has been tested before fixing the improved, the chemical compositions have DEVELOPED IN-HOUSE concept for an industrial trial. been fine-tuned, and refined compositions To extend the excellent corrosion and Alloy selection was based on comprehensive have been produced and tested. mechanical properties of the base material corrosion testing campaigns, consisting Industrial trials at an ArcelorMittal heavy to the weld metal, OCAS launched a project of accelerated lab tests with alternating plate mill have proven the feasibility and to develop a brand-new welding wire (see wet and dry cycles to simulate offshore robustness of the concept. The results of also the chapter ‘Materials for the future’). conditions. The results showed an improved mechanical characterisation showed that an Five different chemistries compatible with

Durability & lifetime prediction 67 the saline weathering steel were selected, The industrial material will be used for processed and tested in the lab. The a first full-scale offshore welding pre- weldability assessment of the 20 mm thick qualification (which is necessary in order industrial plate was made through high heat to approach end-users and certification input multi-pass submerged arc welding bodies) and for long-term durability testing (SAW) experiments, using the lab processed under real-life offshore conditions. To assess welding wires. High strength values the long-term corrosion performance of well above the minimum requirements the new steel grade, outdoor exposure at for S355 and S420 were measured in all two locations with different environmental welds. Excellent weld metal toughness marine conditions is currently running. As was attained using the lab welding wire a lot of applications use painted structural developed in-house. steel, painted saline weathering steel is also being subjected to corrosion testing.

In addition to the successful development of a new steel grade, development of a fully compatible filler wire on lab-scale is a breakthrough. Today, there is no welding wire commercially available that can fulfil both mechanical (in particular, low temperature toughness) and corrosion requirements simultaneously.

Özlem Esma Ayas Güngör

Durability & lifetime prediction 69 By combining OCAS’s welding and coatings competencies with Endures’s experience in marine corrosion, we were able to identify the problem so that it could be prevented in the future.

Philippe Legros Failure analysis taken to sea

After barely six months of intensive collaboration, OCAS and Endures have already solved several customer cases by common inspections, sampling and in-depth analysis . In particular, the complementarity of our welding and corrosion expertise has proven to be especially valuable for our customers .

Marine lock gates were suffering from early MICROBIALLY INFLUENCED weld was the main reason for the observed and excessive corrosion. The welded and CORROSION (MIC) leaks. Chloride corrosion residues were coated structure, comprised of pressurised Our joint team combined its expertise in the found inside the pipes. Furthermore, MIC- pipes, exhibited visible corrosion. Some fields of failure analysis, marine corrosion relevant micro-organisms were identified in pipes clearly showed cracks and leaks, and welding to inspect the lock gate. The low to moderate quantities in the corrosion especially from the welds. quality of the welded pipes was assessed by products of the pipe, which might have As the customer needed to replace some using optical and electron microscopy. Wet accelerated the corrosion process. parts, he wanted to first identify the cause corrosion products from a leaking pipe were The customer was advised to improve the of the defects, and so he consulted OCAS/ analysed to check the potential presence of welding quality. There was no need to Endures to analyse the problem. microbially influenced corrosion (MIC). change the type of steel or its protective The leaking pipe clearly displayed multiple coating. welding defects. The poor quality of the

Durability & lifetime prediction 71 While critical structures are being designed ever larger, OCAS can test them faster to validate that they are better and stronger.

Jeroen Van Wittenberghe and Philippe Thibaux Larger, better, faster, stronger: accelerated fatigue testing of large- scale components

As several industries – such as onshore and offshore wind energy – are developing ever larger structures, materials and components are being pushed to their limits . So, conventional materials and production techniques are being replaced by stronger alternatives that should perform better .

FASTER, BETTER technology, OCAS can offer accelerated LARGER, STRONGER In many cases, proving increased fatigue tests on a wide range of components The uniquely developed loading system performance requires experimental and structures. Typical testing speeds are allows the testing of a wide variety of validation testing. Hydraulic test between 20 to 40 Hz for test pieces weighing components. CRONOS is suitable for equipment fit for testing large-scale more than 10 tonnes – which is considerably accelerated fatigue testing of components components usually takes time and comes faster than hydraulic test set-ups for large and structures such as beams, rails and at a considerable cost. To accelerate the structures, which have a typical testing other profiles; pipeline sections joined by testing speed of such large-scale critical speed of about 1 cycle per second. Using welding, bolted joints, etc. and complete components, OCAS has developed a unique CRONOS, a fatigue test that takes a complete welded structures such as nodes from test rig – called CRONOS – for accelerated month in a conventional test rig can be offshore jackets. fatigue testing. Using our patented test completed in only one day!

Durability & lifetime prediction 73 x x VALIDATION OF THE METHOD Test samples are being thoroughly Therefore, in the Joint Industry Project During the fatigue test programme on instrumented to measure overall JaCo (Jacket Connections for offshore jacket nodes in the framework of the EU- deformation and local strain levels. Next windmill infrastructure), it has been funded JaBaCo project, OCAS demonstrated to that, different state-of-the-art tools are decided to include a comparison between the ability to subject a complex welded being used to measure crack initiation and 6 specimens tested at OCAS with 6 other structure to a wide variety of load cases in propagation. Hence, while structures are specimens tested in another lab. Although its CRONOS set-up. The set-up allows to being designed ever larger, OCAS can test the results are still confidential, we can apply linear reciprocating loads (e.g. to load them faster to validate that they are better report that they are extremely similar. They a specimen in- or out-of-plane); combined and stronger. are actually closer than one would expect ‘circular’ loads, where a rotating force vector Testing metallic components at 20 to from traditional fatigue tests performed on a equally loads the complete circumference 40 Hz is widely accepted in the industry. single machine! of the tested component; and also complex However, some industrial companies asked multi-axial loads that allow a different us to compare the results of fatigue testing load amplitude in the in- and out-of-plane with CRONOS with a more conventional loading modes. method (i.e. with hydraulic jacks).

Durability & lifetime prediction 75 Nice realisation showing engineering requires great team work.

Johan Verlee

The OCAS dip-dry test device is highly versatile and can quickly assess corrosion in a variety of environments.

Krista Van den Bergh Assessing corrosion in various ­environments

Structures can be exposed to all kinds of environments . So, it’s important to assess corrosion using accelerated tests under conditions close to reality .

To speed up its offshore product of weathering steels at 20°C against and dry conditions are alternated. This has development and support activities, OCAS’s previous results obtained with the former resulted in an accelerated corrosion test Engineering team EMTEC developed a dip- dip-dry set-up. with conditions close to natural outdoor dry device for accelerated corrosion tests. As conditions. corrosion performance is largely affected by AN ACCELERATED CORROSION Corrosion assessment uses weight environmental factors such as temperature, TEST SIMULATING NATURAL loss measurements, distribution of pit relative humidity, chloride concentration, OUTDOOR CONDITIONS diameter, and pit height from roughness time of wetness, etc., the experimental The new dip-dry set-up also allows for more measurements. Corrosion products are conditions of cyclic tests are of utmost aggressive temperature conditions (up to analysed by analytical techniques such as importance. 60°C) in the wet and dry stages, which are X-ray diffraction (XRD), Fourier transformed That’s why the new dip-dry set-up with very useful for intensifying the material’s infra-red analysis (FT-IR), and scanning controlled conditions was designed, built ageing or simulating certain exposure electron microscopy with energy dispersive and installed. The new device provides environments. This new set-up is being X-ray spectroscopy (SEM-EDX), providing temperature control in the different cyclic used for testing the recently developed elemental or molecular information. stages as well as the monitoring of O2, weathering steel grades painted with OCAS has successfully implemented this test pH, conductivity and relative humidity. an offshore paint system certified to ISO set-up amongst others for the development At the same time, testing capacity has 20340:2009 and NORSOK M-501 standards. of new weathering steels. been increased. The new set-up has been The device allows to immerse panels in validated using the corrosion performance various electrolytes, whereby wet, humid

Durability & lifetime prediction 77 The customer selected OCAS for this project thanks to our combined competencies in sour testing, hydrogen concentration measurement and modelling.

Marc-Antoine Thual & Philippe Thibaux Combatting sour corrosion in the oil & gas sector Increased demand for energy has pushed the oil & gas sector to shift activities to deeper and harsher production environments . An increasing number of wells contain considerable amounts of hydrogen sulphide H S . Sour corrosion is a serious issue 2 in the slow strain rate test, failure occurs that can cause material failure at stress levels well below the yield strength . almost always. The time or deformation moment when the failure occurs provides OCAS has a fully equipped sour corrosion SLOW STRAIN RATE TESTS useful information about the severity of laboratory that allows to test materials AS A FAST SCREENING METHOD the testing conditions or the sensitivity according to the latest standards (NACE A major pipeline owner needed information of the material. Therefore, by using slow TM0316, NACE TM0198, NACE TM0284, NACE concerning the sensitivity of different strain rate tests, the customer obtains more TM0177, EFC16, etc.). In addition, OCAS also steel grades exposed to oil containing a information while fewer experiments are provides advanced proprietary test set-ups to significant amount of hydrogen sulphide. needed. its customers. Permeation testing under H2S The purpose was to investigate the influence environment gives greater insight into the of different factors such as temperature, pH, OPTIMISING MATERIAL amount of hydrogen going through a material, etc. on the material’s pick-up of hydrogen SELECTION FOR SOUR SERVICE whereas fast extraction tests allow to study and to relate this to the degradation of APPLICATIONS the amount of hydrogen trapped in a material material properties. By testing various In a next step, different experimental results as a function of the exposure time. Our environments, the customer will be able to are related and the material’s behaviour instrumented double cantilever beam device define domains in which specific materials in the presence of hydrogen is modelled. can follow up real-time crack propagation. are applicable or not. The long-term goal is to optimise material Combining these techniques allows OCAS to Sensitivity to hydrogen embrittlement is selection for sour service applications. model hydrogen distribution and transport often investigated using constant load tests. As each well is unique with its own H2S as a function of the exposure time to the However, this method only delivers a pass- concentration, being able to provide an environment and the applied loads. Based or-fail result. In many cases, the results can adequate material for a specific oil field has on this data, the OCAS team can recommend be inconclusive: if all the experiments either the advantage of reducing the CAPEX of the the material that will best fit the customer’s failed or passed, no information is available project without compromising the safety of service conditions. to distinguish different materials. However, the installation and its personnel.

Durability & lifetime prediction 79 OCAS is equipped to submit large components to extreme testing conditions without compromising on safety.

Jeroen Van Wittenberghe Keeping connections tight

As global energy demand increases, the role of natural gas is becoming more important . To explore and produce from natural gas reserves, gas-tight pipeline connections are required . Furthermore, gas tightness for downhole casing and tubing lines will be needed for carbon capture and sequestration (CCS) projects for the ongoing energy transition .

Together with the ArcelorMittal technical subjected to high internal and/or external team in Houston, OCAS has developed a pressure in combination with axial loading, state-of-the-art premium threaded pipe bending, elevated temperature, fatigue and connection, branded AM-BLADE. The dynamic tearing, producing extreme testing connection design was optimised through conditions typical for high pressure - high extensive finite element analysis and temperature (HPHT) applications, leak features the highest technical performance tightness tests, and proof of concept tests in while meeting the most stringent testing a contained environment. qualification conditions. Pressure can be applied with either liquid or gas as pressurisation media. Pressures ENABLING EXTREME TESTING up to 3000 bar can be applied. These CONDITIONS SAFELY severe testing conditions are necessary to These testing conditions are applied inside guarantee safe and gas-tight operation of the OCAS test pits. Large components can be the AM-BLADE connection.

Durability & lifetime prediction 81 Our unique and flexible test device can perform several mechanical tests up to 1000°C. Hardness testing is just one of the many high-temperature properties we can explore.

Michiel Corryn 1000 Failure at 50%YSR 900 Unprotected steel Protected steel 800 >700°C 700 composite steel ~600°C 600 conventional steel 500 C ° 400 Higher FR class for same 300 protection 200 100 0 0 30 60 90 Min Measuring high-temperature hardness to save lives

With an ever-increasing number of steel constructions in residential and industrial buildings, fire safety remains a work of continuous improvement . The main parameter used is the ‘fire resistance period’ – which is the time in which all occupants must leave to avoid the risk of the building collapsing .

Standard steel constructions lose their FINDING A SCREENING METHOD That’s why OCAS has turned to high- strength around 600°C. With insulation The standard method for assessing fire temperature hardness measurement as an and concrete protecting the steel beams, resistance is to carry out a series of tensile alternative to screen the loss of strength as this temperature is reached after about tests at elevated temperature (ISO 6892-2: a function of the temperature. The softening 40 minutes of fire. However, this timeframe 2018). Above a certain temperature, the steel of a steel is well correlated with its loss of can be tight for emergency workers to clear will have lost 40% of its tensile strength, strength – and our automated test device out a building, certainly with response time compared to its initial strength at room can measure hardness up to 1000°C. The taken into account. If the steel would keep temperature. Comparing this temperature major advantage lies in the fact that only its strength up to 700°C (and higher), the with the heating curve of a standard fire one sample of a few square centimetres is fire resistance period would be extended provides a value for the fire resistance sufficient to plot the hardness evolution to at least 1 hour, providing extra time for period. However, this test method is highly across the full temperature range. The most everyone to get out safely. time-consuming and requires large volumes promising materials are then selected for of machined test samples for each grade – further testing in the standard manner. so it’s not really suited for screening 100+ novel grades.

Durability & lifetime prediction 83 MATERIALS FOR THE FUTURE

In the last decades, the big majority of steel developments were concentrated on small additions of alloying elements, combined 4 with more than 98% of iron. Only within this relatively small domain of alloying variation, metallurgists managed to make an impressive series of different steel families with specific properties ranging from soft steels with ultra deep drawing capability to high strength steels with 5 times higher tensile strengths. In recent years, a significant shift in mindset has been observed for two reasons. First and obvious reason is the everlasting quest for higher performance of materials, mostly translated these days in a challenging combination of properties that need to be fulfilled. Second reason is the improved capability of steel plants to alloy more in a cost efficient and qualitative way. Result of this extra degree of freedom for the metallurgical designers is another massive layer of new materials coming closer to industrial reality. MATERIALS FOR THE FUTURE

OCAS is strongly involved in the These evolutions also create needs and Given the huge success of Magnelis®, development and industrialisation of this opportunities for wire products. First of all, a metallic coating with outstanding next generation of products, ranging from these new substrate metallurgies for flat corrosion protection, a strong effort is put the more classical, high-end product range products require to be weldable, and as in the development of the next generation of micro-alloyed and martensitic steels, they exceed the range of available welding metallic coating. This is an exciting program to more exotic solutions like Quench & consumables, dedicated developments exploring old and new metallic coating Partitioning steels pushing the strength of welding wire are needed to be able to production methods hunting several new ductility balance to the next level, pure offer a complete solution to our customers. challenges such as durability, appearance, austenitic iron manganese steels with a Also, some of these metallurgies open sustainability and efficiency. whole range of outstanding properties up very interesting opportunities for Our sustainability efforts are not limited such as extreme formability and toughness components produced via Wire Arc Additive to metallic coatings only but cover a at cryogenic temperatures, and maraging Manufacturing (WAAM) technology. For broad variety of different types of coating steels with the capability to increase non-ferrous alloys, opportunities exist for activities. We continue to work on several multiple times in strength due to heat dedicated metallurgies for WAAM parts. REACH compliant solutions, such as nickel treatments. Both tendencies pushed OCAS to install and cobalt oxides-free enamelling systems All these developments only make sense lab scale bar rolling capacity, in order to be or a hexavalent chromium-free solution for if one manages to make optimal use of the able to make small material batches in an plating. offered performance. OCAS has a strong accelerated manner, so that developments tradition in developing generic steel can be offered quicker. — Tom Waterschoot and Lode Duprez solutions guiding steel users how to take Meanwhile, we pay special attention to the maximal benefit out of the offered steel surface quality of the developed products. properties, and setting up co-engineering To further improve the performance of projects with interested customers to the steel solution, OCAS has a number of translate the theory into an in-field example. projects focusing on improving the surface.

Materials for the future 85 After decades of optimising steel grades based on limited alloy content, it’s exciting to now try out new alloying approaches for the development of future generation steel grades.

Laura Moli Sanchez, Elvan Ekiz, Rolf Berghammer, Ulrike Lorenz, Lode Duprez, Tom Waterschoot Ever stronger and longer-lasting, ever thinner or thicker

The flourishing market segment of yellow & green goods and heavy transport applications continues to evolve to larger, higher-performance constructions . This feeds the need for higher strength grades in moderate and heavy gauges .

Currently, such products are mainly developments will help ArcelorMittal’s hot A growing family of quenched hot rolled available as quenched and tempered plate strip mills make full use of their capabilities. products is being developed for both products. Metallurgists at OCAS are not The extension of dimensional feasibility will structural applications with stringent and only developing more cost-effective plate be rolled out step-by-step for other grades severe quality requirements and wear solutions, but also hot strip products, which and thereby broaden ArcelorMittal’s offer. applications extending the lifetime of the can guarantee properties similar to plate In addition to these micro-alloyed grades, components. grades, such as strength, low-temperature OCAS is also developing hot rolled toughness, weldability and formability. quenchable boron grades dedicated to PUSHING THE LIMITS OF the yellow and green goods market. Our PROCESSING TECHNOLOGY NEXT GENERATION MICRO- developments focus on outperforming In the longer run, we are evaluating new ALLOYED AND MARTENSITIC standard properties – for example, making alloying approaches to introduce specific DEVELOPMENTS production at the customer easier, but microstructural features to raise the steel Moving to heavier gauges while keeping still guaranteeing the final performance performance to another level. For this good mechanical properties is becoming of the application. The high mechanical purpose, OCAS is intensively screening increasingly challenging. Therefore, OCAS properties achieved after quenching and several potential new metallurgies of the has developed and tested new metallurgies, tempering, and the soft hot-rolled material future. as well as adapted processing, on lab scale, (easy to post-process), have allowed us to One of the more advanced solutions before they are implemented industrially. go from prototyping at the customer’s site is the addition of significant amounts These next generation micro-alloyed to full industrialisation. of manganese to typical martensitic

Materials for the future 87 compositions. These so-called medium for structural parts, where complex shape We could even think of reducing the density manganese steels modify martensitic and high-strength requirements can be met of steel by a smart alloying approach, structures and introduce retained austenite, by this steel’s high formability and weight bringing us high strength at lower weight. which allows to improve the combination reduction potential. OCAS is involved in several tracks to of strength, formability and toughness in a The higher alloy content compared to establish this game changer material – two spectacular way. conventional steels makes the production tracks of which have already evolved to Even stronger alloyed, high manganese of high Mn steels very challenging. OCAS industrial feasibility assessments. austenitic steels (FeMn) display a unique and ArcelorMittal are working on the At OCAS, we’re working on even more combination of strength and formability development of a new processing route, complex metallurgical concepts such as with good toughness at high and low impact pushing the limits of existing processing breakthrough maraging steels, which are speeds. This steel’s high work hardening technology to novel boundaries. As the known for their unique capability to show capability makes it get harder as it wears industrial route trials deliver the first huge strength increases by high temperature down. Hence, it is ideal for applications product ready for customer assessment, tempering treatment. These could be good that require high lifetime of components OCAS is continuing to work on improving solutions for niche market applications that subjected to wear and impact, such as in concepts to enhance industrial robustness require a combination of high strength and the yellow and green goods and the rail as well as extending the lifetime of corrosion resistance, for example. industry. The outstanding mechanical components made from this exceptional properties also make this grade promising steel.

Materials for the future 89 Multiple revamps have resulted in today’s versatile equipment, allowing to respond to numerous demands for lab materials with customised geometries and This optimisation will pave the way for both dimensions, processed according to the new generation of hot rolled grades and specific metallurgical concepts. cost reduction of existing products. Johan Verlee, Kris Hertschap & Alexandre Van Sintejan Klaas Poppe Fully automated lab scale heavy gauge hot rolling and cooling

To further enhance our service offer in the field of metal processing, exciting industrially relevant improvements have recently been implemented in our lab .

Lab tools are ideal for cost-effective product The block temperature and dozens of After rolling, air cooling or controlled water development. In order to ensure reliability other material and process parameters are cooling in the laminar cooling line is carried and to collect all the necessary data needed measured and logged throughout the whole out, with minimal time loss and following a for industrial upscaling, precise control and process in order to accurately control the preprogrammed scheme. full data logging is vital. thermal profile from start to end. Thanks to the sectional design of the table, The OCAS engineering team EMTEC Besides carbon steel, OCAS rolls other a multitude of cooling patterns can be automated our heavy gauge reversible materials, such as aluminium, stainless achieved. hot rolling lab scale mill. As manual steel grades, Inconel, copper, etc. We can The advanced and versatile rolling and manipulations are no longer required, reheat up to 1280°C in a convection furnace. cooling equipment have become state- blocks with a weight up to 65 kg can now Our air circulation furnace is better suited of-the-art tools, ready to support new be rolled. The minimal starting thickness is for lower reheating temperatures, allowing developments in hot rolled skelp and heavy 200 mm and can roll down to 5 mm, which highly homogeneous temperatures in the plate. makes the mill suitable for roughing and range 350-600°C, which is suited for e.g. finish rolling. The max. dimensions after aluminium for aerospace applications. rolling 1600 mm (length) x 500 mm (width) The fully automated high width rolling mill allow sampling for a large range of test is connected to the cooling pilot, by an samples. automatic transfer system.

Materials for the future 91 In defining IMpACT, we raised the bar very high. I am delighted to witness the creativity of the team that has been triggered by this breakthrough project.

Beril Corlu

A good surface is only ensured by optimising manufacturing process parameters but also storage conditions and the entire logistics chain – a true challenge!

Marc Leveaux & Filip Geenen Surfaces with impact

impact: /˙ım .pækt/: a marked effect or influence; IMpACT: innovative metallic coating platform .

IMpACT: A BREAKTHROUGH R&D metallic coatings. Today, the OCAS coating finished products that can be used, e.g. for PROJECT GENERATING METALLIC team has the know-how, the network and direct painting after decoiling and levelling. COATINGS OF THE FUTURE the equipment necessary to pull off this In addition to the MASc label, actions have This is where our challenge lies: developing challenge. Shortly after its kick-off, IMpACT been taken to implement a concept to bring the future generation of metallic coatings already started to produce novel ideas on the standard hot-rolled mill-finished surface with outstanding properties. For this promising products and processes, which to a higher level. All users appreciate purpose, OCAS is screening a wide range are currently being tested on pilot scale. cleaner workshops, faster processes of production techniques and alloy and cost savings – so, this concept has compositions in the light of key drivers: IMPROVED SURFACE QUALITY already been extended to several mills in ecology, durability and efficiency. The FOR HOT ROLLED STEEL Europe (some of them now in the ramp-up IMpACT programme approaches this A smooth and clean surface simplifies and phase) registering official orders from demanding challenge from several decreases the cost of downstream processes, customers. A good surface is only ensured angles, including the development of and this is exactly what custormers are by optimising manufacturing process new compositions for hot dip coatings, demanding in hot rolled mill-finished steel. parameters but also storage conditions and exploring electroplating solutions, and Specific metallurgical routes have been the entire logistics chain. using PVD technology for products showing defined for structural grades as well as high- OCAS is actively supporting all ArcelorMittal stronger protection in combination with strength low-alloyed steel grades in order facilities: checking the quality of the excellent appearance, always with an eye for to provide end-users with this improved products after industrial trials, performing industrial applicability. surface. The Micro-Adhesive Scale (branded local audits, and developing customised test Since its foundation 30 years ago, OCAS has by ArcelorMittal as MASc) label guarantees methods. been active in applied research in the field of top surface quality for hot-rolled mill-

Materials for the future 93 Over the years, the Ready-to-Paint development and its industrial implementation have enabled us to build substantial knowledge regarding The new enamel-to-metal link is just about surface treatment. We are already 5 µm thick, and it replaces the functionality looking forward to consolidating this of traditional enamel layers between 30 to expertise in future products. 120 µm!

Nathalie Van den Bossche & Lien Van de Voorde Marc Leveaux New tracks for green coatings

In recent years, driven by ever-stricter environmental legislation, the surface treatment and enamelling industry have evolved by limiting the use of hazardous compounds, or avoiding them altogether .

PEAK LIFE CYCLE ASSESSMENT Since 2018, a new track has been opened By replacing nickel with other metals that (LCA) PERFORMANCE FOR by looking back and rethinking an old, are REACH compliant, OCAS can present an ENAMELLED STEEL yet efficient, enamelling process known alternative. The new metallic layer is applied Vitreous enamelling has been acknowledged as ‘Direct White Enamelling’ or DWE. In by electrodeposition on flat sheet, making for centuries as one of the most durable DWE, the enamel-to-metal link is obtained this substrate ready to enamel in just one ways to protect metals against abrasion, thanks to an elaborate preparation of single layer. This concept allows the end- temperature and corrosion. Recent the steel’s surface. The steel substrate is user to form the sheet prior to enamelling. progress have significantly reduced the pickled first using a strong acid, followed The new enamel-to-metal link is just about environmental footprint of enamelled steel, by nickel treatment. Nickel is key in 5 µm thick, and it replaces the functionality but this is not enough. We need to increase bonding enamel to steel, as it ensures of traditional enamel layers between 30 to the lifetime of manufactured products, the formation of complex phases with 120 µm! improve their recyclability, and reduce the iron from the steel substrate and silicon consumption of raw materials and energy. or titanium from the enamel coating. In READY WHEN YOU ARE In order to solve all of the drawbacks – just a single enamel layer, DWE provides Ready-to-Paint, the first dry surface technical as well as economical – OCAS aesthetics, chemical resistance and colour treatment available for cold-rolled steel, has launched a ‘green enamelling’ to the steel. Nevertheless, the DWE process enables customers to reduce their waste project. Its goal is to propose several new was abandoned as it generates waste. and energy consumption. It avoids oiling, enamelling concepts for the enamelled steel Moreover, today, nickel is classified as degreasing, and the application of a of the future, without compromising on CMR (Carcinogenic, Mutagenic or Toxic for phosphate or passivation layer, and still it performance. Reproduction). enhances paint adhesion.

Materials for the future 95 Our semi-industrial plating unit not only allows us to coat prototypes, it can also be used to prepare and test new ionic liquids at tonne scale.

Ansbert De Cleene So far, feedback from the customers has Thanks to OCAS’s research & development final hard chrome coating and transformed been very positive, leading to consistent efforts since then, this hexavalent chromium- the dull aspect of the deposited coating customer orders. Pushed by market free technology has now matured to semi- at the start of the project into a shiny and demand, production has been extended to industrial level. In addition to enhancing our bright chrome appearance. Several surface another production line in order to enlarge knowledge of plating technology in general, treatment procedures were optimised to its feasibility window. With the roll-out of it has also provided OCAS with fundamental improve the adhesion on various substrates. Ready-to-Paint, the overall quality level of insights into the fine-tuning of process Furthermore, the corrosion resistance of the the production lines has been brought to a parameters, microstructure and the final hard chrome layer could be brought to the higher level. After years of close follow up, properties of the coating. level comparable to traditional hexavalent Ready-to-Paint is now a mature product. chromium applications. EVALUATING ALTERNATIVES OCAS has built substantial expertise in the REACH-COMPLIANT CHROME FOR HEXAVALENT CHROMIUM field of electrodeposition and the evaluation PLATING ELECTRODEPOSITION of metallic coatings from ionic liquids Back in 2012, driven by the need for REACH- Using finite element plating reactor models, as well as from aqueous solutions. A lot compliant alternatives, OCAS initiated taking fluid dynamics and electrochemical of electrodeposition research with ionic a project on hexavalent chromium-free deposition kinetics into account, good liquids is already being performed on lab hard chrome plating. OCAS focuses on process control and thus bath monitoring scale. OCAS’s semi-industrial plating unit the development of alternative plating could be achieved. The models have allows us to coat different applications and technologies for these processes and their enabled us to design experiments in a more to prepare new ionic liquids at tonne scale. up-scaling, and we have been supporting straightforward manner, speeding up the The expertise we have developed in this field industrial partners in their quest for suitable development of durable layers on various is highly valuable for partners evaluating alternatives for conventional plating prototype alloys in different shapes. alternatives for hexavalent chromium processes. For example, careful bath monitoring electrodeposition. significantly increased the hardness of the

Materials for the future 97 The drive for thinner material will continue and future ultra-high-strength grades will be able to satisfy that need!

Koenraad Theuwissen

We believe that steel is still the most suitable material for making transport more efficient and eco-friendly – and we’re continuously developing the microstructures and the tools to make this vision a reality.

John Vande Voorde Heavy-duty loses weight

In recent years, OCAS has developed several new ultra-high-strength products for use in different market segments . In addition to new ultra-high-strength grade development, OCAS also has long-standing experience in weight-reducing solutions for steel structures, ranging from washing machines and agricultural machines, to trucks and trailers and even offshore structures .

FUTURE GENERATION OF ULTRA- Now, OCAS has already started working on extraordinary elongation or superior wear HIGH-STRENGTH STEELS the future generation of such materials, in resistance – the design of components and To reach the optimal design, OCAS which the higher strength is accompanied structures is optimised and customised to combines finite element analysis, expert by even better elongation and better the exigencies specific to the application knowledge of material properties, and in-use properties such as toughness and at hand. By balancing the structural judiciously selected experimental testing. bendability. Indeed, this new generation requirements, the specifics of the customer’s Applications for ultra-high-strength is no longer based on ‘conventional’ production and assembly method, and the products include trucks and trailers for metallurgy but on new and innovative demands put forward by the application transport, agricultural equipment, and concepts. environment, impressive savings in both crane-booms that enable the construction mass and cost can be achieved. of cranes with longer reach and higher WEIGHT- AND COST-REDUCING allowable lifting weight. Weight and cost SOLUTIONS reduction are the main drivers behind By exploiting the particular properties developments aiming for thinner and of the next-generation steel grades being stronger material. developed at OCAS – be it extreme strength,

Materials for the future 99 Without doubt, tailored welding solutions will bring added value to new applications.

Özlem Esma Ayas Güngör, Elke Leunis & Michal Mroz Lab wire with tailored chemistry for accelerated research

In different research portfolios, new steel metallurgies are currently under development which often require new solutions for welding, including the development of an adapted filler wire .

OCAS has developed a laboratory synthesis outside diameter welding on sheets. The with the steel were processed and tested route for wire rods with tailored chemistries, behaviour of the lab wire during welding in the lab. In addition to the expected via casting and rod rolling. Today, this was similar to that of the commercial wire, corrosion performance, excellent toughness allows us to quickly produce small batches and no problems were experienced in terms and tensile properties could be achieved of customised wire for research studies, of wire feeding, arc stability or slag removal. in the weld metal, showing the potential where small quantities of tailored wire When characterising the weld metal, no for a complete ‘substrate + welding wire’ are needed (e.g. investigations related to difference in the hardness of the welds was solution. welding wire, wire for thermal spraying, or observed, and the Charpy impact toughness wire for additive manufacturing). performance was similar. WIRE ARC ADDITIVE MANUFACTURING VALIDATION OF SOLID WIRE NEW WELDING WIRE FOR Similar to welding, the lab wire synthesis PRODUCTION METHODOLOGY NEW STEEL PRODUCT route is under validation for wire arc In order to validate the method of producing This validation of the laboratory route additive manufacturing (WAAM) research. welding wire on lab scale, a commercially allowed us to start using lab wire in Successful single and multiple line printing available submerged arc welding wire was dedicated developments, one being trials were performed using commercial wire reproduced. Both the commercial and a welding wire with saline corrosion compositions as a benchmark to the R&D the lab processed wire were then used for resistance. After achieving exceptional lab-produced wire. Tensile testing, Charpy submerged arc welding (SAW) trials. The corrosion properties on a newly developed testing and microstructural analysis will be performance of the lab-processed wire was saline-resistant weathering steel substrate, performed to confirm the correct quality and assessed through submerged arc welding the development of a dedicated welding representativeness of the laboratory wire. experiments performed on line pipe steel. wire was launched. Submerged arc welding Two-wire welding was used for inside and wires in different chemistries compatible

Materials for the future 101 5 NANO MATTERS NANO MATTERS

To understand our world, we need to In the development and successful analyse it. And we need to do this for many deployment of new steel grades, metal reasons, safety being one of them. alloys and associated coatings or surface OCAS has acquired a lot of experience in technologies, it is ever more important product safety over the last several years. to control the microstructure and surface To comply with safety regulations, accurate conditions in the (sub)nanometre range. At measurements are required on the release the same time, elucidating these structures of toxic substances during the entire is becoming more and more complicated lifetime of the product. This may comprise due to their size and composition. In this high-end organic analyses as well as year’s edition of our Activity Review, we nanometric studies of dust. Failure analysis present some metallurgical examples to is also a matter of safety – this enables show how the combination of high-end us to understand failure and to prevent it microscopic techniques leads to further in the future. OCAS uses a wide range of understanding of material behaviour. equipment to carry out failure analysis. OCAS’s broad array of equipment enables From a simple optical microscope to find us to tackle various problems from different point defects, to depth profiling equipment angles. for coating analyses, to atomic resolution to understand bonding mechanisms. — Ann De Vyt & Jan Scheers

Nano matters 103 Advanced materials research evolved into an astonishing insight into the atomic composition of complex 3D-nanostructures with unprecedented resolution. Whereas there are many characterisation techniques providing spatial and compositional information, atom probe tomography is the only one offering extensive capabilities for both 3D-imaging and chemical composition measurements at the atomic-scale.

Hui ‘Maggie’ Shi & Davit Melkonyan How Atom Probe Tomography can ­expand your horizons

Future generations of wear-resistant, electrical, high-strength-structural and sour-service steel grades will require a much more detailed understanding of the metallurgical mechanisms leading to corrosion protection, ductility and bendability improvement, temper and precipitation strengthening, toughness maximisation, hydrogen trapping, etc .

To tailor the macroscopic properties of A UNIQUE ATOMIC-SCALE coinciding electron and ion beam enables materials so that all of the boxes are ticked, 3D-ANALYSIS TECHNIQUE FOR simultaneous SEM imaging during FIB it is crucial to control atomic distribution. STEELS milling tasks to achieve ultimate levels of To achieve this, various material Within materials characterisation field, precision. characterisation techniques are available Atom Probe Tomography (APT) occupies In this process, part of the bulk sample is to probe and measure the properties of a unique place, as it is the only technique milled away and sharpened by FIB to create materials. Microscopic information enables offering extensive capabilities in both the needle-shaped specimen. In many concepts to be developed to engineer 3D-imaging and revealing chemical cases, these specimens need to be taken materials with tailored macroscopic composition at the atomic-scale. OCAS from a specific place of the bulk sample properties. started using APT* in steel research in 2016. containing regions such as grain or phase The APT technique requires nano-scale boundaries. Often, electron backscatter needle-shaped specimens of about diffraction (EBSD) or transmission 50 nm apex radius. OCAS prepares these electron microscopy (TEM) is required to samples in-house by means of a focused successfully localise the region of interest ion/scanning electron (FIB/SEM) dual in a nano-scale sample before the final APT beam system. The configuration with analysis is conducted.

Nano matters 105

MANUFACTURING STEELS WITH properties of steels. For instance, adding processes, such as constraining grain TAILORED PROPERTIES a small amount of boron to low-alloy growth and stabilising the microstructure, OCAS has developed a methodology to steels can improve their hardenability, are also closely linked to precipitation. routinely analyse prior-austenite grain which is attributed to the segregation of OCAS uses APT to study the mechanisms boundaries (PAGB) and phase boundaries. boron at PAGBs. Therefore, the nano-scale leading to nucleation of precipitates and This allows us to quantify the presence of grain boundary analysis is useful for the precipitate evolution for varying processing different elemental segregations at these manufacturing of steels with tailored conditions of different steel grades. APT boundaries for different steel grades and to properties. allows us to extract composition, size evaluate their dependence on the processing Studying precipitation in steels is another distribution, volume fraction and 3D routes. The segregation of different aspect for which APT has proven to be very morphology of precipitates. solutes at grain and phase boundaries useful. Precipitation hardening improves * OCAS wishes to acknowledge the Flemish Hercules can noticeably alter the macroscopic the mechanical properties of steels. Other Foundation for large-scale research infrastructure.

Nano matters 107 It’s exciting to be able to zoom in from what is visible with the naked eye to magnifications up to 30,000 times, or even more, in order to determine the cause of the failure and help the customer with the corrective actions needed to prevent failure in the future.

Annick Dhont Zoom into the problem and see the solution

When an installation fails, the customer needs to know why . OCAS’s technical support team helps customers get to the source of a failure as quickly as possible . More importantly, the root cause analysis provides recommendations for addressing and correcting the issue causing the failure .

In most cases, failure analysis is a observed in several positions only two years tools, our skilled staff addresses the multidisciplinary process. OCAS has a after installation. Leakage of an installation problem with the highest priority. The wide range of equipment to carry out is a disaster in any case. But in a food first step in the investigation consists of failure analysis: from visual inspection processing environment, with stringent listing the operating conditions. Linking to metallographic microscopy, down to regulations concerning food safety, leakage these conditions to observed features scanning electron microscopy. In addition, might require a production shutdown during the investigation often leads to an chemical analysis and mapping, and even resulting in serious economic damage for understanding of the failure. numerical simulations, are also often used the company. So, understanding the cause to identify the root cause. of the problem is of great importance for the MACRO LEAKAGE CAUSED BY food processing company as well as for the MICRO CRACKS UNDERSTANDING THE FAILURE designer and supplier of the installation. In this case, visual observation revealed A customer from the food processing Many questions arise in every failure that all affected areas were located in the industry called on OCAS to investigate the analysis case: does the material meet its immediate vicinity of a weld in the tubing leakage of a stainless-steel tubing system. specifications? Is there an overlooked system. Optical microscopy showed small Although the design conforms to food corrosion problem? Do environmental cracks in the affected areas. No pitting or processing standards, leakage is being conditions play a role? Using the right red rust spots were observed, meaning

Nano matters 109 that no corrosion occurred. Based on the present cracks were initiated. These the concerned tubes, irregularities occurred, these findings, we identified the primary phases typically influence toughness and causing the material to become sensitive areas for cross-section preparation. These crack resistance. Analysis of the chemical to cracking in the heat-affected zone of cross-sections were studied by means of composition confirmed that the right the weld. To avoid similar issues in the optical and electron microscopy (the latter stainless-steel grade had been used for the future, OCAS provided recommendations is also equipped for chemical analysis and installation. for optimising the welding parameters: mapping). Electron microscopy revealed As no corrosion was observed, the material alignment, composition of the filler the presence of chromium carbides and that was used is compliant for use in this material, welding speed, protective gas delta ferrite phases in the weld area where application. However, during the welding of composition and flow, cooling rate, etc.

Nano matters 111 At OCAS, measurements are much more than merely a list of results. Thanks to our experience, we know how to address safety topics. We can help in selecting the best formulations and provide recommendations for adapted collective and personal protection.

Philippe Legros To measure is to know

REACH* and CLP** regulations improve the protection of human health and the environment from the risks that can be posed by hazardous chemicals . To comply with these regulations, accurate measurements are required not only on the release of these substances from end-products, but also from the raw materials used during the production process or in the air at the workplace during processing .

For more than a decade, OCAS has gained leaching tests of coated panels. During safety parts for cars, which are hot formed. experience in checking paints, varnishes painting, the concentration of formaldehyde This allowed us to ensure the air quality at and coated samples or air for the presence sampled at the workplace was measured by the workplace. of potentially hazardous substances. OCAS high-performance liquid chromatography The risk associated with ultra-fine particles is equipped to collect the air samples at (HPLC). Test results were used to compare emitted through plasma cutting of metallic the customer and carry out the analysis and rank different coatings and enabled coated plates for offshore wind has been of dust and gases with its state-of-the-art the customer to identify compliant paint evaluated to validate the collective and equipment. Examples below illustrate formulations. personal protection of workers. recent work. Regarding insulating varnishes for electrical The risk associated with the presence of steel, the presence of formaldehyde, hazardous and toxic residual compounds in CASE FORMALDEHYDE a carcinogenic compound, in liquid marine paints, such as lead and hexavalent To perform risk assessment, OCAS varnishes and from coated plates has chromium, has been assessed. The painted investigated the release of formaldehyde, been evaluated. The results are being used steel structures for a lock had to be repaired: volatile organic compounds (VOCs) and for communication with the factory and cutting and welding had to be performed. isocyanates from a range of paint systems customers. * REACH: European regulation on Registration, as well as from panels coated with these Evaluation, Authorisation and Restriction of Chemicals paints. The OCAS team selected the best FROM PRESS SHOP TO OFFSHORE ** CLP: Classification, Labelling and Packaging of sampling method and analysed the samples AND MARITIME CONSTRUCTIONS substances and mixtures in-house. OCAS carried out measurements on Formaldehyde was measured in water combustion gas in and outside thermal solution using UV-spectrometry after hot treatment furnaces for a manufacturer of

Nano matters 113 Manganese Carbon

EBSD phase map Electron image

OCAS’s know-how and state-of-the-art equipment enable the interpretation of more complex multi-component metallic microstructures, raising product development to a new level.

Mélanie Gauvin & Ann De Vyt The power of combining micro- and nano-analysis equipment (ferrite, martensite, austenite and pearlite) In the previous edition of this report, we zoomed in on the OCAS equipment performed by EBSD. SXES is used locally to used to perform micro- and nano-analysis . Now, we focus on the strength of quantify the concentration of C. combining these state-of-the-art instruments . AN EXHAUSTIVE PICTURE OF THE MICROSTRUCTURE OCAS combined its brand-new Field HIGH IMAGE RESOLUTION, The comparison between EPMA and EBSD Emission Gun – Electron Probe Micro HIGH SPATIAL RESOLUTION, AND mappings shows that most microstructural Analyser (FEG-EPMA), equipped with four HIGH SENSITIVITY features are consistently observed at the Wavelength Dispersive Spectrometers (WDS) Austenite Reverted Transformation (ART) same location. Austenite domains (blue and a Soft X-ray Emission Spectrometer steels rely on the stabilisation of austenite domains) on the EBSD phase map correlate (SXES), with its Field Emission Gun – by Mn diffusion to obtain their excellent directly with carbon/manganese-rich Scanning Electron Microscope (FEG-SEM) mechanical properties. The amount of domains evidenced by EPMA. Other carbon- and Electron Back-Scattering Diffraction austenite, and its morphology, location and rich phases such as pearlite or cementite (EBSD). Whereas, EPMA-WDS is a micro- stability greatly affect these properties. In- particles can be found. These are known to analysis tool providing the chemical depth characterisation of micro/nanometre- modify mechanical properties. Although, distribution of elements, SXES is dedicated sized austenite domains is challenging and usually invisible for EBSD, they are very well to trace analysis of light elements. As such, requires our most powerful analytical tools. evidenced by EPMA, illustrating the power SXES is complementary to EPMA-WDS for Techniques combining high image of combining structural with chemical carbon analysis. EBSD is a micro-analysis resolution, high spatial resolution and analyses at the very same spot to reveal an tool that identifies the orientation and high sensitivity are essential. We combined exhaustive picture of the microstructure. phases of crystalline samples. EPMA and EBSD analyses to correlate The amount of austenite as detected by both chemical and structural information EPMA is in good correlation with X-ray at the same location in the sample. High Diffraction measurements. Moreover, the resolution C and Mn mappings acquired by general conclusions made from this study EPMA-WDS are used to validate and improve are well in accordance with equilibrium the identification of the constituents calculations.

Nano matters 115 6 WORKING WITH OCAS To speed up the R&D processes of our Striving to be a research facilitator for its customers, OCAS makes sure to have all customers, over the last few years OCAS assets in place and continuously strives has invested immensely in three research to improve the quality of its services and domains to keep our performance at the increase its output by adding value and/or highest level: combinatorial research, reducing costs. digitisation and nano investigation. Next to aiming to consistently deliver high- This way, we focus on more efficient quality R&D services, supported by several data generation, data capture and data ISO17025 accredited tests, we combine the visualisation. By also targeting the expertise of our teams with our engineering data-mining side, we enable smarter and testing capability to deliver a total experimentation by performing digital solution approach addressing our screenings using advanced computational customers’ ever more complex problems: tools. The nano axis allows us to investigate from product design all the way through materials down to the atomic level to the optimisation phase. acquire fundamental understanding of the mechanisms behind material behaviour. WORKING WITH OCAS

OCAS continues to invest strongly in both and combinations thereof. In 2019, company repairs, refurbishes and produces building competence and developing our innovative, large-scale accelerated large metal parts, using wire arc additive business in the following focus areas: fatigue testing set-up for welded nodes manufacturing to extend the lifetime, — Environmentally supportive, was successfully bench-marked against or reduce the downtime, of industrial ‘green’ alloy and metallic coating the traditional test methods within our equipment. developments such as low-weight steel JaCo project (same results, 20 times OCAS has won a tender for projects from solutions, taking not only strength faster). the Belgian Energy Transition Fund and is requirements into account but other — Support to, and co-engineering with, now leading a consortium whose objective production and design requirements FININDUS portfolio companies, where is to investigate the combination of fatigue too (such as bendability, formability, the deep-niche specialisation of these and corrosion of offshore structures to etc.), as well as in-use durability and companies is complemented by OCAS’s extend the life of wind energy convertors. sustainability. In the field of metallic multi-competence capabilities. Furthermore, OCAS was chosen as the coating, a REACH-compliant hard chrome In this context, OCAS is excited to announce preferred partner for a flagship project of plating technology has been further its collaboration with the ENDURES team. the Carbon Trust Offshore Wind Accelerator. matured towards industrial levels. By joining forces, we extend our on/offshore We also participated in the European JaBaCo — Non-standard, large-scale testing and maritime service offer by combining our project to develop a modular concept capabilities and modelling tools of expertise in the field of corrosion. for jacket foundations for offshore wind material and component damage In 2019, GUARANTEED was created as a turbines. mechanisms, such as fatigue, wear, spin-off company from OCAS, FININDUS corrosion, hydrogen embrittlement, and ArcelorMittal Belgium. The new — Nico De Wispelaere & Marc Vanderschueren

Working with OCAS 117 Synergy and complementarity between Endures and OCAS were evident from the very first moment.

Joost De Strycker OCAS and Endures embark on joint offshore and maritime journey

In June 2019, Finocas Group NV and First Dutch Innovations (FDI) BV agreed with a FINOCAS majority stake in Endures BV – an independent contract research company, specialising in applied research on marine corrosion and anti-fouling, based in Den Helder (The Netherlands) . Thus, Endures BV became a sister company of OCAS . AN ENDURING COLLABORATION Estimated at roughly 3-4% of the global expose samples to maritime weathering OCAS’s expertise in alloy and coating GDP by NACE, protection against corrosion conditions, both aerial and immersed, design, metal surface engineering, in industry and society is a multi-million as well as in the tidal or splash zone. non-standard testing and modelling business each year. By selecting appropriate Endures also has a raft for efficacy tests of complements Endures’s in-field inspections materials and protection systems in various anti-fouling paints and can carry out lab and current knowledge of corrosion, environments, customers can reduce their experiments in running natural seawater. electrochemistry, MIC, anti-fouling and corrosion costs. In addition, Endures has all of the protective coatings. tools to estimate the contribution of After barely six months of intensive ADDING VALUE AND microbiologically influenced corrosion collaboration, we’ve already solved several REDUCING COSTS (MIC) to failure mechanisms with sampling customer cases via common inspections, OCAS is excited to announce its procedures, micro-organism culture sampling and in-depth analysis. The collaboration with the Endures team. By breeding capabilities, DNA mapping complementarity of our welding and joining forces, we combine our expertise equipment and in-house microbiological corrosion expertise has been especially in the field of materials science to extend experts. Endures conducts applied research noteworthy. In addition to these services, our on/offshore service offer and provide on vessels, offshore installations and land- even a first common investment file for a custom-made solutions adding value, based structures and buildings to determine customised set-up for accelerated testing in reducing costs and preventing materials the type of corrosion damage, and to living sea water was launched. damage for our customers. prevent future damage. Certified corrosion OCAS and Endures will further deepen Based in the harbour of Den Helder, Endures inspectors are also part of the Endures their offshore and maritime activities in an has a C3/C4 seaside testing location to team. integrated approach.

Working with OCAS 119 Born from Innovation, GUARANTEED uses unique state-of-the-art simulation, monitoring and inspection tools to guarantee ‘right first time’ production. Being raised in Industry, we guarantee one-stop-shop industrial reliability.

Joachim Antonissen Value the future, upgrade the past GUARANTEED was created in 2019 as a spin-off company of OCAS, Finindus and ArcelorMittal Belgium . The new company creates value for its customers by ONE-STOP-SHOP TO GUARANTEE repairing, refurbishing and producing large metal parts, using wire arc additive QUALITY manufacturing to extend the lifetime or reduce the downtime of industrial GUARANTEED offers a one-stop-shop equipment . This initiative is establishing a worldwide unique ecosystem in which approach in order to maintain full control cutting-edge metal innovation is combined with entrepreneurship and supported over our quality and lead-times as well by an industrial footprint to guarantee ‘right first time’ part production and provide as to respond to our customers’ needs to one-stop-shop reliability . receive ready-to-install parts at the lowest possible TCO (Total Cost of Ownership). In an industrial environment, large BEYOND CONVENTIONAL This is why GUARANTEED’s operations are production equipment is often tailor-made TECHNIQUES currently embedded within ArcelorMittal and exposed to severe operational conditions GUARANTEED’s focus is on repairing or Belgium, which provides us direct access to that demand high structural integrity for a rebuilding large slow-moving components a state-of-the-art workshop, and even more long lifetime. This results in long lead times beyond conventional techniques, thereby importantly to highly skilled workers within when components break down or sometimes prolonging the life of ageing industrial an environment where safety, quality and even entire installations must be replaced equipment, reducing long lead times, and customers are the top priorities. as components have become obsolete, eliminating storage costs. As our customers A key element in achieving short moulds have been lost, or suppliers have rely on us to respect tight lead-times, we lead-times and ensuring high-quality gone bankrupt. This either leads to huge work with proven and robust industrial components is the ‘right first time’ zero- financial losses due to unforeseen lengthy components to ensure a high TRL-level and defect capability of our process. For this production standstills or to high storage the reliability of our production equipment. purpose, GUARANTEED uses the most and logistics costs. GUARANTEED offers a In-situ process monitoring capabilities advanced WAAM process software currently solution to these problems, as its technology allow for closed-loop process control to available, which is developed by one of our allows these large slow-movers to be repaired minimise the risk of defect formation, while strategic partners. This is complemented and rebuilt on demand, reducing the long on-line NDT implementation guarantees any with unique in-house-developed specific lead times and eliminating the storage costs. residual defects are detected and corrected welding, metallurgical and in-use property Moreover, as no dies, tools, moulds or set- on the fly in order to achieve zero-defect simulation capabilities, which ensure that up costs are required, manufacturing cost manufacturing capabilities – which is fully optimal production parameters are selected reduction can be an additional advantage. aligned with the GUARANTEED brand. from the very first produced part.

Working with OCAS 121 Finindus has been an ideal shareholder for us, investing with a long-term horizon and showing commitment in everything they do. Over the past 10 years, and by participating actively in our board, they have contributed with very valuable strategic as well as more industry-specific knowledge, and have shown a tremendous engagement in the development of the company.

Per Wassén, President and CEO of PowerCell Sweden AB (publ) STRONG MOMENTUM FININDUS GOES DIGITAL … Finindus is an investment company backed by ArcelorMittal and the Flemish region. Finindus invests in Finindusearly is stage an investment and growth company companies backed by ArcelorMittal at the forefront and the Flemish of innovation region. Finindus in materials, invests in early materials stage and growthprocessing, companies at the sustainableforefront of innovation manufacturing. in materials, materialSince 2016, processing, Finindus sustainable has manufacturing broadened and its industryinvestment 4.0, with scope a positive in byimpact adding on the planet. We differentiateindustry 4.0. ourselves Digital through technologies our industrial are DNA transforming and the hands-on in support a rapid to the pace entrepreneurs materials we research, partner with. manufacturing processes, maintenance, supply chains … The steel and metals industry are no exception to that.

materials material processing sustainable industry 4.0 manufacturing

OverThe the periodcore 2018-2019,business we of screened Finindus over is 400 investing, technology buildingcompanies. and As we exiting have intensified companies. our cooperation The experience, with ArcelorMittal’s hands -globalon CTOattitude and global and R&D industrialorganisations, mindset a substantial make part Finindusof these companies a valuable has been partner introduced for to both OCAS the and ArcelorMittal.entrepreneurs and co- Duringinvestors. the same period,Finindus we made has twoa unique new investments: and valuable SENTEA, access which is to developing industry robust, experts, low-cost research FBG interrogators infrastructure for condition and a monitoringstrong and international GUARANTEED, industrial a JV with OCAS network and ArcelorMittal, by working aiming together at repairing with and hybridOCAS, manufacturing its sister company of industrial and parts using directArcelorMittal. energy deposition In technologies. return OCAS Unfortunately, and ArcelorMittal we also had to get let go a twofront of our-row portfolio view companies. on innovation in emerging We arecompanies proud that mostand of the our marketsportfolio companies of tomorrow have gained and significant the possibility traction andto connectrecognition and from workcustomers with and these partners young and are enteringtechnology a new phase companies. in their development.

Working with OCAS 123 PORTFOLIO HIGHLIGHTS

borit Borit has successfully completed its investment program aiming at a more automated production of bipolar plate assemblies. This platform was of paramount importance to be able to reliably deliver components in high volumes to a premium automotive OEM. Borit also received external recognition in 2018, as “Factory of the Future”. In 2019, the company has reached a positive operating cash-flow and bottom-line profitability.

PowerCell Sweden AB (publ) In April 2019, Powercell entered into a joint-development and license agreement with Robert Bosch for its 100 kW automotive stack. The deal included a 50 MEUR upfront payment and additional royalties. Later in 2019, Robert Bosch also decided to acquire a substantial stake in Powercell. Powercell has furthermore been quite successful in attracting Chinese customers for its S2 fuel stack platform (up to 35 kW). On Finindus side, we have successfully divested part of our shareholdings.

Keystone Tower Systems 2019 was a banner year for Keystone Tower Systems. The company succeeded in landing its first commercial contract to supply wind turbine tower segments to a major wind turbine OEM in the US, and brought a strategic partner on board to build and operate the first full-scale industrial plant implementing Keystone’s patented spiral welding technology. The plant is expected to be fully operational in the second half of 2020. In addition, KTS was awarded a 5 MUSD grant from the Department of Energy (DOE) to demonstrate its ‘in-field’ manufacturing technology to build a first tall tower (> 160 m hub height) on the US East Coast, enabling a whole new wind energy market in the US.

Expanite After years of double digit growth in its service centers in Europe and the US, 2019 was the year of further global expansion. Expanite commissioned two additional furnaces in the Far East as part of two license deals, one for a customer in China and one for a customer in South-Korea. The full range of Expanite technologies is now available to customers in China, a milestone in the company’s history.

Rein4ced 2019 was a pivotal year for Rein4ced. What started out a couple of years ago as an engineering consultancy in composites, has now transformed into a developer and manufacturer of bike frames using a proprietary hybrid composite material and a new manufacturing approach. Rein4ced succeeded in securing its first customer contracts and in commissioning its manufacturing plant. INVESTMENT PORTFOLIO

BORIT (BE, 2010) POWERCELL SWEDEN AB (publ) (SE, 2009) One-stop-shop for metal bipolar plates for Leading European producer of fuel cell stacks fuel cells and electrolysers with a proprietary and fuel cell systems for stationary and mobile forming technology. applications. Listed on Nasdaq First North since 2014. www.borit.be www.powercell.se

CALYOS (BE, 2012) REIN4CED (BE, 2017) Two-phase passive heat transfer systems Development and manufacturing of bike for cooling power electronics and electronic frames made using a hybrid composite material components. Calyos targets applications in containing thin steel fibers thereby increasing automotive and high-performance computing. safety and durability, while maintaining lightweight. www.calyos-tm.com www.rein4ced.com

EXPANITE (DK, 2014) SENTEA (BE, 2018) Surface hardening technologies for stainless Low-cost, robust and reliable interrogators for steel and titanium based on proprietary gas fibre optic sensors. phase processes. sentea

www.expanite.com www.sentea.com

KEYSTONE TOWER SYSTEMS (US, 2017) GUARANTEED (BE, 2019) Design and fully automated (in-field) Repair and hybrid manufacturing of large manufacturing of (tall) tapered wind turbine industrial parts using direct energy deposition towers. technologies. www.keystonetowersystems.com www.guaranteed.be

Working with OCAS 125 Sharing experiences among multi-disciplinary teams is key to accelerating the success of innovations.

Joost De Strycker Ionic liquid technology – green ­alternative to hexavalent chromium

In the past, hard chrome plating was typically performed with hexavalent chromium electrolytes . However, REACH environmental legislation banned the use of hexavalent chromium processes, unless special authorisation was acquired . Driven by this need for REACH-compliant alternatives, OCAS further matured a project on hexavalent chromium-free hard chrome plating from ionic liquids .

Thanks to OCAS’s research & development is one of the key factors for success at this in addition to a technical answer. efforts, a lab concept invented at university stage – so, partners in different areas of the A basic cost model was built and is now was scaled up from litres to tonnes. Basic value chain were approached to make an being challenged by different partners requirements such as hardness, corrosion in-depth evaluation of the technology. Some at multiple positions in the value chain. protection, friction, etc. were checked and technical bottlenecks surfaced from these Fine-tuning will require in-depth process optimised. evaluations. Several lab programmes were studies on bath and electrode life-time, launched and are running to resolve these replenishment strategies, etc. Taking these A ROBUST GREEN ALTERNATIVE issues to result in a robust green alternative last steps will bring the technology close to In this way, the technology has now matured to hexavalent chromium. industrial validation readiness. to enter the prototyping stage and field During exchanges with partners, it was also testing in several applications. Partnering proposed to provide an economical solution

Working with OCAS 127 Such a programme is usually too large for one operator only. So, collaboration through a central platform, such as the OWA initiative in the UK, was crucial to a successful outcome. We are now on track to reducing the jacket production cost by more than 10%.

Marc Vanderschueren Teaming up to combat climate change

LEADING FATCOR, A BELGIAN FEDERAL ENERGY TRANSITION FUND PROJECT The Belgian Energy Transition Fund supports research projects and research infrastructure contributing to various aspects of energy supply to Belgium, including renewable energy from the North Sea .

OCAS has won a tender for projects from the or because it accelerates the growth of 1/3 of their originally estimated fatigue Belgian Energy Transition Fund and is now cracks. Therefore, offshore structures are life – or should they be classified as almost leading a consortium composed of Ghent generally protected against corrosion either protected? University, the Belgian Welding Institute, by paint or cathodic protection. The project will provide the wind park two wind farm owners (Parkwind and The problem that the FATCOR project will owners with a more quantitative method for Rentel), and one steel fabrication company investigate is the degradation of materials estimating the degradation caused by the (Smulders). The total budget for the project that were initially protected against combination of fatigue and corrosion and is close to €1.2 million and will span four corrosion, but for some operational reason will potentially extend the life of the wind years. the corrosion protection did not completely energy convertors installed in the Belgian The objective of the project – called FATCOR perform its task. Examples are impressed part of the North Sea. – is to investigate the combination of current cathodic protection where the fatigue and corrosion. It is well known that electrical system is interrupted, or paints corrosion leads to faster fatigue degradation that have been damaged by impact. So, of components, either because it supports should such materials be considered to be the creation of pits that will provoke cracks, un-protected – and, as a result, have only

Working with OCAS 129 CARBON TRUST OFFSHORE WIND ACCELERATOR TEAMS UP WITH OCAS FOR FLAGSHIP PROJECT The Carbon Trust Offshore Wind Accelerator (OWA) has initiated a project towards reducing the cost of new jacket structures for offshore wind foundations . With the ever-growing importance of offshore wind for producing electricity, the turbines are being installed in deeper waters and sometimes difficult soil conditions . Jacket structures are becoming increasingly more competitive . DNV-GL, Bureau Veritas and technical authority BAM are also an integral part of the project, with the aim of checking whether we can obtain upgraded S-N curves for implementation in real projects. The design of these structures is governed to traditional hydraulic testing. Now, it The offshore wind supply chain is very by fatigue loads and must follow strict rules is possible to collect enough fatigue data active in the project and is contributing established by certification authorities who for comparison to the current standards substantially too. In this respect, it is have based their codes on testing data from in a reasonable project time. As such a important to mention that we are focusing the 1970s and 80s. However, taking new programme is usually too large for one on robot-welded node technology, which steel-making processes and evolutions in operator only, it has been crucial to be able can fabricate critical components more welding technology into consideration, it’s to collaborate through a central platform consistently and at a lower cost. Therefore, time for a thorough update. such as the OWA initiative in the UK. we are benchmarking automatic-welded OCAS has proposed a programme to push components with manual-welded ones. the limits of the offshore design codes to JACO JOINT INDUSTRY PROJECT The project is running very well to the upgrade the fatigue performance of welded IS EXPANDING! participants’ great satisfaction. We are jacket nodes. The objective is to reduce the The overall framework has convinced currently coming to the end of a work thickness of critical joints so that they need leading developers ORSTED, VATTENFALL, package that benchmarked classical less welding and are lighter and cheaper. EQUINOR, SIEMENS GAMESA, SCOTTISH hydraulic testing against OCAS’s accelerated Executing such a programme means that POWER (Iberdrola) and ENBW to join forces method with very promising results. This a lot of data points are needed, which with us. The great news is that SSE and means that we plan to move ahead solely requires time-consuming testing. Through SHELL have recently joined as well. Today, with the OCAS testing method, which is best its patented resonant bending methodology, the JaCo (Jacket Connections) Joint Industry placed to obtain fatigue data of the end-of- OCAS has made it possible to reduce this Project now consists of 8 top-notch offshore life of a critical component. Thus, we are on testing time by a factor of 20 compared wind developers. The certification bodies track to reducing the jacket production cost. OPTIMISING AND VALIDATING MODULAR JACKET DESIGN OCAS participated in the European JaBaCo project, which developed a modular concept for jacket foundations for offshore wind turbines, using prefabricated standardised components . Thanks to these components, the investment costs of offshore wind energy can be reduced by implementing prefabrication of sub-structures that are based on prefabricated components and are scalable in a significant range of environmental conditions . The consortium was led by RINA, with the collaboration of Ramboll, National Technical University of Athens (NTUA), IDESA, University of Thessaly (UTH), and OCAS .

The concept was based on an integrated performed at high frequency. This included design for water depths of 30-80 metres detection of crack initiation, non-destructive and turbine sizes of 5-10 MW in the North testing to monitor crack growth, and post- OCAS successfully and the Mediterranean Seas. In the last mortem analysis of the fracture surfaces. performed large-scale case, seismic loading was considered. The Four X-joints with a brace diameter of project included the design of six structures 711 mm were tested until failure. The accelerated tests from (depending on water depth and metocean failure location differs between specimens, the very beginning of the data) for fatigue testing and numerical indicating that the manufacturing has an JaBaCo project. simulations of structural components, influence on the construction’s weak points. conducted with a sensitivity analysis. The fatigue resistance of these tubular joints In this project, OCAS was responsible for was compared to the fatigue design curve. Philippe Thibaux fatigue testing of large-scale components

Working with OCAS 131 The fruitful cooperation of the four partners has resulted in a joint scientific publication. Going forward, research data can now be used to optimise the design of metal-to-metal seals.

Marc Vanderschueren & Dennis Van Hoecke Optimising the design of metal-to-metal seals

Metal-to-metal seals are used in threaded pin/box connections of casing and have been conducted for a variety of thread tubing in oil and gas wells . compounds and applied pin/box surface coatings. These results were then used to SHELL Projects and Technology decided specimens at gas or liquid pressures up to validate a stochastic numerical sealing to set up a multi-year programme in order 1500 bar. The set-up and experimental design model for seal-ability. Once validated, the to better describe the mechanisms of are aimed at simulating conditions during a model was used with the experimental ­metal-to-metal sealing, focusing on the full-scale ISO 13679:2011 (2011) CAL IV test results to better understand the sealing surface conditions in particular. This has not programme. Whereas the CAL test is aimed at mechanisms of metal-to-metal seals. At the only required specialised levels of expertise, qualifying leak tightness, the SSMUR is used same time, OCAS developed a numerical but SHELL has also needed their various to deliberately find the onset and the location model to demonstrate the effects of out-of- partners to be able to work in an open and of leakage. The testing can include multiple roundness deviations of the pipe geometry collaborative way. SHELL decided to work make-up and breakout cycles to modify the on the connection sealing performance. with OCAS. Moreover, to add fundamental metal-to-metal seal through wear and plastic The test and model results indicate that academic knowledge about modelling of deformation. In addition, micro-sliding the onset of leakage depends strongly on wear evolution and sealing behaviour, they can be imposed to simulate the additional the type of thread compound that is used. established a consortium between­ SHELL, wear caused by the movement of (cyclic) The thread compound affects the amount OCAS and the partner universities of Lulea mechanical loads. of wear and thus changes the surface and Twente. The methodology­ they have topography of the interacting surfaces. implemented takes advantage of a numerical DEPENDING ON THE TYPE OF Furthermore, the model shows that certain sealing model and a co-developed experi- THREAD COMPOUND surface topographical features improve mental setup called SSMUR (SHELL Sealing The effect on the seal-ability can the sealing performance. This has proven & Mock-Up Rig) for which OCAS designed subsequently be quantified by a leakage to be novel, so that the validated models and realised the hard and software. test using gas or fluid pressure. This is can subsequently be used to predict the In this set-up, assembly, micro-sliding, and performed both to validate the models seal-ability of casing-connection metal-to- seal-ability can be investigated with scaled and to differentiate the performance of metal seals in combination with their thread (100 mm diameter) metal-to-metal seal different samples. Several experiments compound.

Working with OCAS 133

Collaborative materials’ research to ­accelerate the R&D of our customers

Belgian Nuclear Research Centre SCK .CEN and DEME Offshore, explain the benefits of working with OCAS .

HIGH-TEMPERATURE-RESISTANT OCAS’s metallurgical expertise and exploratory domains. A good knowledge MATERIAL WITH IMPROVED INITIAL SCK.CEN’s long-standing nuclear material of the application requirements is key to BRITTLENESS AND DAMAGE science knowledge have been put in developing a suitable material. Although, RESISTANCE synergy to launch a joint project to explore at OCAS, we only have minimal knowledge In the fusion reactor under construction composites and high-entropy alloys of what happens in a nuclear reactor, our in France (ITER), tungsten (W) is the main based on refractory metals (tungsten and long-standing partnership with SCK.CEN candidate to create an armour for plasma- chromium). Such binary alloys are potential ensures the needed exchange of information facing components in spite of its principal options for alleviating the initial brittleness with its specialists to co-develop good lab drawback: brittleness! as well as improving resistance to the harsh materials for advanced, international R&D Commercially produced W already has irradiation damage caused by the post- programmes. a rather high ductile to brittle transition products of the fusion reaction. (about 300°C) and prolonged operation in a This collaboration in the field of synthesis fusion environment will raise it up further, of high melting point elements/alloys was causing a risk to the component’s structural highly appreciated by the customer, as it integrity. opened up a broad range of fascinating

Working with OCAS 135 Our vessels are part of our critical assets, so they need to operate under harsh conditions. In order to counter specific degradation on a critical component in one of our vessels, we needed specialist steel know-how. OCAS provided us with an innovative testing solution to screen the available options in a fast and very flexible way. This has enabled us to choose the best possible material combination and meet the challenging timeline to upgrade the part. Thus we could significantly reduce degradation and obtain operational savings, improving the vessel’s performance over time.

Luca Zanette, Project Engineer at DEME Offshore

Factual, flexible, fast and fit for purpose. This is how we operate with our customers in an industrial environment to bring them value for money.

Marc Vanderschueren & Steven Keyzer LIFE EXTENSION OF A CRITICAL works had to be done during the limited In this investigation, OCAS and DEME COMPONENT ON AN OFFSHORE time the vessel was in drydock. This also Offshore were looking for the optimum JACK-UP RIG meant that analysis and solutions needed combination of material to minimise Jack-up rigs are intensively used in the to be made very quickly and efficiently from wear of a critical component of the ship. wind energy market to install turbines data collected offshore, so that the solutions An automatically controlled test system offshore. DEME Offshore bought an existing could be implemented straightaway when allowed us to investigate the wear under model that had previously been used in the vessel was under maintenance in a port. high pressure for a contact length of the oil & gas segment. For offshore wind Therefore, DEME Offshore came to OCAS hundreds of meters. The results revealed operations, jack-up platforms need to move to benefit from our very interactive and that some material combinations were up and down many times more than in the flexible way of working, combined with significantly more efficient than others. In traditional markets for which the vessels the available expertise and equipment, the meantime, the proposed solution has were originally designed. to reproduce the life the vessel’s critical been implemented full-scale onto the vessel This has an impact on the lifetime of some components had seen. OCAS has been able to the great satisfaction of all! of the rig’s key components. The problem to satisfy both challenging criteria in a was that exchanging such large components record timeframe. during operations at sea is not possible; the

Working with OCAS 137 At OCAS, we strive to bring tailored solutions to our customers.

John Vande Voorde & Katia Linck Bringing tailored solutions to our ­customers

OCAS is collaborating closely with customers to solve their design and engineering challenges . The objective is to position ArcelorMittal as a highly competent supplier and to support the implementation and marketing of new products such as Amstrong®Ultra 900MCL and Relia®450 high-strength hot rolled grades or Magnelis® coated steel grades .

CO-ENGINEERING WITH needs. They also discuss the technical required. In a final stage, the team can assist CUSTOMERS specifications and the requirements and in prototyping and, ultimately, in testing the In 2018-2019, the OCAS team conducted constraints of the application. Using this final design. co-engineering projects with customers in a input, they then make a first analysis and In a recent project, a heating ventilation wide variety of market segments, including offer some suggestions for improvement, and air conditioning manufacturer had transportation, agricultural machinery, which can include a switch to other steel been making its products out of commodity household appliances and heating grades or even design changes. At this stage, steels. However, for a new product line, ventilation and air conditioning. The key Finite Element Analysis is very often used to the company wanted to optimise the steel drivers are most often cost and weight study the behaviour of the application. grades used while improving the product’s reduction, energy savings, and improved The customer considers the performance. The team proposed a design performance. recommendations, along with the cost based on Magnelis® coated higher strength In the first stage, the team works with impact. Then, the team supports the steel, which the customer is currently the customer to identify the customer’s customer with experimental testing, as implementing.

Working with OCAS 139

GENERIC SOLUTIONS Each of these examples is based on a guidelines for implementing modern steel Customer service and collaboration are of generic, relevant and representative design. grades are included in the show cases. central importance to OCAS. To help grow Using the latest Finite Element techniques, In 2018-2019, OCAS updated such show budding contacts and relationships with the design and the selection of steel cases for applications in the trailer and customers, OCAS has put considerable grades are optimised with the objective of tipper market and launched a new study for effort into illustrating the benefits that can substantially lowering the cost, reducing the container market. The results are made be attained when the latest steel grades the weight, extending the functionality, available in presentations distributed to our and design revisions are joined. OCAS has and combinations of these aims. The customers and in dedicated workshops and developed several example cases in a range relevant production methods – welding, during customer visits. of markets with the explicit goal of opening bending, etc. – as well as the fatigue and up new vistas for our customers and wear behaviour are studied, and general sparking collaboration.

Working with OCAS 141 OCAS’s broad expertise and state-of-the-art equipment can facilitate companies in their R&D endeavours.

Sofie Vanrostenberghe & Pieter Vanduynslager Facilitating companies in their R&D ­endeavours

OCAS assists its customers successfully in a variety of sectors with a wide spectrum of technical issues .

With our multi-disciplinary teams, we Furthermore, OCAS has a dedicated team AN EXAMPLE FROM WELDING support customers from product design that handles assignments for which we Support was delivered first of all to optimise all the way through the optimisation already have the equipment and expertise. the bias weld to improve fatigue resistance phase. This can be achieved by combining This approach ensures efficiency and of the final product, while at the same experimental work and finite element short response times, which are highly time bearing in mind production efficiency modelling tools available within the lab. appreciated when providing technical improvements. After having supported Technical support can be provided on support to production plants as well as laser welding experiments in Northern diverse topics covering metallurgical, other customers. America, OCAS arranged and supervised surface or application related expertise, in experiments at two laser manufacturers’ fields including: facilities in Europe. Furthermore, OCAS — forming assisted the customer on the lay-out of a — welding new heat treatment line and proposed a — durability: fatigue, wear, corrosion physical model capable of predicting the mechanical properties after heat treatment. The customer appreciated the research assistance highly.

Working with OCAS 143 Our front & back office model ensures a good combination of availability and expertise. The plant has direct access to all of the competencies and advanced equipment available in the R&D centre at an affordable cost.

Nico De Wispelaere, Veerle Van Lierde & Annick Willems Front & back office model quickly meets technical support requests from ­neighbouring plants

For more than 15 years, OCAS has been providing technical support to ArcelorMittal Belgium . Through these support activities, neighbouring plants have access to all of the lab’s competencies . At the same time, researchers are given the opportunity to valorise their knowledge in real-life situations .

As technical issues occurring in a SUPPORT FOR A WIDE VARIETY OF Another example involves a working group production environment always demand TASKS investigating a technical problem for which urgent assistance, the effectiveness of These support activities cover a wide OCAS provides support – for example, by the technical support delivered by OCAS range of tasks. A first example concerns assisting in material selection, optimisation is of utmost importance. That’s why a production and quality follow-up. If the of welding parameters, etc. – to ensure ‘front & back office model’ is successfully neighbouring plant does not have the long-lasting and robust performance in a employed: the front office is staffed with necessary equipment at hand, OCAS carries production environment. dedicated generalists, who have access to out a validated procedure guaranteeing Of course, OCAS is also called upon for ad the assistance of various experts from all of a quick response time for a continuous hoc requests: troubleshooting and random the teams of the R&D centre, which make up sample flow. Test results can automatically sudden short-term requests for which urgent the back office. Thus, a good combination be uploaded into the plant’s mainframe assistance is needed to resolve the issue. of availability and expertise is ensured, database. In 2019, OCAS tested approx. This is often the case when components of and the customer has direct access to all 2500 coils for hole expansion, performing production installations show early damage competencies and advanced equipment five measurements per coil, to evaluate or even break down. The affected part is available in the R&D centre at an affordable the formability of specific steel grades in then sent to OCAS for investigation and cost. combination with a cut edge. advice. In a lot of cases, the root cause of the

Working with OCAS 145 failure leading to rapid material degradation TRAINING ON FAILURE Participants gave positive feedback and is a combination of mechanisms (fatigue & MECHANISMS requested that this initiative be continued, stress concentrations, corrosion, wear, …). Following similar requests from several as it became apparent that similar material In addition to analysing the failure, OCAS departments within ArcelorMittal Belgium, a problems were being encountered in can also be included in discussions with the training programme on failure mechanisms different departments. Thus a self- supplier’s material specialists and help the was developed in close collaboration learning network, which would ensure a production plant claim compensation. with OCAS experts. The training primarily continuous sharing and learning of each targeted support functions in maintenance other’s experiences, was launched with and engineering and focused on failure Arcelormittal Belgium. mechanisms of metal components in the field of corrosion, fatigue and wear.

Working with OCAS 147 OCAS assists customers in their production process to achieve the desired bend angle after load removal, even for heavy-gauge and high-strength steel grades.

Steven Cooreman Bending the rules

Bending is the main deformation mode for heavy-gauge, advanced high-strength steel grades . Although bending a steel sheet may seem to be straightforward, one should respect some basic rules . Therefore, OCAS provides theoretical and practical guidelines to help customers choose the appropriate tools and machine settings to obtain a high-quality product .

BENDABILITY, REQUIRED BENDING to thickness and material strength, other GUIDELINES FOR CUSTOMERS FORCE AND SPRINGBACK parameters such as die width, friction To gain detailed understanding of the When bending a steel sheet, one must between the tools and the steel sheet, bending behaviour of high-strength consider three things: the material’s and punch radius also strongly affect the steel grades, OCAS conducts extensive bendability, the required bending force, and required bending force. experimental campaigns in the lab, the springback phenomenon. Springback refers to the phenomenon of supported by FEA (Finite Element Analysis) To avoid the appearance of cracks in the elastic recovery after load removal. When studies. FEA makes it possible to study bent material, one should respect the bending a steel sheet, both elastic and the effects of different parameters on the minimum guaranteed bending ratio, which plastic deformation occur. Furthermore, bending behaviour. is a measure of the material’s bendability. the induced strain varies over the sheet’s Furthermore, FE simulations provide more The minimum guaranteed bending ratio thickness. After removing the load, part of insight into the deformation process and is defined as the smallest possible ratio the elastic strain is recovered. Consequently, help explain experimental observations. The of punch radius to sheet thickness for both the bend angle and the bend radius data gathered from these experimental and which no cracks can be observed by visual change. This phenomenon can be easily numerical studies typically result in general inspection. This ratio is determined through counterbalanced by over-bending the sheet guidelines, recommendations and even lab-scale bending tests during which the so that the desired bend angle is achieved analytical formulas which we share with our material is bent to either 90° or 180°. after load removal. However, the level of customers. It can be imagined that powerful presses springback depends on many parameters, are needed to bend heavy-gauge, high- including sheet thickness, the material’s strength steel sheets. However, in addition strength, punch radius and die width.

Working with OCAS 149 OCAS has been helping ArcelorMittal satisfy the needs of its customers in the areas of cost reduction and environmental sustainability. And we’re already working on the newer generation of these grades!

Tom Waterschoot Expanding the product range in a cost-effective manner

ArcelorMittal strives to continuously innovate and improve their products for its many customers . Reducing cost, while expanding the usability of the grades for more extreme environments and ever-demanding applications in industry, requires applied research . Thanks to our expertise and to our broad range of research equipment available, OCAS is a natural R&D partner to ArcelorMittal . OCAS can reproduce the entire process of industrial steel production, at a cost- effective lab scale, significantly reducing the overall cost of commercialising the product .

OCAS has been helping ArcelorMittal addition, current developments at OCAS plate alternative. Developments that are satisfy the needs of its customers in the have made it possible to guarantee strength favourable for both the environment and areas of cost reduction and environmental and toughness in both directions in steel lower costs. sustainability. Structural and wear- sheet, providing more freedom when cutting In the yellow and green goods sector, resistant steels are good examples of new blanks from the sheets and thus improving aesthetic aspects are becoming increasingly concepts developed by OCAS that have material yield. Further reducing the cost for important. Therefore, OCAS’s metallurgists been industrialised and commercialised by the end-customer. are developing new concepts to minimise ArcelorMittal in the last few years. OCAS is also expanding the applicability surface defects on hot-rolled sheets. of hot-rolled products by developing The development of the above-mentioned STEELS FOR CHEAPER, GREENER abrasion-resistant steel with prolonged grades has been possible thanks to OCAS’s PRODUCTS lifetime for the thin-gauge product segment level of expertise and to the refinement of Trucks and trailers can be made cheaper and high-strength materials in thicker our instruments and equipment. by using stronger steels in lighter gauges. Providing these thicknesses as hot- In the meantime, OCAS has already started constructions, resulting in lower fuel strip products delivers a pronounced cost tackling the newer generation of these consumption for a given payload. In advantage over the quench and tempered products!

Working with OCAS 151 With this multitude of initiatives, OCAS aims to ensure the satisfaction of its customers and research partners.

Lode Duprez Research 4.0 – Efficient and smart, with an eye for detail

The holy grail for industrial research is to have technological solutions at the push of a button . The reality is that research is still a costly and time-consuming activity . Consequently, for a research lab such as OCAS, striving to be a research facilitator for its customers, continual improvement is key to maximising our output quality and offering a highly differentiating and competitive service catalogue of research capabilities to our customers .

In this context, over the last few years, OCAS screenings using advanced computational CROSS-FERTILISING FOR has invested immensely in three research tools. Digitisation also allows us to extract AGILITY, VERSATILITY AND domains to keep our research performance much more information from complex TRANSVERSALITY at the highest level: data sets (such as images via artificial Next to equipment and competencies, — Digitisation intelligence and machine learning the appropriate laboratory organisation — Combinatorial techniques). The third axis addresses the also needs to be implemented to achieve — Nano investigation opposite side of the research spectrum: maximum agility, versatility and looking at nano areas of well-selected transversality. For that reason, ‘cells’ have COMPETENCE AND STATE-OF-THE- samples to investigate those materials been created that team up researchers from ART EQUIPMENT down to the atomic level in order to different departments to cross-fertilise The focus of the combinatorial domain acquire fundamental understanding of the among these domains: is to have more efficient data generation, mechanisms behind material behaviour. — The digital cell data capture and data visualisation. OCAS has the competence and access to — The combinatorial cell Digitisation has multiple targets on the state-of-the-art equipment in this field. — The nano-investigation cell data-mining side, which enables smarter Furthermore, our researchers have regular With this multitude of initiatives, OCAS aims experimentation by performing digital exchanges with the scientific and academic to ensure the satisfaction of its customers community worldwide. and research partners.

Working with OCAS 153 FACT SHEET evolution of turnover of OCAS (M€)

25,80 25,85 25,50 25,24 23,71 24,87 22,72 21,59 19,35 19,62 18,97 17,66 16,89 14,75 15,13 13,63

FORE CAST 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

evolution of staff (FTE)

149 149 143 139 137 142 143 146 129 125 130 127 133 115 116 93

FORE CAST 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

number of trainees

49 42 41 41 39 32 34 33 35 34 29 27 30 28 28 22 FORE CAST 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

155 Knowledge building

In order to support OCAS’s major activities in product & solution development, the necessary methodology and fundamental insights must be obtained in parallel to those developments . This is exactly the goal of the research carried out in the framework of ‘knowledge building’, and therefore knowledge building activities are of key importance to reach the objectives set .

Knowledge building projects are often map and quantify the Sn enrichments, supported by PhD theses, or include which in combination with modelling collaboration with third parties adding allowed to propose and verify different valuable expertise. Sharing knowledge on hypotheses. generic topics proves to have an important — A clear step forward has been achieved leverage effect. Furthermore, through the in the understanding of material knowledge building projects ideas arise for degradation mechanisms in H2S renewal of portfolios. environments. This progress was realised In 2018-2019, significant progress has been via the implementation of various achieved in multiple research domains of advanced new methodologies. From a the knowledge building programmes. mechanical point of view, it concerned Examples of realisations include: instrumented double cantilever beam — Via extensive nano-scale (DCB) testing in combination with a characterisation experiments, an in- hydrogen diffusion model. From a surface depth insight was obtained in the Sn point of view: a “hydrogen permeation segregation behaviour in Fe-Si steels. test under stress” was designed for

Multi-technique characterisation over H2S environment. Combining all these various process steps and with variation techniques with classical hydrogen of key process parameters allowed to thermal desorption tests allowed to Knowledge building

In order to support OCAS’s major activities in product & solution development, the necessary methodology and fundamental insights must be obtained in parallel to those developments . This is exactly the goal of the research carried out in the framework of ‘knowledge building’, and therefore knowledge building activities are of key importance to reach the objectives set .

get new insights in the H2S response of analysis and using the fit of probability collaborative EU funded DURAMECH various sour grades. distribution plots. The ICBTI method is project was to investigate the possibilities — Mechanical properties of zinc coatings a new way to analyse nanoindentation to convert a welded assembly to a are well-known and have been studied grid dataset. An automatic correlation bolted one, whilst increasing the in detail during the last decades. procedure between mechanical property fatigue strength. Practical design rules However, the fundamental behaviour and microstructure maps is applied and were developed for dimensioning of of coatings of zinc- or aluminium-based leads to the exclusion of measurement bolted joints in applications involving alloys is much less understood. Above, artefacts, ensuring a more reliable fatigue of high strength steel grades. understanding the contribution of quantification of the mechanical Furthermore, guidelines were developed the different phases in their complex properties of each phase. on how to transform either a welded or a structure requires new approaches. — High strength steels offer a unique bolted low strength steel assembly into a Mechanical property maps were built opportunity to reduce weight in heavy- high strength steel bolted assembly that using a grid nano-indentation technique duty machinery such as trucks, trailers has at least the same static strength but and were quantitatively correlated to and agricultural machinery. These types an increased fatigue strength. the microstructure map. Then, phase of applications require significant fatigue volume fractions and mechanical resistance. It is well-known that fatigue — Nikolas Mavrikakis, Franck Nozahic, properties of each individual phase failure typically originates at stress Lode Duprez, Joost De Strycker & Sofie were extracted using image correlation concentrations caused by the joining Vanrostenberghe based targeted indentation (ICBTI) procedures. The main objective of the

157 OCAS PROVIDES WORKSHOPS TO SUPPORT STEM ACTIVITIES 159 Seminars “Use of EPMA in materials research” seminar Pursuing our tradition and expertise in organising January 29th, 2018 scientific and technical conferences, OCAS organised a series of seminars in 2018-2019 . We were able to This seminar brought together users and suppliers to exchange attract highly motivated and enthusiastic “out-of-the-box” experiences with this technique in different application domains. international speakers, willing to share novelties and An overview of the evolution of the EPMA technique and available knowledge insights . detectors, including the latest soft X-ray emission spectrometer allowing for even better detection limits, was given. Various users presented case studies illustrating the assets of EPMA analysis.

Programme — “Electron Probe Microanalysis: something old, something new”, Stefan Kuypers, Jeol Europe — “Some decades of EPMA analysis in metallurgy”, Blandine Remy, ArcelorMittal Global R&D Maizières — “Soft X-ray emission spectrometer for EPMA: a new micro- analytical tool for steel research”, Mélanie Gauvin, OCAS — “Six years of FEG EPMA at KU Leuven and its application in the field of metals, metallurgical residues and refractories”, Annelies Malfliet, KULeuven 3rd Structural Integrity “Abrasion resistant steels: seminar (OCAS and its MSC modelling and experimental partners) challenges” wear seminar May 24th, 2018 June 15th, 2018

This seminar was organised in collaboration with OCAS’s Metal The abrasion resistance of a material is not solely determined Structures Centre partners. Structural integrity evaluations by the ratio of its hardness as compared to the hardness of the serve to judge the acceptability of detected or assumed defects. abrasive medium. It is also affected by the surface state and the This method relies on the actual performance of the material as level of residual stresses at the surface. At the same time, systematic used in the structure and has proven on numerous occasions to screening has indicated that the material’s microstructure as well as give the best performance at minimum cost. its mechanical response to impact have a pronounced effect on the abrasion resistance. This effect is not captured in the conventional Programme design criteria, where only the material hardness is taken into — “Structural integrity challenges for power plants in the current account. energy transition race”, by Frits Petit, Engie Laborelec — “FFS assessment reactor case: out of roundness reactor”, by Programme Willem Deraedt, Sintra engineers — Keynote presentation “Atomistic simulation in tribology: — “Design, build and in-service follow-up of a dynamically potentials, perspectives and limitations”, by Michael Moseler, loaded steel structure”, by Peter Neven, TCS Fraunhofer IWM, Microtribology Center µTC (Germany) — “Structural integrity beyond the standard”, by Stijn Hertelé, — “Materials, service life and wear mechanisms in agricultural tools”, UGent & Philippe Thibaux, OCAS by Jacob Sukumaran, UGent (Belgium) — “Assessment of corrosion damage affecting the girth or long — “Modelling of macroscopic loads on agricultural tools with seam weld in vintage pipelines”, by Troy Swankie, DNV-GL the Discrete Element Method”, by Florian Schramm, TU- — “Challenges and opportunities for offshore single sided welded Braunschweig (Germany) tubular joints”, by Jo Willems, Smulders — “Micromechanical modelling in design of wear resistant — “Structural integrity in risk based design of inland waterway microstructures”, by Anssi Laukkanen, VTT (Finland) tankers”, by Joep Broekhuijsen, Damen Schelde Naval — “Macro-damage mechanical modelling of abrasion in agricultural Shipbuilding tools”, by Peerapon Wechsuwanmanee, RWTH Aachen (Germany)

161 “Artificial intelligence for image processing in metallurgy” seminar February 1st, 2019

At present, digital images of the microstructure of metals must be analysed by expert scientists who are trained for this task. This leads to a bottleneck on the number of images that can be analysed, and a certain subjectivity in the resulting classification of the image. By organising this seminar, OCAS aimed to shed a light on the latest techniques to process and classify images by machines, using methods derived from artificial intelligence, machine learning, big data and computer vision. The development of such algorithms promises to significantly increase the understanding of materials and accelerate research in metallurgy.

Programme — “Person identification (classification) from radar images”, by Dr. Ivo Couckuyt, IDLab research group, Department of Information Technology, UGent (Belgium) — “AI for image and video processing: applications and model architectures”, by Jean-Yves Parfait, Multitel (Belgium) — Presentation on the correlation between microstructure and mechanical properties, by Prof. Geurt Jongbloed, Delft Institute of Applied Mathematics, TU Delft (The Netherlands) — “Advanced Steel Microstructural Classification by Classic and Deep Learning Methods”, by Dr. Seyed Majid Azimi, German Aerospace Center (Germany) — “Metallography 4.0 – How Machine Learning can help to make Microstructural Classification more reliable”, by Dr Dominik Britz, Material Engineering Center Saarland (MECS) (Germany) Integrated computational materials engineering (ICME) seminar July 9th, 2019

The properties of steel must be continuously improved to perform well in the challenging competition with other materials on the one hand, and to fulfil sustainability requirements on the other hand. The conventional measures for mechanical property optimisation have been widely exploited for many years, so that tailoring the microstructure morphology is the most promising approach for future steel development. This seminar was organised in the framework of RFCS project “Toolkit for the design of damage tolerant microstructures”. The overall objective of the RFCS project TOOLKIT was to develop a simulation toolbox for the computer-assisted design of damage tolerant microstructures. Involved partners: RWTH Aachen, Universiteit Gent, University of Thessaly, Corinth Pipeworks, thyssenkrupp and OCAS.

Programme — “Keynote lecture: DAMASK – The Düsseldorf Advanced MAterial Simulation Kit for studying multi-physics crystal plasticity phenomena”, Franz Roters, Max-Planck- Institut für Eisenforschung — “Toolkit for the design of damage tolerant microstructures”, Sebastian Münstermann, RWTH Aachen University — “Identification of relevant mechanical properties and numerical simulations”, Sarath Chandran, Gent University & Nikolaos Aravas, University of Thessaly — “Tailored microstructure configurations for required mechanical properties”, Wenqi Liu, RWTH Aachen University — “Process design to achieve improved microstructures”, Margianna Tzini, University of Thessaly — “Complementarity of computational design versus experimental screening in metallurgical developments”, Lode Duprez, OCAS

163 Metal plasticity seminar: Towards a virtual test environment October 1st, 2019

This seminar was organised in collaboration with KU Leuven. Material forming and shaping through plastic deformation is still one of the most efficient and economical manufacturing processes and is therefore extensively used in large industries such as automotive, appliance, energy, etc. Since many years, FEA (Finite Element Analysis) is used to optimise metal forming processes, as it reduces the cost of the trial-and-error phase and the time- to- market. The reliability of such FE simulations to a large extent depends on the capability of the constitutive model to reproduce the mechanical material behaviour, which can be quite challenging in the case of metals. The aim of this seminar is to promote a platform for people working in the field of metal plasticity, to discuss the state-of-the-art, the current research and future developments. The intent is to strengthen the cross-fertilisation between theoretical material modelling, computational and experimental plasticity and the development of industrial applications.

Programme — “Steel industry – latest developments and future trends”, Dr. L. Bracke, ArcelorMittal Global R&D — “Some features of the strain rate dependence of metal plasticity”, Prof. P. Verleysen, Universiteit Gent — “Advanced phenomenological models”, Prof. A. H. van den Boogaard, University of Twente — “New advances for evolving meshes/discretization methods in 3D large deformation problems. Application to metal forming, wear, crack propagation and fluid-structure interactions using FEM, DEM and PFEM”, Prof. J.-P. Ponthot, Université de Liège — “Statistical crystal plasticity models and their implementation in FE models for plastic forming simulations”, Prof. A. Van Bael, KU Leuven — “Application of plasticity models for the design of damage tolerant microstructures, Prof. S. Münstermann”, RWTH Aachen University — “Quantitative full-field measurements for material identification and model validation”, Dr. P. Lava, MatchID NV High productivity welding processes for thick section steels seminar October 23rd, 2019

This seminar was organised in collaboration with the Belgian Welding Institute. This international seminar highlighted some welding options available for increasing productivity when welding thick section steels. These include both traditional and more modern arc welding techniques, as well as other options, such as beam and friction welding. Aim of the seminar was to provide a non-commercial introduction to some of these lesser used techniques, with a focus on (near) industry-readiness. In addition to the lectures from international speakers, there was a short tour of the welding facilities and a visit to the large-scale testing laboratory. The target audience includes welding engineers and co-ordinators, production and operations managers and R&D personnel.

Programme — “Friction-based welding processes for thick section steels”, by Koen Faes, Belgian Welding Institute — “Welding of high thickness plates using different methods – laser submerged arc hybrid welding and laser beam welding under vacuum”, by Simon Olschok, Welding and Joining Institute ISF of Aachen University — “Advances in high productivity electron beam welding processes for power generation and related industry sectors”, by Chris Punshon, TWI Ltd. — “Old technologies facing new requirements – (Re-)Introduction of electrogas-arc- and electroslag-welding in shipbuilding”, by Andreas Gericke, Fraunhofer Research Institution for Large Structures in Production Engineering — “High productivity welding processes for thick section steels – Narrow Gap welding”, by Alexis Ferrari, Institut de Soudure — “Productivity improvement methods for submerged arc welding of thick section steels”, by Christoph Gerritsen, OCAS .

165 LIST OF PUBLICATIONS 2018/2019 PAPERS PUBLISHED IN SCIENTIFIC JOURNALS

Publication Title Author(s) Journal/Reference

Corrosion protection of steel cut-edges by H. Simillion, O. Dolgikh, S. V Lamaka. H. Xue, Materials And Corrosion - Werkstoffe Und hot-dip galvanized Al(Zn,Mg) coatings in 1 A. Bastos, A. R Oliveira, M. G Taryba, C. Allély, Korrosion wt.% NaCl: I. Experimental study B. van den Bossche, K. Van den Bergh, J. De Vol. 70, 5 (2019) pp. 768-779 Strycker, J. Deconinck

Corrosion protection of steel cut-edges by H. Simillion, O. Dolgikh, S.V. Lamaka, Materials And Corrosion - Werkstoffe Und hot-dip galvanized Al(Zn,Mg) coatings in 1 A.C. Bastos, H.B. Xue, M.G. Taryba, Korrosion wt.% NaCl: II. Numerical simulations A. Oliveira, C. Allély, B. Van Den Bossche, Vol. 70, 5 (2019) pp. 780-792 K. Van Den Bergh, J. De Strycker, and J. Deconinck

Influence of water content and applied Jon Ustarroz, Monika Lukaczynska, El Amine Electrochimica Acta potential on the electrodeposition of Ni Mernissi Cherigui, Andrea Ceglia, Krista Van Vol. 319 (2019) pp. 690-704 coatings from deep eutectic solvents Den Bergh, Joost De Strycker, Herman Terryn

Can carbides resist nitriding? E. Leunis, M. Gauvin Journal of Heat Treatment and Materials Vol. 74 (2019) pp. 3-11

A fully coupled fluid-structure interaction Reza Talemi, Steven Cooreman, Haroun Theoretical and Applied Fracture Mechanics simulation of three-dimensional dynamic Mahgerefteh, Sergey Martynov, Solomon Vol. 101 (2019) pp. Pages 224-235 ductile fracture in a steel pipeline Brown

The third Sandia Fracture Challenge: S. Kramer et al.; S. Cooreman, P. Thibaux International Journal of Fracture predictions of ductile fracture in additively Vol. 218 (2019) pp. 5–61 manufactured metal

Effect of Silicon on the Hot Flow Behavior P. Rodríguez-Calvillo, J. Schneider, Materials Performance and Characterization of Ultra-Low Carbon Austenite Y. Houbaert, J. Cabrera, and R. Colás Vol. 8 (2019) pp. 15

167 A multi-scale study of the interaction of N. Mavrikakis, C.Detlefs, P.K.Cook, M.Kutsal, Acta Materialia Sn solutes with dislocations during static A.P.C.Campos, M.Gauvin, P.R.Calvillo, Vol. 174 (2019) pp. 92-104 recovery in α-Fe W.Saikaly, R.Hubert, H.F.Poulsen, A.Vaugeois, H.Zapolsky, D.Mangelinck, M.Dumont, C.Yildirim

Combining MCR-ALS and EXAFS as tools Tim Verdonck, Philippe Verpoort, Joost Dalton Transactions for speciation of highly chlorinated De Strycker, Ansbert De Cleene, Dipanjan Vol. 48 (2019) pp. 2318-2327 chromium(III) in mixtures of deep eutectic Banerjee, Peter Nockemann, Rik Van Deun, solvents and water Kristof Van Hecke

Chromium(III) in deep eutectic solvents: Tim Verdonck, Philippe Verpoort, Joost Green Chemistry towards a sustainable chromium(VI)-free De Strycker, Ansbert De Cleene, Dipanjan Vol. 21 (2019) pp. 3637-3650 steel plating process Banerjee, Peter Nockemann, Rik Van Deun, Kristof Van Hecke

Quantification and microstructural origin F. Tankoua, J. Crépin, P. Thibaux, International Journal of Fracture of the anisotropic nature of the sensitivity S. Cooreman, A.-F. Gourgues-Lorenzon Vol. 212 (2018) pp. 143–166 to brittle cleavage fracture for hot-rolled pipeline steels

Damage behaviour of full-scale straight J.C.R. Pereira, Jeroen Van Wittenberghe, Journal of Constructional Steel Research pipes under extreme cyclic bending A.M.P. de Jesus, Philippe Thibaux, Vol. 143 (2018) pp. 97-109 conditions J.A.F.O. Correia, A.A. Fernandes

Deformation induced degradation of hot- B. Lemmens, H. Springer, M. Peeters, I. De Materials Science And Engineering - A - dip aluminized steel Graeve, J. De Strycker, D. Raabe, K. Verbeken Structural Materials Vol. A 710 (2018) pp. 385-391

Harder, better, faster, stronger C. Garcia Mateo, L. Bracke, M. Somani, Image And Vision Computing A. Latz, D.A. Porter, F.G. Caballero Vol. 218 (2018) pp. 94-96

A first-principles reassessment of the Fe-N Sam De Waele, Kurt Lejaeghere, Elke Leunis, Journal of Alloys And Compounds phase diagram in the low-nitrogen limit Lode Duprez, Stefaan Cottenier Vol. 775 (2018) pp. 758-768

Effect of Al on martensite tempering: Kangying Zhu, Hui Shi, Hao Chen, Coralie Journal of Materials Science comparison with Si Jung Vol. 53 (2018) pp. Volume 53, Issue 9, pp 6951-6967 Influence of initial heating during final P. Rodriguez-Calvillo, E. Leunis, T. Van De AIP Advances high temperature annealing on the offset of Putte, S. Jacobs, O. Zacek, W. Saikaly Vol. 8 (2018) primary and secondary recrystallization in Cu-bearing grain oriented electrical steels

Prediction of Martensite Start Temperature R. Zhang, W. Zheng, X. Veys, G. Huyberechts, Journal of Phase Equilibria And Diffusion for Lightweight Fe-Mn-Al-C Steels H. Springer, M. Selleby Vol. 39 Issue 5 (2018) pp. 476-489

Thermal stability of ARMCO iron processed J. A. Muñoz, O. F. Higuera,A. Hernández International Journal of Advanced by ECAP Expósito, A. Boulaajaj, R. E. Bolmaro, Manufacturing Technology F. D. Dumitru, P. Rodriguez-Calvillo, Vol. 98 (2018) pp. 2917-2932 A. Moreira Jorge Jr, J. M. Cabrera

169 CONFERENCE CONTRIBUTIONS

Publication Title Author(s) Conference

Large-scale resonant fatigue testing of Jeroen Van Wittenberghe, Philippe 2019/06/09 — Glasgow, United Kingdom welded tubular x-joints for offshore jacket Thibaux, Maarten Van Poucke 2019 OMAE-International Conference on Ocean, foundations Offshore and Arctic Engineering

Numerical simulation and result Philippe Thibaux, Jeroen Van 2019/06/09 — Glasgow, United Kingdom interpretation of large scale fatigue testing of Wittenberghe, Maarten Van Poucke 2019 OMAE-International Conference on Ocean, tubular x-joint close to resonance frequency Offshore and Arctic Engineering

Saline resistant weathering steel for offshore Krista Van den Bergh, Lucia Fernandez 2019/09/08 — Seville, Spain and naval: corrosion testing? Macia, Joost De Strycker, Martin EFC EUROCORR 2019 Liebeherr

Fatigue response of high-strength steel bolted Okan Yilmaz, Carlos Jimenez Pena, 2019/11/20 — Senlis, France connections under in-plane shear and out-of- Dimitri Debruyne Fatigue Design 2019 plane bending loading modes

Fatigue testing of large-scale steel structures Jeroen Van Wittenberghe, Alexis Coste 2019/11/20 — Senlis, France in resonance with directional loading control Fatigue Design 2019

Iron loss modelling of electrical traction Johan Rens, Lode Vandenbossche, 2019/05/19 — Lyon, France motors for improved prediction of higher Ophélie Dorez 32nd Electric Vehicle Symposium (EVS32) Lyon, harmonic losses France, May 19-22, 2019

Can carbides resist during nitriding? Elke Leunis, Melanie Gauvin 2018/04/12 — Friedrichshafen, Germany European Conference on heat treatment: Nitriding and Nitrocarburizing

influence of the enamelling process on Marc Leveaux, Laura Moli Sanchez, 2018/05/28 — chicago, USA Hydrogen permeation, comparison between Zinedine Zermout, Irati Lizarraga Ferro 24th intenrnational enamelling congress permeation & high temperature charging Brittle out-of-plane cracking in pipeline steels S. Cooreman, P. Thibaux, F. Tankoua, 2018/04/10 — Gent, Belgium J. Crépin, A.-F. Gourgues-Lorenzon Technology for Future and Aging Pipelines 2018 10- 12 April 2018 Gent

Prediction of mechanical properties on large S. Cooreman, P. Thibaux, M. Liebeherr 2018/07/30 — Tokio, Japan diameter welded pipes through advanced NUMISHEET 2018 constitutive modelling

Advanced constitutive model for the accurate S. Cooreman, D. Van Hoecke, 2018/09/24 — Calgary, Canada evaluation of the structural performance of M. Liebeherr, P. Thibaux, H. Luccioni 12th International Pipeline Conference (IPC 2018) welded pipes in offshore applications

Development of a welding sequence P. Thibaux, E. Van Pottelberg 2018/06/17 — Madrid, Spain optimized for the fatigue resistance of tubular OMAE : 37th International Conference on Ocean, joints with a novel representative welded Offshore & Arctic Engineering sample

Towards a better understanding of hydrogen Krista Van den Bergh, Zinedine 2018/09/09 — Krakow, Poland embrittlement of steel in sour service Zermout, Dennis Van Hoecke, Lode Eurocorr 2018 conditions Duprez, Joost De Strycker

Towards a better understanding of hydrogen Krista Van den Bergh, Zinedine 2018/05/29 — Ghent, Belgium embrittlement testing of steel in sour service Zermout, Patrick Goes SteelyHydrogen 2018 29-31 May 2018 Ghent conditions by coupling h diffusion to fracture mechanics

Influence of applied potential, water Monika Lukaczynska, Krista Van den 2018/05/13 — Seattle, USA content and forced convection on the Bergh, Joost De Strycker, Herman 233rd ECS MEETING electrodeposition of ni films on steel from Terryn, Jon Ustarroz choline chloride based deep eutectic solvents

Recommendations for submerged arc spiral M. Liebeherr, O.E. Gungor, N. Sanchez, 2018/09/24 — Calgary, Canada welding with optimized ctod properties He. Luccioni, N. Ilic 12th International Pipeline Conference (IPC 2018)

The influence of chemistry inhomogeneity Junyan Ni, John Vande Voorde, Joachim 2018/9/23 — Seggau Austria on microstructure development and residual Antonissen, Magd Abdel Wahab 12th International Seminar Numerical Analysis of stress Weldability, 23-26 Sept 2018

171 Fretting fatigue fracture in lug joints made of Reza H. Talemi, Jie Zhang, Stijn Hertelé, 2018/05/27 — Poitiers, France high strength steel Wim De Waele 12th International Fatigue Congress

Prediction of the leakage threshold for John Vande Voorde and Jeroen Van 2018/07/15 — Prague, Czech Republic hertzian contact seals: a cellular automata Wittenberghe PVP2018 model

Prediction of the leakage threshold for Jeroen Van Wittenberghe and John 2018/07/15 — Prague, Czech Republic hertzian contact seals: an experimental Vande Voorde PVP2018 approach

Optimization of the structural performance John Vande Voorde, Filip Van den 2018/06/17 — Madrid, Spain for corrugated blast panels on offshore Abeele, Steven Cooreman OMAE : 37th International Conference on Ocean, platforms Offshore & Arctic Engineering

Three-dimensional simulation of dynamic Reza Hojjati Talemi, Haroun 2018/09/19 — Verona, Italy ductile crack propagation in steel pipeline Mahgerefteh, Sergey Martynov, The 6th International Conference on Crack Paths using coupled fluid-structure modelling Solomon Brown (CP 2018)

Cleavage fracture assessment of cold charged Reza H. Talemi, Antônio de Souza Braga 2018/08/26 — Belgrade, Serbia steel slabs using experimental and numerical Neto, Annick Willems, Negar Gilani, 22nd European Conference on Fracture — ECF22 approaches Quang Tien Ngo

Innovative resonant bending test setup for Jeroen Van Wittenberghe, Philippe 2018/04/10 — Gent, Belgium fatigue testing of pipelines with directional Thibaux Technology for Future and Aging Pipelines 2018 10- loading control 12 April 2018 Gent

Improved loss modelling of electrical traction Jan Rens, Sigrid Jacobs, Emmanual 2018/11/07 — Nottingham, United Kingdom motors by including magnetic skin effect Attrazic ESARS-ITEC: Electrical systems for aircraft, railway, ship propulsion and road vehicles and international transportation electrification conference

Improved core loss modelling of electrical Jan Rens, Sigrid Jacobs, Lode 2018/09/30 — Kobe, Japan traction motors through simulation of skin Vandenbossche, Emmanuel Attrazic Electrical Vehicle Symposium EVS31 effect in laminations Dark Field X-ray Microscopy Study of Heat Can Yildirim, Nikolas Mavrikakis, 2018/11/06 — Helsingør (Elsinore), Denmark Treatment of Fe-Si and Fe-Si-Sn Alloys Melanie Gauvin, Phil Cook, Mustafacan 4th international congress on 3d materials science Kutsal, Ashley Bucsek, Henning (3DMS) Poulsen, Wahib Saikaly, Roger Hubert, Carsten Detlefs

Iron loss measurements of non-oriented Lode Vandenbossche, Sigrid Jacobs, 2018/09/23 — Portland, USA electrical steels at elevated magnetic Vinicius Araujo Rabello Landeira, ECCE (IEEE Energy Conversion Congress & polarization: comparison of calorimetric and Emmanuel Attrazic Exposition) field-metric methods

Finite element model in abrasion analysis for P. Wechsuwanmanee, J. Lian, 2018/06/09 — Gent, Belgium single-asperity scratch test J. Sukumaran, Á. Kalácska, H. Ben Fracture Fatigue and Wear 2018 (FFW) Hamouda, P. De Baets, S. Münstermann

Segregation affecting the evolution of N. Mavrikakis, P. R. Calvillo, W. Saikaly, 2017/11/05 — St George, USA primary recrystallization textures in a ternary M. Descoins, D. Mangelinck, M. Dumont ICOTOM — 18th International Conference on Fe-Si-Sn alloy Textures of Materials

Abrasive slurry testing of different type of A. Kalácska, J. Sukumaran, H. Ben 2019/04/14 — Miami, USA steels used in agricultural machinery Hamouda, P. De Baets Wear of Materials 2019

Combined in-field and laboratory monitoring H. Ben Hamouda, S. Vanrostenberghe 2019/04/14 — Miami, USA techniques to understand the wear failure Wear of Materials 2019 origin in martensitic steels

Electrochemical deposition of Nickel films Monika Lukaczynska, Krista Van den 2018/02/21 — Blankenberge, Belgium from choline chloride based Deep Eutectic Bergh, Joost De Strycker, Herman ChemCYS2018 Solvents Terryn, Jon Ustarroz

Hydrogen uptake by high-strength steels Krista Van den Bergh, Kurt De Sloover, 2018/05/29 — Ghent, Belgium during electrodeposition process Joachim Noens, Dennis Van Hoecke, SteelyHydrogen 2018 29-31 May 2018 Ghent Joost De Strycker

A comparative study of the durability of Philippe Verpoort, Beril Corlu, Joost De 2018/09/24 — Brussels, Belgium metallic-coated profiles used as structural Strycker EU PVSEC 2018 elements in PV solar energy fields

173 The ‘complex’ route to sustainable Cr(VI)-free Tim Verdonck, Philippe Verpoort, Rik 2018/06/17 — Gent, Belgium steel plating Van Deun, Kristof Van Hecke ISIEM2018 (International Symposium on Inorganic and Environmental Materials 2018)

Saline resistant weathering steel for Krista Van den Bergh, Lucia Fernandez 2019/04/01 — Antwerp, Belgium offshore and naval: corrosion testing and Macia, Joost De Strycker, Martin 2nd Corrosion and Fouling Symposium characterisation? Liebeherr

Heavy gauge linepipe steel developent and Christoph Gerritsen, Nuria Sanchez 2018/07/18 — Bali, Indonesia applications research at ArcelorMittal Mourino, Özlem Esma Ayas Güngör and IIW C-XI meeting, 18 July 2018 Bali Indonesia Steven Cooreman

The ‘complex’ route to sustainable Cr(III) Tim Verdonck, Philippe Verpoort, Rik 2018/02/21 — Blankenberge, Belgium steel plating Van Deun, Kristof Van Hecke ChemCYS2018 (Chemistry Conference for Young Scientists)

Quantitative mapping of nanoscale F. Nozahic, D. Rosseel, D. Mercier, 2018/09/11 — Liège, Belgium mechanical properties of Zn-Al-(Mg) coatings M. Gauvin, K. Van den Bergh Indentation 2018 on steel by nanoindentation

Combinatorial metallurgical screening: what Nele Van Steenberge, Serge Claessens, 2018/07/08 — Paris, France — Thermec’2018 is in it for high temperature applications? Lode Duprez International Conference on Processing & Manufacturing of Advanced Materials

ocas

OCAS is an advanced R&D centre active in metallurgy, coating and application development, and providing metal based products and services. OCAS speeds up the R&D processes of its customers through a specialised multi-disciplinary approach combined with innovative testing methodologies. www.ocas.be | [email protected]

OCAS is part of the FINOCAS holding which is a joint venture between ArcelorMittal and the Flemish Region.