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					Corus automotive contact details                                                                             Inside this issue...
                                                                                                             St. Petersburg: Is it the new
Body & closures                     Chassis & suspension               Powertrain                            Detroit? Independent journalist
Steel body sheet                    Tubes for Automotive               Precision Engineering                 Mark Bursa explains
Corus Strip Products IJmuiden       Structures and Interior            Steels
Netherlands                         Systems                            Corus Engineering Steels




                                                                                                                                                        emotion
t: +31 (0)251 496126
cspy.salessupport@corusgroup.com
                                    Corus Tubes - Automotive &
                                    Engineering
                                                                       United Kingdom
                                                                                                             New material developments:
                                                                       t: +44 (0) 01709 826814
                                    Netherlands                        enquiries.ces@corusgroup.com          SmartLite™ and spring steels
Corus Strip Products UK             t: +31 (0) 26 3689111
United Kingdom                      corustubes.a&e@corusgroup.com      Wire rod
t: +44 (0)1633 755201                                                  Corus Construction & Industrial
cspuk.marketing@corusgroup.com                                         United Kingdom
                                                                                                             Advanced High Strength
                                    Innovative semi-finished
                                                                       t: +44 (0) 1724 404040
                                                                                                             Steels: An introduction
                                                                       rods@corusgroup.com
                                    products for Tubular                                                     to Dual Phase
Tailor welded blanks                and tailor rolled blank
CDBS Automotive Service Centre,     applications in body
                                                                       European automotive
United Kingdom                      structure and chassis              service centres
t: +44 (0) 1902 638900              Corus Strip Products IJmuiden
Richard.Down@corusgroup.com         Netherlands                        Corus Degels Service Centre
                                    t: +31 (0)251 496126               Germany
                                    cspy.salessupport@corusgroup.com   t: +49 (0) 2131 74950-0
                                                                       steven.dijkstra@corusgroup.com

                                                                       Corus Service Centre Gelsenkirchen
                                                                       Germany
                                                                       t: +49 (0) 209 98460
Interior & trim                     Electrical steels
                                                                       Corus Feijen Service Centre
Plated steel strip                  Cogent Power Ltd                   Netherlands
Corus Special Strip Head Office      United Kingdom                     t: +31 (0) 43 3688444
c/o Hille & Müller GmbH             t: +44 (0) 1633 290033                                                                                         Issue 13: 2007
Germany                             orb@cogent-power.com               Corus MultiSteel Service Centre
t: +49 (0)211 79 50 471                                                Netherlands
css.marketing@corusgroup.com                                           t: +31 (0) 43 3688444

Hot rolled components                                                  Corus Unitol
Corus Engineering Steels - Narrow                                      France
Strip                               Technology Services                t: +33 1693 92 300
United Kingdom                                                         t: +33 1649 66 832
t: +44 (0) 1709 842527              Corus Automotive Engineering
bsmsales@corusgroup.com             United Kingdom                     Corus Service Centre Milano SpA
                                    t: +44 (0) 2476 241 244            Italy
Envirobond® - Adhesive              automotive@corusgroup.com          t: +39 024 457651
coated steel
Corus Firsteel Coated Strip         Corus RD&T                         Corus Steel Service Hungary
United Kingdom                      Netherlands                        Hungary
t: +44 (0) 1922 629593              Product Application Centre         t: +36 96 518 168
firsteel.sales@corusgroup.com        t: +33 (0) 251 498276              stephan.flapper@Corussteelservice.hu




                     www.corusautomotive.com
                                                                                                             A passion for design and technical excellence
Contents Foreword                                                                                                                  News in brief
page 3                News in brief                           The move east                                                        Pressed into service                         Automotive World                            opportunities that the industry drivers for
                                                                                                                                                                                                                            change offer the UK industry and Corus.
page 4                More robust designs                     Fifteen years ago, we considered the Soviet bloc as a somewhat       Driven by the industry hunger for                                 Professor Jon          Besides the topics of changing consumer
                                                              spent force in the carmaking world. Today, the situation is          advanced data needed to study the                                 King - Director of     demands, patterns in the use of cars and
page 5                Corus buys in to tool
                                                              very different with a significant number of OEMs and their Tier       forming capabilities of the stronger                              Corus Automotive       automotive occupant safety, the topic
                      buy-off
                                                                                                                                   Advanced and Ultra High Strength                                  Engineering            of environmental legislation was an area
page 6                Value from every gram
                                                              suppliers setting up new operations in both Russia and Eastern       Steels, Corus Research, Development                               group at Warwick       where Prof. King saw “a real opportunity
                                                              Europe. Production levels may seem modest at the moment,             and Technology have invested in a new                             University, was a      for materials suppliers and OEMs to
page 7                Every three minutes                                                                                          Erichsen research press. The press
                                                              but we should make no mistake that the region is set to                                                                                guest speaker at       collaborate better”. The fields of light-
                                                                                                                                   is being used intensively within many                             the Automotive         weighting, better design to meet the End
page 8 & 9            The new Detroit?                        become one of the major auto-making areas of the world over          Corus research programs to determine                              World ‘Innovation      of Life Vehicle Directive and use of novel
page 10               Developments in valve                   the next ten to fifteen years. Corus like every other business        the forming characteristics of a material                         and Growth’            engineering methods to speed up and
                      spring steels                                                                                                using e.g. Forming Limit Curve testing
                                                              that supplies to the automotive industry is making appropriate                                                                         conference in          therefore reduce the energy consumed
                                                                                                                                   and hole expansion testing. It is proving    London on the 30th October. Professor       during the traditional vehicle development
page 11               AHSS - what is it?                      preparations to serve this important new marketplace.                to be an essential tool for the generation   King spoke about the challenges and         cycle, are “particularly relevant” he said.
page 12               Steel: fundamental in a                 Independent journalist Mark Bursa gives his own view on the          of material data used by those performing
                      low CO2 future                          growth in the region, on pages 8 and 9.                              Finite Element formability calculations      Expert input                                Open for business
                                                                                                                                   within Corus and throughout its customer
page 13               Onto the big stage                                                                                                                                        Since late 2006 Corus have been
                                                                                                                                   base. The data generated will be available
                                                              Investment pays                                                                                                   involved in a unique approach from UK
                                                                                                                                   for all major Corus steel grades in the
page 14               SmartLite™: automotive                  In line with its commitment to the industry, Corus continues                                                      Government to debate the topic of
                      potential                                                                                                    Aurora database. Moreover, with the
                                                                                                                                                                                sustainable production and consumption
                                                              to make investments in its Research and Development and              new press now in service, Corus is also
page 15               Alumni gather                                                                                                                                             nationally. The Sustainable Development
                                                                                                                                   able to align with the coming prescribed
                                                              steel-making in the field of Advanced High Strength Steels.                                                        Commission (SDC), an independent advisor
                                                                                                                                   standards for AHSS forming tests.
                                                              Alongside these investments, Corus also continues to develop                                                      to the UK government, who’s chair and
                                                                                                                                                                                patron is the sustainability commentator    On 25 September the new central
                                                              its service offering to its automotive customers in the form of
                                                                                                                                                                                Jonathan Porritt, have been engaging with   office of Corus Research, Development
                                                              engineering and press-working help services. New investments                                                      industry on how business can contribute     & Technology on the IJmuiden site of
                                                              by Corus into its production facilities to better serve particular                                                to the reduction of the carbon footprint,   Corus was officially inaugurated by Mr.
                                                                                                                                                                                and of products in development and use.     Ratan Tata, Chairman of Tata Sons Ltd.,
                                                              markets are also paying off – an example in this issue relates
                                                                                                                                                                                So far Corus’s contribution has been to     in the presence of Mr. B. Muthuraman,
                                                              how Corus Tubes are gaining new interest from automotive                                                          offer expert knowledge in lightweight       Managing Director of Tata Steel, Mr.
                                                              suppliers following their Zwijndrecht plant developments, to                                                      affordable solutions for car body           Philippe Varin, CEO of Corus, Dr. Peter
                                                                                                                                                                                structures, and to help explode some        Jongenburger, Managing Director of
                                                              provide special tubes to those who manufacture the Land Rover
                                                                                                                                                                                of the myths associated with passenger      Corus RD&T and 150 guests from various
                                                              chassis-frame.                                                                                                    cars as the SDC helps to define UK           countries. In a speech preceding the
Cover image: Royal College of Art                                                                                                                                               government policy on personal mobility.     opening proper, Mr. Tata referred to the
‘Connections’ project 2007, overall group                     Hope . . . or help?                                                                                                                                           good prospects for the steel industry,
winner
                                                              Four of the top issues driving the future of the automotive          New Website                                                                              steel being the key material for the
                                                              industry were debated at a recent conference at the IMechE           Corus Steel Service Hungary has recently                                                 automotive, engineering and construction
                                                                                                                                   launched a new website at                                                                businesses. He also said that continuous
                                                              in London. One of these - helping carmakers to meet the              www.corussteelservice.hu. The                                                            innovation and meeting customer
                                                              CO2 legislation - (particularly as the industry looks forward to     company has moved to a new office                                                         requirements are essential for the industry
              Editor Clive Sutton                                                                                                  building in Györ (Hungary) and is                                                        to survive in the long term. The new
                                                              the probable 2015 deadline), is emerging as an area where
              Email emotion@corusgroup.com                                                                                         targeting new business amongst the                                                       building, that has been named “De Brug”
              Enquires tel +44 (0)1869 327732                 materials suppliers can increasingly offer expert help. But whilst   automotive supply community in the                                                       (The Bridge) houses about 200 IJmuiden
              Enquires fax +44 (0)1322 421552                 aluminium might appear to be better than steel in supporting         CEE region. Commenting, Steel Service                                                    based employees of Corus RD&T. Making
                                                              reduced CO2 emissions, recent independent research does not          Hungary manager Stephan Flapper said                                                     ample use of steel and glass in his
Design Tina Baxter
                                                                                                                                   “The growth in automotive demand in                                                      design, architect Jan Elissen has aimed
                                                              bear this out. Find out why on page 12.                              this region is remarkable - both OEMs                                                    to create an atmosphere of openness
Corus has taken care to ensure that this information is
accurate, but Corus including its subsidiaries does not ac-                                                                        and their tier suppliers are ramping                                                     and transparency, with the objective
cept responsibility or liability for errors or
information which is found to be misleading.                  We hope you find this edition of emotion useful                       up their operations rapidly. Being able                                                  of fostering contact and exchange of
                                                                                                                                   to offer local service, an outstanding                                                   information between the people working
Trademarks                                                    and, as always, we welcome your feedback to:                         quality product and a reliable delivery      customers are looking for, and the reason   in the building as well as with visitors from
In-Form™, PHAST™, SmartLite™, F2C®, F2S® and F2F®
are trademarks of Corus Group plc.                            emotion@corusgroup.com                                               performance is exactly what these            why we are here”.                           business units and customers.

                                                                                                                                   Articles: Corus                                                                                                      Images: Various

  2                                                                                                                                                                                                                                                                 3
More robust designs
Corus has been working with one of its automotive customers Tallent Engineering, to develop a new predictive engineering
modelling technique called Forming to Strength (F2S®).

As all manufacturing processes can change the physical
properties of a material it is essential that component
manufacturers and carmakers understand how steel will perform         “Corus’ predictive modelling techniques
and behave in service after it is formed into new shapes.             allow us to evaluate new materials in
Forming to Strength (F2S®) is the latest in a series of new
modelling techniques from Corus that enable customers to use          order to successfully introduce these
more accurate material properties changed by forming, into            modern steel products to the benefit of
crash, fatigue or strength analyses.
                                                                      our customers.”
Corus worked with Tallent to validate the F2S® technique on a
suspension lower control arm which uses Corus Tenform XF300                               Dr Adam Towse, Analysis Supervisor,
and XF400 HSLA steel grades. Conventional finite element                                                  TKA Tallent Chassis
strength modelling does not include changes in the steel


                                                                                                                                      Corus buys in to tool buy-off
properties resulting from the forming process. However, the
Corus F2S® technique takes the formed thickness and material      Technology Corus Strip Products said: “Our F2S® predictive
strength from PAM-STAMP forming analysis and uses this as         model is just one of a number of unique analysis simulation
inputs to ABAQUS (finite element software) strength analysis.      tools, which include Forming to Crash (F2C®) and Forming to
                                                                  Fatigue (F2F®), that we can provide customers with, to help them    Tool buy-off is an important step             The purpose of a forming limit diagram           Freelander II, Land Rover Discovery,
Simulation model accuracy improved                                maximise the value of the steel Corus supply. Crucially, by using   in the pre-production stage of any            is to minimise the splitting risk of newly       Jaguar S-type and Ford Mondeo, to name
Strength tests conducted by Tallent on the lower control arm      these CAE tools, customers such as Tallent, can more quickly and    new vehicle, where the toolmaker              designed panels once they go into regular        but a few. A wealth of experience has
showed that conventional finite element modelling under-predicts   more robustly evaluate the potential benefits of introducing new     demonstrates the robustness and               production. New tooling will only be             been gathered during these programmes
the measured strength by 13%. However, when using the Corus       materials to the component production process during the life       capability of a new pressing to               accepted and delivered to OEMs once              and, coupled with a policy of continuous
F2S® technique, the accuracy of the prediction was within 1%      span of a vehicle without incurring prohibitive cost and time.”     the OEM. It is a process that is              a panel with a satisfactory safety factor        improvement, many enhancements to the
of the measured strength. By utilising this new computer aided                                                                        increasingly involving steel suppliers        has been produced. The safety factor is          process have resulted.
engineering approach, Corus and its customers are able to work    Successful introduction                                             working closely with OEMs and                 calculated from the forming limit diagram.
together to reduce lead times and therefore costs during the      Dr Adam Towse, Analysis Supervisor, TKA Tallent Chassis             toolmakers – Ford Premier Automotive                                                           For instance, Corus use a 2mm dot grid,
development process.                                              added: “The ability to introduce new materials is particularly      Group (PAG) policy now requires steel         To produce a forming limit diagram it            which is found to give higher accuracy
                                                                  important as there is a growing demand from our OEM customers       suppliers to buy in to the tool buy-off       is necessary to first grid a blank using          than the commonly used 2.5mm circle
Commenting on the benefits to customers of using Corus’            to use today’s modern High Strength and Dual Phase steels           process.                                      an electrochemical technique (squares,           grid and enables smaller, localised peaks
specialist analysis techniques, Rene Kieft, Manager Product &     in order to meet the on-going need to reduce vehicle weight                                                       circles or dots can be used). The blank          in strain to be identified. Compared with
                                                                  whilst maintaining performance and strength. Corus’ predictive      As a fundamental part of this process,        is then pressed and the resulting strains        circles or squares, the percentage of the
                                                                  modelling techniques allow us to evaluate new materials in order    steel suppliers have to provide forming       from the forming operation can be                surface that is etched is less, and means
                                                                  to successfully introduce these modern steel products to the        limit diagrams for the parts they wish        calculated by measuring the dimensions           that friction during the try-out is more
                                                                  benefit of our customers.”                                           to supply in a new model. As Corus is         of the deformed grid compared to the             representative of standard conditions.
                                                                                                                                      committed to offering world-class service     undeformed grid. For each grid segment
                                                                                                                                      and support, the provision of forming limit   that is measured, both the major and             More recently the emphasis has been
                                                                                                                                      diagrams is seen as a key competence,         minor strains are recorded. The strains          on improving speed, and a Value Stream
                                                                                                                                      and is continuously scrutinised to identify   are then plotted using the minor strain          Mapping exercise was carried out to
                                                                                                                                      improvement opportunities. In particular,     as the x-axis and the major strain as the        identify opportunities to make the process
                                                                                                                                      response time is considered critical by       y-axis. A forming limit curve, which shows       leaner and faster. An example of the
                                                                                                                                      OEMs, and therefore one area targeted for     the maximal attainable strains for a given       success of this exercise was during a
                                                                                                                                      improvement.                                  material is then added to the diagram.           recent tool buy-off, when Corus was
                                                                                                                                                                                    Any measured strains above the forming           asked to prioritise the measurement of a
                                                                                                                                                                                    limit curve indicate a high risk of splitting.   particular panel. The panel was pressed
                                                                                                                                                                                                                                     in the afternoon by a toolmaker in Spain
                                                                                                                                                                                    Formability support within Corus is              and sent over night to Corus laboratories
                                                                  Contact: Iain McGregor,                                             Contact: Nico Langerak, Department            undertaken by the Stamping Technology            in the Netherlands where it arrived mid
                                                                  Manager Technology                                                  Manager, Automotive Applications              Group of Corus RD&T in IJmuiden and in           morning. The panel was measured and
                                                                  t: +44 (0) 2476 241213,                                             t: + 33 (0) 2541 498507                       recent years the group has participated          a report sent by e-mail to the customer
                                                                  e: iain.mcgregor@corusgroup.com                                     e: nico.langerak@corusgroup.com               in tool buy-offs for the Land Rover              before the end of the afternoon.

Article: Corus                                                                                                       Image: Corus     Article: Corus                                                                                                             Image: Corus

 4                                                                                                                                                                                                                                                                        5
Value from every gram
You might think Corus just make          Listening comes first                          knowledge available through the Corus-
steel, but we do more – a lot            By listening to customers, attending key      Vegter materials model - data which
more. Be it changes in emissions,        European automotive forums and through        Corus has made freely available on www.
safety performance legislation,          undertaking our own market analysis, our      corusautomotive.com for engineers
the contemporary needs of car            specialists keep abreast of the key auto      who work out how to form complex 3D
designers, or pushing the boundaries     industry trends. We look for opportunities    parts from 2D blanks. The data model
of material performance, Corus           to bring a new competitiveness or             can be accessed directly inside the
shares its knowledge and responds        performance edge to automotive                industry standard PAM-STAMP™ forming
to the industry challenges of our        manufacturing through innovative              analysis software package to improve the
automotive customers. Our aim is to      specifications and new applications of         accuracy of simulated virtual prototypes.                                                 Michael Schumacher adds his name to the Make Road Safe petition
help customers get the best value from
every gram of steel they buy from us.
                                         steel. This puts Corus in a position to
                                         advise on materials selection from a point
                                         of comprehensive industry knowledge.
                                                                                       The improved confidence that results,
                                                                                       enables engineers to develop reliable
                                                                                       parts using computer simulation, long
                                                                                                                                    Every three minutes
                                                                                       before hardware prototypes are made.
                                         When Xtrac approached Corus asking for                                                     Statistically, in the next three minutes,                                                Philippe Varin, Chief Executive of Corus
                                         gear steels with better impact resistance,                                                 a child will die from a road accident          “We are delighted to offer our            added: “We are delighted to offer our
                                         machinability and carburising qualities,
                                         Corus offered to adjust the standard
                                                                                         We don’t just make                         somewhere in the world.                        support for this worthwhile               support for this worthwhile campaign.
                                                                                                                                                                                                                             For Corus, safety is the first priority. Make
                                                                                                                                                                                   campaign. For Corus,
                                         chemistry of its Hy-Tuf product, improving
                                         its chemistry tolerances and cleanness.
                                                                                         steel, we bring                            Everyday road accidents kill around
                                                                                                                                                                                   safety is the first priority.
                                                                                                                                                                                                                             Roads Safe should be applauded for
                                                                                                                                                                                                                             challenging government and industry alike
                                                                                                                                    3000 people, 500 of them children. More
                                                                                                                                                                                   Make Roads Safe should be
                                         The resulting XMO materials enabled
                                         Xtrac to make narrower gears that can run
                                                                                         ‘value in steel’.                          than 8 in 10 of those deaths occur in
                                                                                                                                                                                   applauded for challenging
                                                                                                                                                                                                                             to work towards making roads around the
                                                                                                                                                                                                                             world safer today and anything we can do
                                                                                                                                    low and middle income countries. Per
                                         at higher temperatures, requiring smaller                                                  month, these figures become even more           government and industry                   to highlight this issue to our employees is
                                         oil-coolers and thereby improving the                                                      alarming. Global road traffic accidents         alike to work towards making              welcomed.”
                                                                                       How we deliver
                                         aerodynamics of the vehicle.                                                               kill 100,000 people every month and in
                                                                                       To make cars efficiently, it is vital that                                                   roads around the world safer
                                                                                                                                    terms of economic impact, cost estimates                                                 As part of the campaign, Make Roads
                                         Wide range of expertise
                                                                                       supplies of parts and materials are                                                         today and anything we can                 Safe has launched a global petition calling
                                                                                                                                    indicate the impact of these losses
                                                                                       delivered to OEMs and their Tier suppliers                                                  do to highlight this issue to
                                         When Ford was looking for ways to                                                          can mount up to $100 billion across                                                      on the United Nations to hold urgent
                                                                                       on time. Consistent quality, integrated
                                         improve the crash performance and                                                          low and middle income countries, and           our employees is welcomed.”               ministerial summit on the issue and to
                                                                                       supply chains and timely supply are all
                                         lightness of its latest Galaxy model, Corus                                                more than $500 billion globally when                                                     support increased funding for traffic injury
                                                                                       critical factors that need to be satisfied.
                                         was ready with its High Strength Steels                                                    including developed countries. Only                                   Philippe Varin,    prevention.
                                                                                       To meet these needs, Corus has its own
                                         and the advanced automotive engineering                                                    AIDS kills more young men. Reducing                         Chief Executive of Corus
                                                                                       TS16949 accredited distribution network,
                                         services needed to implement them in                                                       this horrendous tally has become a truly                                                 Anybody wishing to sign the petition
                                                                                       including numerous pre-production
                                         body structures.                                                                           global challenge.                                                                        should visit www.makeroadssafe.org
                                                                                       capabilities at service centres around the                                                Triathlon event in Corby, and amongst
                                         When Mitsubishi wanted help to improve        world for de-coiling and blanking sheet                                                   local schools. Corus has also run a Make
                                                                                                                                    In May 2007, Corus became the first
                                         press-shop performance on its five-            steel, including more recently, a new                                                     Roads Safe Roadie game competition,
                                                                                                                                    steel company to sponsor the global
                                         door Colt model, Corus was ready with         service centre near Györ in Hungary.                                                      giving away a Nintendo Wii to the winner.
                                                                                                                                    Make Roads Safe campaign, which aims
                                         a unique portable measurement and                                                                                                       Commenting on the announcement of
                                                                                       When BMW wanted to use extra-thick           to raise public and political awareness
                                         analysis system, PHAST™ and In-                                                                                                         Corus’s sponsorship, Edmund King,
                                                                                       sheet steel bodysides for its new Mini       of this road traffic accident epidemic.
                                         Form™, which helped NedCar to improve                                                                                                   Executive Director, RAC Foundation said:
                                                                                       Cabriolet (compensating for the lack of      Coordinated in the UK by the RAC
                                         capability in its bodyside stamping                                                                                                     “As part of our drive to raise awareness
                                                                                       roof), Corus was ready with a large-bed      and FIA Foundations and backed by
                                         process. It is a common story with our                                                                                                  of the real human and economic cost of
                                                                                       press blanking line, capable of pressing     organisations including RoSPA, the British
                                         OEM customers.                                                                                                                          this growing issue, it’s important to get
                                                                                       out blanks up to the required 3mm            Red Cross, PACTS, ROADSAFE and
                                                                                                                                                                                 support from the commercial sector and
                                         Innovation in everything                      thickness. The Wednesfield Automotive         Transaid, the Make Roads Safe campaign
                                                                                                                                                                                 from companies such as Corus. Corus
                                         Our customers don’t just buy our metal,       Service Centre that supplied these           is calling on governments and the United
                                                                                                                                                                                 is a company that combines research         Contact: Sarah Middleton, Manager
                                         they buy the thinking and innovation          blanks boasts a comprehensive line-up        Nations to tackle the unreported growing
                                                                                                                                                                                 and development with steel expertise to     Market Communications & Branding
                                         that have gone into its development and       of dedicated automotive processing           epidemic of road deaths and injuries in
                                                                                                                                                                                 offer on-going material innovations that    t: +44 (0) 1536 404325
                                         distribution and gain from the technology     facilities. A range of automotive            the world today.
                                                                                                                                                                                 contribute to improved vehicle passenger    m: +44 (0) 7775 676259
Contact: Clive Sutton                    we have invested in to help them deploy       customers, including Land Rover, benefit
                                                                                                                                                                                 and pedestrian safety.”                     e: sarah.middleton@corusgroup.com
Manager Marketing                        that metal in the most effective way          from the full-bodyside-capable 400 and       Since then, Corus Tubes have been
t: +44 (0) 2476 241253                   – ‘intelligent metal’.                        600-tonne blanking lines, and a Tailor       encouraging its employees to sign the
m: +44 (0) 7802 682617                                                                 Welded Blank facility to create blanks for   petition to heighten awareness, and it has
e: clive.sutton@corusgroup.com           One example of this is the hands-on           door and body-structure parts.               been promoted at the Corus Kids of Steel

Article: Corus                                                                                                     Images: Corus    Article: Corus                                                                                 Image: Make Roads Safe campaign

 6                                                                                                                                                                                                                                                                  7
The new Detroit?
                The Russian car industry has been on a rollercoaster ride since the fall of Communism in 1990
                - but things are changing for both car makers and their suppliers – in a dramatic way.
                by Mark Bursa, Emerging Markets Editor, Just Auto




Back in the 1990’s, carmakers, starved       Development and Trade Ministry, vehicle       and running as early 2008. Located in           allow us to offer our unique capabilities to   models, AvtoVAZ is gearing up for the        AvtoVAZ. It’s also done a deal with GAZ,
of investment for years, scrambled           output in Russia could hit 3 million units    the town of Shushary, it will produce           other major OEMs that have established         future. Rosoboronexport, the state-          Russia’s second-largest producer, to
to get into bed with foreign partners.       a year by 2010, including more than 1         approximately 50,000 Camrys a year.             themselves in the region including Nissan,     owned Russian armaments company, was         build Chrysler Sebring and Dodge Stratus
But just as these deals were maturing,       million foreign-brand cars assembled in       Suzuki is also moving in to St Petersburg,      GM, Toyota and Suzuki.”                        put in control of the car maker in 2005.     models at GAZ’s Nizhny Novgorod plant.
the wheels came off the Russian              the country. This is more than double the     but is taking a more cautious approach,                                                        And at the end of 2006, AvtoVAZ, agreed      - MagnaSteyr has long been assembling
economy in spectacular fashion. As           expected output for 2007, where Russian       planning a CKD plant that will build            The Russian car industry may be                an outline plan to build a new plant in      Mercedes, Jeep and Chrysler models
the Rouble headed south, the effect          companies are forecast to produce             10,000 Grand Vitara SUVs a year from            concentrating in St Petersburg, but other      partnership with Magna International,        for DaimlerChrysler, notably at Graz in
on the car industry was catastrophic.        860,000 vehicles.                             2009.                                           manufacturers have set up elsewhere.           the Canadian-owned supplier whose            Austria.
Planned joint ventures were put on                                                                                                         Renault is in Moscow – its Avtoframos          MagnaSteyr division undertakes contract
hold, prices crashed and credit became       Foreign joint ventures are driving much       Why invest in Russia?                           plant, a JV with the Moscow city               manufacturing for automakers. This           “We are proud that we are in such contact
unavailable. Selling cars became a very      of the growth. Ford and Renault for           With the rapidly-expanding Russian              government, occupies the factory that          partnership will see a new family of cars    with the two major Russian carmakers,”
tough game indeed.                           example have pioneered local assembly,        market rising more than 20% in 2006, the        once built Moskvich cars. In May, the          brought to market to replace the Ageing      Magna co-CEO Siegfried Wolf said. The
                                             and Ford’s St Petersburg plant is seen        growing concentration of automakers is          partners agreed to expand the operation        110 series range, and a new 450,000-         Magna-GAZ venture will adapt Chrysler
But in a way, that economic crisis was       as the blueprint for market entry. Toyota,    good news for suppliers. All the market         to 160,000 cars a year, at a cost of           unit factory set up at Togliatti. At the     cars for the Russian market, with many
no bad thing. The cautious approach          Nissan, Suzuki and General Motors have        entrants are looking for high-grade parts,      $150m. The plant will concentrate on           Geneva show, AvtoVAZ showed a new            parts made locally. GAZ last year acquired
taken by manufacturers such as Ford,         all announced similar plans to build plants   and they need to source them locally to         building the hugely successful Renault         concept car, the Lada C, which is the        UK-based van-maker LDV, and has hired
Renault and General Motors at the time,      nearby. And judging by the performance        take advantage of tax and duty benefits.         Logan “world car” – including a new            first evidence of the cars it plans to        former Ford of Europe boss Martin Leach
meant the market didn’t overheat. And        of the $330m Ford St. Petersburg plant        The ability to supply the same component        version of the car. Logan is the best-         make with MagnaSteyr. The Lada C is an       to run this operation and develop new
the surviving domestic car makers such       (built to make 25,000 units a year but        types to a variety of manufacturers makes       selling foreign saloon in Russia.              aggressive-looking C-segment three-door      business for GAZ – and the MagnaSteyr
as AvtoVAZ and GAZ gained a bit of           scheduled to make 125,000 by 2009), the       the investment in a Russian plant more                                                         hot hatch, powered by a 2-litre gasoline     deal is part of this.
breathing space too.                         potential on offer is obvious.                viable. One parts maker that has taken          Fiat is also making a much-delayed             engine. Based on a new platform, it will
                                                                                           this option is body stampings specialist        re-entry to Russian car market, building       spawn a family of cars, including a sedan,   Finally, it looks like Russia is coming good
Since then, the Russian economy              As Ford announced its expansion, Nissan       Stadco, which signed a letter of intent         its own Punto-based Linea saloon with          a five-door hatch, a compact MPV and a        as a car market – and for suppliers such
has recovered strongly, and powerful         was cutting the ground at its own $200m       in June with the Leningrad regional             Severstal Avto in Tatarstan province in        crossover, according to Lada spokesman       as Stadco, MagnaSteyr and others, it’s
businesses have emerged – for example        St Petersburg plant, which is due to open     government to build a dedicated body            2008. Perhaps even more significantly,          Denis Metalnikov.                            clearly the place to be.
steel suppliers like Severstal, which took   in early 2009. At full capacity, the plant    in white (BIW) stampings and assembly           Fiat is in talks with the dominant Russian
the logical step of buying up some of        will produce around 50,000 vehicles a         facility - the first such operation to be        domestic automaker, AvtoVAZ, with a            Strong sales in Russia have kept AvtoVAZ
the struggling car makers to which it        year and employ up to 750 people from         established in Russia by a European             view to making engines in Russia.              alive – the company still builds around
supplied its products. And foreign auto      the local region. It’ll build two models      supplier.                                                                                      700,000 cars a year, and is currently
makers finally put their planned market       – a large Japan-market sedan called the                                                       This would be an amazing return                profitable. But despite growth of around
entry strategies into operation, with many   Teana, followed by the X-Trail SUV.           Initially this will serve the Ford plant from   – AvtoVAZ is known in the west as              8% last year, AvtoVAZ is losing ground
concentrating their activities around St                                                   January 2009, but Stadco managing               Lada, and its business was built on the        in the rapidly expanding Russian market.
Petersburg, Russia’s second city, now fast   General Motors is expected to open            director Andrew Morriss believes it will        old Fiat 124, which Fiat licensed to the       New models remain an imperative.
becoming Russia’s “Detroit”.                 its $100m, 25,000 cars a year plant           lead to more business: “The location of         Russians in the early 1970s. Much has
                                             just down the road around the same            our 15-hectare site in Vsevolozhsk in           changed since then. Although the old           Finally coming good
From Bear to Bull                            time. Toyota’s new assembly plant,            the St Petersburg area is convenient for        124, or Zhiguli, as it’s known locally, is     MagnaSteyr is becoming a major player
According to Russia’s Economic               already under construction, may be up         Ford, and the site is also well located to      still being made alongside newer Lada          in Russia - its links are not limited to

Article: Mark Bursa, Just Auto                                                                                                                                                                                                                    Images: Mark Bursa, Just Auto

 8                                                                                                                                                                                                                                                                            9
Developments in valve                                                                                                                 AHSS - what is it?
spring steels                                                                                                                         The generic term AHSS describes
                                                                                                                                      the range of high performance steels
                                                                                                                                      being used by carmakers worldwide, to
                                                                                                                                                                                                     Stress/Strain comparison of HSLA and Dual Phase steel

                                                                                                                                                                                                     700
                                                                                                                                      implement stronger and safer vehicle
Corus Wire Rod business at              Springs for engine valves are the most         A trial rolling was carried out in the rod     structures. But what is AHSS and                               600
Scunthorpe is joining a select group    demanding application. During the lifetime     mill to produce 5.5mm diameter rods from       how does it work? Dr David Hanlon of
of global steelmakers able to supply    of the engine, these springs will undergo      this modified steel specification, including                                                                    500
                                                                                                                                      Corus R&D explains:
ultra clean steel in wire rod form to   constant high stress cycles while the          use of some experimental cooling




                                                                                                                                                                                      Stress (MPa)
the automotive industry. These steels   engine is in use and this results in fatigue   regimes. Detailed microexamination                                                                            400
                                                                                                                                      The AHSS steel family incorporates
are used to manufacture springs         strength being a critical requirement. The     of rod coils demonstrated that the             a broad spectrum of elemental                                  300
for a range of applications such as     steel rods required to manufacture these       microstructure was free from martensite.       compositions and microstructures,
suspension springs, clutches and        springs require very low levels of non-        Corus works closely with key companies         optimised so they exhibit a wide range of                      200
springs for engine valves.              metallic inclusions, and this demands          involved in the spring manufacturing           properties. Common AHSS steels include
                                        tight control of chemical composition and      industry as part of the process to develop     Dual Phase (DP), Transformation Induced                        100
                                        mechanical properties during steelmaking       and test spring steels. Joint testing and      Plasticity (TRIP), Partially Martensitic (PM)
                                        and rolling. Within the industry, valve        development of new products ensures            and Complex Phase (CP). Advanced High                          0
                                        spring steels are known as 55SiCr6             that industry specifications are achieved,      Strength Steels (AHSS) are distinguished                             0               10                 20                    30
                                        and the wire rod business has supplied         and products are optimized to suit             in terms of special microstructures and                                                     Elongation (%)
                                                                                                                                                                                                     Key
                                        them to customers in diameters of 7mm          individual company processes. Corus            properties, many of them metallurgically
                                        and upwards for drawing and spring             has worked with Haldex Garphyttan in                                                                                HSLA          Dual Phase
                                                                                                                                      defined as ‘multiphase steels’. ‘Phases’
                                        manufacture.                                   Sweden, and most recently with J Pengg         in this context describe the crystalline
                                                                                       in Austria.                                    forms of steel that are induced by                                                                   If we compare the stress strain curve of
                                        Corus is keen to continue developing its                                                      their inherent chemistry and by the                                                                  a DP grade with a similar yield strength
                                        position in the market for spring steels,      As part of the current development for         combination of controlled heating and                                                                High Strength Low Alloy (as graph above),
                                        and recent research and development            5.5mm diameter rods, a trial coil has been     cooling rates applied during manufacture.                                                            we see DP steel gains relatively higher
                                        activity has focused on development            supplied from the rod mill to J Pengg.         AHSS steels owe their performance to                                                                 levels of strength after yield. This effect
                                        of smaller diameter rods down to               This company successfully drew the rod         carefully engineered microstructures                                                                 is seen in most metals and is known as
                                        5.5mm diameter, which are suitable for         to wire without the use of heat treatment.     comprised of two or more of these                                                                    work hardening. In the case of DP steels
                                        direct processing by customers. This           Following the success of this trial, further   phases.                                                                                              the presence of hard islands of martensite
                                        is a challenging development, because          work is planned at Corus’ Wire Rod
                                                                                                                                                                                                                                           both suppresses the yield strength of the
                                        narrower diameters result in faster cooling    business to continue developing supply         Since DP steel is the class of AHSS most
                                                                                                                                                                                                                                           ferrite matrix and enhances its capacity
                                        rates, and the risk of formation of hard       of valve spring steels for the automotive      widely used in the automotive sector, a
                                                                                                                                                                                                                                           for work hardening. Taken together, these
                                        and brittle martensite.                        market.                                        brief description follows. (TRIP, PM and          Above: Tint etched micrograph of a
                                                                                                                                                                                                                                           features of DP steels offer a number of
                                                                                                                                      CP grades will be covered in more detail          DP600GI illustrating a microstructure
                                                                                                                                                                                                                                           significant benefits to car makers, as they
                                        In order to understand the relationship                                                       in future editions of emotion magazine)           typical of DP steels. Discrete islands of
                                                                                                                                                                                                                                           are stronger (meaning less is needed)
                                        between prior austenite grain size, cooling                                                                                                     white etching martensite are distributed
                                                                                                                                                                                                                                           but still formable (meaning it can still be
                                        rate and microstructure, a series of                                                          Dual Phase (DP) Steels                            throughout the brown etching ferrite
                                                                                                                                                                                                                                           pressed into parts). One major benefit to
                                        laboratory heat treatments were carried                                                       DP steels are a subset of the AHSS steel          matrix.
                                                                                                                                                                                                                                           carmakers is that well designed, structural
                                        out to derive the critical cooling rate                                                       family, and are typically produced in a
                                                                                                                                                                                                                                           components in a car made from DP steels
                                        above which martensite will form for a                                                        range of strengths between 450-1000MPa
                                                                                                                                                                                        hardening rates and also they typically            can be lighter, but still absorb high levels
                                        range of reaustenitising temperatures.                                                        (and may be supplied as hot or cold-rolled
                                                                                                                                                                                        possess a very good combination of                 of energy in a crash.
                                        This work has been supplemented by a                                                          and as either coated or uncoated coils).
                                                                                                                                      All DP steels exhibit microstructures             strength and formability, meaning they
                                        series of mill trials carried out at the rod
                                                                                                                                      comprised of a ferrite matrix containing          are generally well suited to a wide range
                                        mill to determine the effect of rod size
                                                                                                                                      hard islands of martensite. The principal         of engineering applications. Compared to
                                        on the prior austenite grain size, tensile
                                                                                                                                      DP strengthening mechanism is described           most other members of the AHSS family,
                                        properties and microstructure.
                                                                                                                                      as ‘composite hardening’ and its strength         DP steels also have good spot weldability
                                                                                                                                      is largely determined by the hardness             performance. However, DP steels are not
                                        Most recently, a lower silicon trial steel
                                                                                                                                      and amount of martensite in the final              without their disadvantages, and these
                                        cast was produced (within the allowable
                                                                                       Contact: Paul Lyons, Business                  microstructure.                                   include having a relatively high sensitivity
                                        limits of the specification) and tested in
                                                                                       Development Manager, Wire Rod                                                                    to edge cracking (e.g. flangeabilty and             Contact: Dr. Dave Hanlon, Corus
                                        the laboratory. This demonstrated that
                                                                                       t: +44 (0) 1724 405198                         DP steels exhibit a unique combination            hole expansitivity are generally low), and a       Research Development & Technology
                                        the critical cooling rate for martensite
                                                                                       m: +44 (0) 7711597424                          of properties and exhibit both continous          tendency to undergo shear fracture before          t: + 31 (0) 2514 96399
                                        increased due to the lower hardenability.
                                                                                       e: Paul.A.Lyons@corusgroup.com                 yielding and very high initial work               the onset of local necking.                        e: dave.hanlon@corusgroup.com

Article: Corus                                                                                                      Images: Corus     Article: Corus                                                                                                                     Images: Corus

10                                                                                                                                                                                                                                                                               11
                                                                                                                                                                                                                                                                                 11
Steel: fundamental in a
low CO2 future
Concerns over global warming and potential legislation to curb                     - an equivalent aluminium BIW weighs 216kg. For vehicles such


                                                                                                                                                        Onto the big stage
vehicle CO2 have accelerated research and development across                       as these, the University of California’s Life Cycle Assessment
a wide range of advanced vehicle technologies.                                     calculates a fuel saving of 0.2l/100km per 100kg weight saving.

Raising powertrain efficiency and vehicle downsizing will                           The graph below illustrates the pay back period resulting from
undoubtedly make the biggest contribution to reducing CO2                          this switch from steel to aluminium. The green house gas (GHG)
emissions. Research by TNO (the Netherlands Organisation for                       emissions are calculated in terms of Carbon Dioxide equivalence      Three years on from the award of a             set up a dedicated production line at its   to ensure best results. We worked to
Applied Scientific Research) found that weight reduction makes                      (CO2eq). The higher CO2eq from primary aluminium manufacture         landmark contract for the supply of            Zwijndrecht mill site – chosen because      guarantee the relative tight dimensional
a much smaller, but significant, contribution of between 3.5 and                    negates the beneficial effects of lightweighting, resulting in a      specialised tubes for hydroformed              of investment and developments made         tolerances on gauge, diameter and
6.5% CO2 reduction for every 10% weight saved*.                                    pay back distance between 180,000 and 200,000km. As part of          parts, new doors are opening for               for series production of the tubes using    length.”
                                                                                   this assessment the benefits of recycling at end-of-life were also    Corus. With tube production ramping            formable low carbon steel and high
Aluminium can provide component weight savings between                                                                                                  up to over 100,000 vehicle sets per            strength low alloy steels. Hugo: “It is     Ideal for chassis products
                                                                                   included.
20 - 45%, (see Table 1.) Where economics allow, a vehicle                                                                                               year in 2005, the pressure was on for          simply essential to be able to repeat the   Hugo is keen to invest further in capacity
manufactured with aluminium BIW (Body-In-White) and closures                       More exotic materials, such as carbon fibre reinforced                Corus Tubes to maintain the supply of          product on a reliable and continuous        and enlarge the size range of material
may account for a 5% reduction in the weight of the final vehicle.                  composites, also require large amounts of energy to manufacture      high quality tubes to the hydroformer,         basis”.                                     suitable for structural applications, he
However it takes many thousands of kilometres of vehicle use                       the raw material feedstock. Furthermore, carbon fibre                 Finow Automotive in Germany. Zero                                                          maintains that success with CSL “ Put
to ‘pay back’ the extra CO2 produced from the manufacture                          manufacturing requires lengthy thermal processes that also           defects was – and still is – the name of       Robert Flipsen, Business Development        us onto the big stage and opened new
of (mostly primary) aluminium relative to the steel in an AHSS                     generate large amounts of GHGs.                                      the game.                                      Manager Corus Tubes agrees.                 doors”. He says: “People are curious to
intensive design.                                                                                                                                                                                      “Customers expect us to be very             see what we’re doing - we have made
                                                                                   In conclusion, alternative materials do not appear to have the       No rest                                        responsive. It’s a strict and demanding     new contacts.”
Table 1: Alternative materials - potential weight saving vs cost                   big environmental benefit that was originally expected; however       Hugo de Zeeuw, Business Director Corus         environment and we’ve proven that it is
                                                                                   they continue to gain acceptance in high performance vehicles        Tubes – Automotive and Engineering,            essential to work closely according to      Robert Flipsen believes the business is
              steel   aluminium magnesium   % weight reduction       % cost
                                                                     increase      where weight saving can both contribute to acceleration figures       likens the challenge to that of a top-         the customer’s demands in order to be       ready to exploit new market opportunities.
              (kg)     (kg)      (kg)       (part)    (vehicle)       (part)       as well as benefiting handling. For the foreseeable future we         flight football team aiming to retain its       successful. As a result, we are gaining a   “The Land Rover Discovery 3 has been
Body in         285     218       N/A        23.5       3.90           250         therefore expect the majority of high volume A, B, C and D           championship spot. “Chassis Systems            reputation for reliability and quality”     a landmark programme for Corus Tubes
                                                        example
white                                                 vehicle mass                 segment vehicles to remain steel intensive, especially in light of   Limited (CSL), our Tier 1 customer, are                                                    and has opened up the market for us”
(BIW)                                                  of 1700kg
                                                                                   the continuing development and availability of ever more high        satisfied and we believe we are ahead of          “...Put us onto the big                   says Robert. “We have also won other
Bonnet         14.8     8.3       N/A        44          0.48         300          performance grades.                                                  the competition in terms of technology,                                                    business, producing up to 3,000 tonnes
(assembly)                                              example
                                                      vehicle mass
                                                                                                                                                                                                         stage and opened new
                                                       of 1350kg                   Illustrating the pay back period resulting from the switch           equipment levels and the way we are                                                        of precision tube per year for production
Door           15.7     9.5       N/A        39          0.40         275          from steel to aluminium.                                             organised, plus our logistical performance       doors...People are curious                of the Ford Transit underbody at GKN
                                                                                                                                                                                                         to see what we’re doing
                                                        example
(assembly)                                            vehicle mass                                                                                      is also very good. But we are not taking                                                   Autostructures at Telford in the UK. We
                                                       of 1550kg
                                                                                                              Crossover distance                        a rest – it is possible for a competitor to                                                are also involved in projects with other
                                                                                                                                                                                                         - we have made new
                                                                                  CO2 eq




IP Beam        11.4     N/A       6.3        45          0.33         350                                                                               surface in as little as two years, so we are                                               Tier 1’s which will hopefully lead to
(instrument                                             example
panel                                                 vehicle mass
                                                       of 1550kg
                                                                                                                                                        committed to continual improvement.”             contacts.”                                business. Since we’ve spent more time
support)
                                                                                                                                                                                                                                                   exploring the automotive market we are
                                                                                                                                                        Engineering help and production                     Hugo de Zeeuw, Business Director
For some time it has been accepted that this pay back distance                                                                                                                                                                                     finding it’s an area where our tubes are
                                                                                                        Vehicle use                                                                                            Corus Tubes – Automotive and
                                                                                                                                                        consistency are key                                                                        turning out to be ideally placed for those
for an aluminium vehicle is around 85,000km, or 1/3rd of the
                                                                                                                                                        Hugo maintains that two major elements                                  Engineering
vehicle’s life. However, recent research by Roland Geyer of the                                                                                                                                                                                    that make chassis components”.
                                                                                                                                                        have contributed to the success story so
School of Environmental Science and Management, University of
                                                                                                                                                        far. The first is Corus involvement, right      The road to success
California, has found the pay back period to be closer to 200,000
                                                                                                                                                        from the beginning, in the development of      Line Manager at Zwijndrecht, Hoessein
km.
                                                                                                                                                        technology for the vehicle’s hydroformed       Chouaati, has worked on the programme
If this proves to be true, it means that an aluminium intensive                                                                                         chassis. It is an approach that Corus          since the outset. He says: “The biggest
vehicle will only start to be of benefit to the environment as it                                                                                        Tubes is repeating with other automotive       challenge was to consistently achieve
reaches the end of it’s life.                                                      Material                km (1,000s)                                  customers.                                     the right fit-for-purpose mechanical
                                                                                   production
                                                                                                                                                                                                       properties. For this reason, a complete
                                                                                   Key                                                180 - 200
For example: an ‘average’ European B segment vehicle weighs                                                                                             The second key to success, according           mill section was designed and installed     Contact: Sarah Middleton, Manager
1260kg and has a fuel consumption of 6.4l/100km (44mpg).                                   HSS            Aluminium
                                                                                                                                                        to Hugo, has been our ability to create        to minimise the work hardening of the       Market Communications & Branding
Contributing to that 1260kg is a steel BIW that weighs 270kg                       Contact: Andy Clough, Senior Consultant, Corus Automotive            and maintain a repeatable production           material during tube manufacturing. The     t: +44 (0) 1536 404325
                                                                                   t: +44 (0) 2476 241215                                               process. When Corus Tubes began                material was selected with Corus Strip      m: +44 (0) 7775 676259
* Review and analysis of the reduction potential and costs of technological and
other measures to reduce CO2-emissions from passenger cars, TNO, Oct 2006          e: andy.clough@corusgroup.com                                        cementing its relationship with CSL, it        and Corus Automotive Engineering            e: sarah.middleton@corusgroup.com

Article: Corus                                                                                                                   Table & graph: Corus   Article: Corus                                                                                                           Table: Corus

12                                                                                                                                                                                                                                                                                       13
                                                                                                                                        Alumni gather
                                                                                                                                        A year of Corus sponsorship of the                                       students have benefited greatly from                          recent trends and advances in the use
                                                                                                                                        Royal College of Art’s ‘Connections’                                     the extensive materials know-how that                        of materials. Because the automotive
                                                                                                                                        project, will reach a climax on the 7th                                  an industry leader such as Corus is                          industry is constantly changing, it remains

SmartLite™: automotive potential                                                                                                        December 2007, at an ‘alumni’ night,
                                                                                                                                        where students, sponsors and big
                                                                                                                                        names in the vehicle design world will
                                                                                                                                                                                                                 able to provide. It is the kind of industry
                                                                                                                                                                                                                 involvement that is giving our students
                                                                                                                                                                                                                 the opportunity to generate innovative
                                                                                                                                                                                                                                                                              critical that they are able to adapt
                                                                                                                                                                                                                                                                              their approaches and ideas whilst also
                                                                                                                                                                                                                                                                              understanding the consequences of their
                                                                                                                                        gather in London. Corus will present a                                   designs which really do follow the most                      choices.”
Making complex and lightweight              SmartLite™ and automotive                      a welded component is the ‘twistlock’
                                                                                                                                        prize to the best individual design.
components takes more than just             Aggressive weight reduction ambitions in       used by Dutch trailer manufacturer D-
materials technology, it takes              the transport industry mean SmartLite™         TEC. These twistlocks are used as the
                                                                                                                                        The Royal College of Art’s Vehicle Design
innovation and engineering know-how.        ready-to-use cast components can               means of locking sea-containers onto
                                                                                                                                        Department is the world’s only wholly
These two capabilities are exactly what     provide ideal alternative and cost-effective   heavy goods trailers. As highly loaded
                                                                                                                                        post-graduate university of art and
is offered by Corus SmartLite™ (a spin-     solutions for this market. Good examples       components, they need to be tough and
                                                                                                                                        design. The connections project has
off from Corus Technology BV).              where SmartLite™ can give a weight and         durable to withstand the considerable
                                                                                                                                        sought to generate innovative mobility
                                            cost advantage in the transport market         in-use and abusive loadings in daily
                                                                                                                                        solutions for those living in rural areas.
Corus SmartLite™ is a unique and            are structural chassis components or           service. Besides being cost competitive,
                                                                                                                                        During the design project, Corus has
complete solution for lightweight cast      interior part applications.                    the Corus development of this product
                                                                                                                                        been on-hand to provide the students
iron components where the ability to cast                                                  using SmartLite™ has resulted in a weight
                                                                                                                                        with an insight into the impact of future
high strength parts with wall thicknesses   Real advantages                                saving of almost 50%.
                                                                                                                                        technologies, and the most effective use
down to 2mm is critical. Using thin-        The Corus patented SmartLite™
                                                                                                                                        of steel materials and technologies.
walled material, the SmartLite™ process     casting process is based on normal             A second automotive product is an
offers excellent strength and fatigue       sand casting, but delivers parts with an       armrest support for BM-Constructions.
                                                                                                                                        Commenting on the project, Professor                                       The overall group winners were Sergio Loureiro da Silva, Ilaria Sacco and Yunwoo
performance characteristics for complex-    exceptional combination of properties          Whilst a more modest weight advantage
                                                                                                                                        Dale Harrow, Head of Vehicle Design                                        Jeong for their transport system that links the home, car and public transport through
shaped components. It is also able to       and wall thicknesses without making            has been realised, a considerable cost                                                                                  information technology.
                                                                                                                                        Department at the RCA said “Our
overcome the limitations of traditional     any concessions to strength or fatigue         saving has been achieved, since the



                                                                                                                                        WIN One of 20 portable toolkits
casting methods which are only able to      performance. The latest SmartLite™             component was previously fabricated
produce fully nodular (not brittle) cast    product is a “Safety gripper” developed        from 7 individual machined parts.
iron down to 5mm. Thus SmartLite™           for the UK company, Cable Safe.
can achieve lightweighting by replacing     Compared to the original product, this         Under one roof
existing (heavy) cast products, or          new design of gripper is stronger, has         With SmartLite™, Corus differentiates                                                     By taking a minute to                                          Compared to the other steel publications you
substitution of welded or machined steel    improved aesthetics, has a lower cost          itself in the approach it takes to                                                                                                                       read, please rate emotion magazine for the
components. SmartLite™ is completely        price and a more robust failure mode,          application and the end-product supply                                                    complete and return this                                       following:
recyclable, offers corrosion resistance,    since no welds are used.                       chain. Corus offers the design, materials,                                                                                                                                         Disagree         Agree
has strengths comparable to steel plate                                                    engineering applications and foundry/
                                                                                                                                                                                     short survey, you could
and has proven fatigue and creep-           50% weight saving potential                    manufacturing expertise all under one                                                     win one of these useful                                        “It is relevant to my job”
resistant qualities.                        In automotive, one example of a                roof. Every part of the supply chain is
                                            lightweight SmartLite™ alternative to          taken into account during the engineering                                                 toolkits.
                                                                                           phase, meaning that the final design
                                                                                           gives the best possible component with                                                                                                                   “I learn by reading it”
                                                                                           regards to weight, cost and strength. The
                                                                                                                                        Name: .............................................................................................
                                                                                           end result inevitably accounts for all the
                                                                                           requirements of design, performance,
                                                                                           ergonomics and safety.
                                                                                                                                        Job Title: ........................................................................................         “I hand it on to a colleague”
                                                                                                                                        Company Name: ...........................................................................
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                                                                                                                                        Address: ........................................................................................
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                                                                                                                                        Post Code: .....................................................................................            ..........................................................................
                                                                                           Contact: Justus de Wit
                                                                                           New Business Development                     Country: .........................................................................................               Photocopy then fax this page to
                                                                                           t: +31 (0) 2514 91096
                                                                                           e: Justus.de-Wit@corusgroup.com              Email: .............................................................................................                       +44 (0)1322 421552
Article: Corus                                                                                                         Image: Corus     Articles: Corus                                                                                                                               Images: Corus/Royal College of Art

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