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  Fire resistance of innovative and slender concrete filled tubular composite columns (FRISCC)
  Final report

  Concrete-filled steel tubular (CFST) members are commonly used as composite columns in modern buildings. However, current guidelines for member design in fire (EN1994-1-2) have been proved to be unsafe once the relative slenderness is higher than 0.5. In addition, the simplified design methods o...

  Concrete-filled steel tubular (CFST) members are commonly used as composite columns in modern buildings. However, current guidelines for member design in fire (EN1994-1-2) have been proved to be unsafe once the relative slenderness is higher than 0.5. In addition, the simplified design methods of Eurocode 4 are limited to circular or square CFST columns, while in practice columns with rectangular and elliptical hollow sections are being increasingly used because of their architectural aesthetics. This project aims at correcting the current simplified design methods of EN1994-1-2 for CFST columns, extending their applicability to elliptical and rectangular sections and developing new calculation rules for the fire resistance of circular concrete-filled tubular columns with embedded steel core profile. A new Simplified Design Method is proposed within this project and a user-friendly design tool is developed, based on the results of an extensive experimental program, followed by numerical modelling and comprehensive parametric studies. This project has delivered useful advances in the understanding of the fire performance of CFST columns. Additionally, the proposed design rules will be circulated through the Technical Committees of the Eurocodes for broader dissemination.

  • Published: 2016-10-13
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Iglesias, Gorka ; Gardner, Leroy ; Lozano, Carlos ; Laim, Luís ; Bihina, Gisèle ; Kleiboemer, Inka ; Christophe, Renaud ; Schaumann, Peter ; Romero, Manuel L ; Espinós, Ana ; Rodrigues, Joao Paulo
  • Subject: advanced materials, building industry, building materials, fire protection, industrial research, iron and steel industry, iron and steel product, materials technology, metal structure, research project, research report, resistance of materials, special steels, steel
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  Development of a toolbox for direct defect prediction and reduction through the characterisation of the meniscus-slag bed behaviour and initial shell solidification in CC (DIRECT DEFECT TOOLBOX-DDT)
  Final report

  The aim of this project is to produce a set of novel numerical and experimental tools to predict explicitly the formation of defects. These tools imply the development of new measuring/modelling techniques and improved physics to understand the CC process. The output of the project will be a “to...

  The aim of this project is to produce a set of novel numerical and experimental tools to predict explicitly the formation of defects. These tools imply the development of new measuring/modelling techniques and improved physics to understand the CC process. The output of the project will be a “toolbox” including measurement methods, experimental set-ups and numerical models. This project seeks to directly determine the transient occurrence of defects and process problems during slab casting of peritectic and Advanced High Strength Steels. Direct-defect prediction is possible through numerous plant trials and liquid-metal experiments to characterise the heat-transfer and dynamic behaviour of the slag-bed and meniscus (particularly, at the meniscus where initial solidification occurs). A series of different types of plant measurements have been performed at SSAB Luleå and Tata Steel, Ijmuiden. These measurements have generated input data for numerical models but it has also generated process knowledge for the plants. Extensive parametric campaigns have been performed in the liquid metal model (CCS1). And the findings in the metal level are in remarkable agreement with plant operational practices, which shows the applicability of the Simulator as well as opening the possibility of using CCS1 as a benchmark for testing process conditions and translate them directly into the casting practice. Microstructural evolution including the apparition of cracks has been observed through novel in-situ experiments. Steel properties have been addressed through high temperature measurements in a Gleeble 3800 equipment. Numerical models have been developed that predict metal-slag-argon flows, heat-transfer, mould-oscillation, solidification, stress-strain and microstructural evolution of the shell. The potential use of the “toolbox” developed in the project has already been proved at SSAB and TATA. Two process changes at SSAB Luleå have been implemented based on the results in the project, it has been validated and the result is improved yield. One change has been implemented at TATA with decreased defects.

  • Published: 2016-02-18
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Van Der Plas, Dirk ; Jalali, Pooria ; Nilsson, Christer ; Jonsson, Thomas ; Mohammed, Azeem ; Mills, Ken C ; Shahbazian, Fatemeh ; Luo, Chunhui ; Björkvall, Johan ; Lee, Peter D ; Ramirez Lopez, Pavel ; Andersson, Peter
  • Subject: defective product, iron and steel industry, materials technology, metal by-product, metallurgical industry, metalwork, public conduct of debates, research method, research project, research report, resistance of materials, special steels, steel, testing
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  Advanced high strength cold rolled sheet steels (AHSS) with optimised profiling properties produced through different lines (AHSS-PROFILE)
  Final report

  The current work aimed to develop cold rolled steel sheets with Rm > 1000 MPa optimised for roll forming to be produced in existing continuous annealing lines with either gas (CAL-GQ) or water quenching (CAL-WQ) and in hot dip galvanising (HDG) lines. The result of the project is a significant i...

  The current work aimed to develop cold rolled steel sheets with Rm > 1000 MPa optimised for roll forming to be produced in existing continuous annealing lines with either gas (CAL-GQ) or water quenching (CAL-WQ) and in hot dip galvanising (HDG) lines. The result of the project is a significant improvement in roll formability for materials produced in all three lines, compared to state of the art materials of the same strength level. The three steels developed within the project also reached the target values in terms of bendability (Ri/t < 2) and hole expansion ratio (punched) >25%. For the HDG line, the optimum microstructure consisted of bainite and small amounts of untempered martensite to reach the necessary strength level. A key to produce these steels is to avoid polygonal ferrite by using a relative high annealing temperature and well balanced amount of hardenable elements. For CAL-GQ with overaging section, the optimum microstructure consists of lower bainite, tempered martensite, and possibly a few percent ferrite. The process window in this line is largest, even Rm > 1200 MPa materials were produced in this line with good formability. For CAL-WQ with tempering section, the optimum microstructure is a highfraction martensite DP steel tempered at relative high temperature. This steel can be produced with very lean chemistries but controlling the amount and distribution of martensite is challenging.

  • Published: 2016-01-05
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Jussila, P ; Rüskamp, A ; Haglund, A ; Lindell, D ; Winkelhofer, F
  • Subject: iron and steel industry, materials technology, research project, research report, resistance of materials, special steels, steel, technology assessment
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  Novel nano-structured bainitic steels for enhanced durability of wear resistant components: microstructural optimisation through simulative wear and field tests (BAINWEAR)
  Final report

  Nanobainitic steels present a very high strength/toughness as a consequence of their extremely fine microstructure. They have also demonstrated potential for wear-resistance applications. The aim of BAINWEAR is to investigate such microstructure-wear mechanisms relationship to develop a new fami...

  Nanobainitic steels present a very high strength/toughness as a consequence of their extremely fine microstructure. They have also demonstrated potential for wear-resistance applications. The aim of BAINWEAR is to investigate such microstructure-wear mechanisms relationship to develop a new family of bainitic steels with a unique combination of mechanical and wear properties. In this project, four different industrial applications with harsh requirements in terms of wear and contact fatigue have been selected: Mill rollers, Punches for cutting sheet metal, Ball bearings and Reducing elements in a shredder machine. For these applications, the main requirements and damage mechanisms have been investigated and defined. In parallel, work has been performed in characterizing three steel grades with potential to form nanobainitic microstructures. Transformation dynamics, resulting microstructure and mechanical properties have been analysed. After these development, the new materials in different microstructures have been subject to a battery of tests reproducing requirements from the studied applications. The new grades outperformed the standard 100Cr6 in pure contact fatigue conditions, while showing comparable abrasive wear resistance when treated at the same hardness level. Based on the results of these studies, grades were applied on the different industrial applications. Rollers matched the standard roller performance, slightly improving it in selected conditions. Sheet metal punches showed good results, particularly when coated. In bearing application, the new grades outperformed 100Cr6, approaching more expensive material options. Finally, in pure abrasion applications as in reducing elements on a shredder machine, the materials did not increase performance.

  • Published: 2019-03-14
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): García-Caballero, Francisca ; Sourmail, Thomas ; Prakash, Braham ; Vuorinen, Esa ; Pujante, Jaume ; Dierickx, Pierre ; Ferrer, Pere ; Dietrich, Dirk ; Hardell, Jens ; Moghaddam, Pouria Valizadeh ; Casellas, Daniel ; Llanos, Jose Manuel ; Soto, Aintzane ; Rementeria, Rosalia
  • Subject: iron and steel industry, metal product, metalwork, metalworking, research project, research report, special steels
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  Effects of corrosion on low-cycle fatigue (seismic) behaviour of high-strength steel reinforcing bars (Rusteel)
  Final report

  The dissipative capacity of modern r.c. and composite steel/concrete structures is directly related to the rotational capacity of the elements in which plastic hinges are located: it strictly depends on the geometrical and mechanical characteristics of the sections and, moreover, on the ductile ...

  The dissipative capacity of modern r.c. and composite steel/concrete structures is directly related to the rotational capacity of the elements in which plastic hinges are located: it strictly depends on the geometrical and mechanical characteristics of the sections and, moreover, on the ductile capacity of the steel reinforcing bars (deformation and dissipated energy). Nowadays the lowcycle fatigue/seismic behaviour of steel reinforcing bars is not well known and, at European level, no production control tests are prescribed for the mechanical characterisation of the seismic performance of reinforcing steels. This situation is well reflected in the framework of the revision of European standard EN10080 and in Mandate M115 which tends to harmonise production control for reinforcing steels also introducing low-cycle fatigue tests. Full knowledge about the effective ductility requirements imposed on bars by real seismic events is necessary: a detailed analysis of the ductility demand on reinforcements, considering both r.c. and composite steel/concrete structures, is consequently necessary and deeply analysed in the project. At the same time, the ductility capacity of steel reinforcing bars has been investigated considering also the detrimental effects due to aggressive environmental conditions, generally resulting in a progressive decrease of the mechanical characteristics of deformation, strength and dissipative capacity. The evaluation of the ability of corroded steel bars to still sustain the ductile requirements due to seismic action has been analysed, finally providing practical indications for the protection of bars from corrosion, in addition to what was already suggested by Eurocode 2.

  • Published: 2014-09-19
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Moersch, J ; Braconi, A ; Ascanio, C ; Caprili, S ; Apostolopoulos, C ; Bianco, L ; Finetto, M ; Salvatore, W ; Ferreira Pimenta, G
  • Subject: applied research, corrosion, industrial research, iron and steel product, materials technology, metalworking, research project, research report, resistance of materials, special steels, steel
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  New creep resistant stable steel for USC power (CRESTA)
  Final report

  This program targeted the development of new stable martensitic steel which is able to operate at higher temperatures and in more aggressive environments in steam power plants. The main results obtained are as follows: The current available thermodynamic tools give the wrong results in predictin...

  This program targeted the development of new stable martensitic steel which is able to operate at higher temperatures and in more aggressive environments in steam power plants. The main results obtained are as follows: The current available thermodynamic tools give the wrong results in predicting transformation temperatures and thermodynamic stability. Fundamental investigations need to improve databases, tools optimisation and calibration; The Z-phase steel is still not optimised: it is too brittle and the Z-phase is not stable; A more conventional steel without Nb has been developed; tests are promising, but due to late manufacturing the creep tests are currently still ongoing (extra project conclusion) (no longer than 15 000 hours); Fabricability and weldability of the Nb-free steel has been demonstrated: semi-industrial heat manufactured, thick pipe produced and steam line welded prototype realised. The target to avoid PWHT for thin weld has not been reached; The consortium lost one industrial partner; partnership decided to complete program in order to obtain the most available results and to increase the knowledge for further development of high temperature steel applications. In spite of the worldwide economic crisis, the consortium partnership appears to have the intention to continue the steel development activities. The 700 °C steam technology concept for the next generation power plant, nickel-based super alloys, is still not consolidated and an advancement in available steel technology base could generate, shortly, additional efficiency increases in coal consumption and in the reduction of CO2 generation. The consortium will propose a new RFCS program for further improvement in the composition of Nb-free steel and activities still running towards conclusion.

  • Published: 2014-01-31
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Di Gianfrancesco, Augusto ; Turconi, C ; Sommith, C ; Herhart, G ; Helmrich, A ; Pillot, S ; Hald, J ; Danielsen, H ; Chovet, C ; Matera, S ; Beal, B
  • Subject: heat-resisting materials, iron and steel industry, iron and steel product, materials technology, metallurgical industry, power plant, research report, resistance of materials, special steels, steel
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  Safe laser hybrid welding of structural steel by robust systems (HYBRO)
  Final report

  The project addressed the widening of the robustness of laser hybrid arc welding, LAHW, with fibre or disc lasers, for steel structures. The study particularly focused on applicability for two large scale demonstrators, namely an excavator part and a truck component. This involved challenging jo...

  The project addressed the widening of the robustness of laser hybrid arc welding, LAHW, with fibre or disc lasers, for steel structures. The study particularly focused on applicability for two large scale demonstrators, namely an excavator part and a truck component. This involved challenging joint edge variations as well as load conditions for fatigue and toughness. Fifteen truck beams were welded and success of the six fatigue tested beams has qualified them for a company internal business case evaluation. Two excavator booms were hybrid welded, compared to one arc-welded boom, which enabled the identification of challenges in joint fit-up and robustness for large parts. Additionally, wider mapping of the process capabilities was carried out, including its limiting welded joint imperfections and the mechanisms behind them. Apart from modelling and testing, methods like scanning the fit-up and the weld topology as well as high speed imaging of the process supported the robustness analysis. This resulted in a systematic quality tracking procedure. The 1040 experimental welding results and condensed process guidelines are stored in the HYBRO e-Archive, accompanied by publications. Six new hybrid welding technique options were studied, by certain arc and laser beam shaping in space and time. Three of those promising techniques, namely remelting of undercuts, LAHW twin arc and double-sided LAHW already meet quality criteria in ISO 12932:2013 and are ready to be implemented. The findings are very promising to enable more robust hybrid welding of structural steel applications with fibre or disc lasers.

  • Published: 2019-01-04
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Ilar, Torbjörn ; Tolf, Erik ; Frostevarg, Jan ; Kaplan, Alexander ; Gerritsen, Christoph ; Ohse, Peter ; Jansen, Ulrich ; Staufer, Herbert ; Kohler, Stephan
  • Subject: computer assisted manufacturing, industrial research, iron and steel industry, materials technology, production technique, report, research project, special steels
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  Ultra high-strength and ductile FeMnAlC light-weight steels (MnAl-steel)
  

  The aim of this project is to introduce and establish ultra high-strength and ductile light-weight steels containing high manganese, aluminium and carbon contents forindustrial production and applications for light-weight constructions. This class of steels is of great interest for the automotiv...

  The aim of this project is to introduce and establish ultra high-strength and ductile light-weight steels containing high manganese, aluminium and carbon contents forindustrial production and applications for light-weight constructions. This class of steels is of great interest for the automotive industry as new components with reduced weight and with increased crash performance can be realised. Simultaneously, the understanding of the physical metallurgical mechanismscausing outstanding properties needs to be clarified in order tooptimise the microstructures and the resulting mechanical properties. In preceding tests at the MPIE, results demonstrated the general processabilityof six different FeMnAlC alloys. Based on this study the industrial partners AMR, TKSE and VAS then investigated the feasibility of industrial up-scaling in 100 kg-scale laboratory tests and by applying processing parameters of industrial relevance.So hot strips of all compositions were produced by conventional ingotcasting and hot rolling. These were then pickled, cold rolled, annealed and Zn-coated.The produced cold strips were characterised in detail including special in-useproperties like investigations on metal forming, fatigue, corrosion and joining,which are especially relevant for applications in the automotive sector.The feasibility of using continuous casting and strip casting as possible industrial processing routes was tested for FeMnAlC steels. The investigations were completed with simulations of crash deformations of concretecar body components and their validation with experiments performed on real partsmade of FeMnAlC steel. The conclusion is especially focused on industrialup-scaling and risk assessment.

  • Published: 2013-04-15
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Samek, L ; Bausch, M ; Frommeyer, G ; Hofmann, H ; Soler, M ; Didier, M ; Balichev, E
  • Subject: alloy, industrial research, iron and steel industry, iron and steel product, motor vehicle industry, research and development, research report, special steels, steel
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  Building active steel skin (BASSE)
  

  The objective of the project was to develop a biomimetic energy harvesting system having the dual function of being the enclosing envelope of the building and the main provider of heating, cooling and hot water requirements for buildings. The system should be suitable for three climatic regions,...

  The objective of the project was to develop a biomimetic energy harvesting system having the dual function of being the enclosing envelope of the building and the main provider of heating, cooling and hot water requirements for buildings. The system should be suitable for three climatic regions, Southern (Spain/Italy), Northern (Sweden) and Temperate Europe (UK) During the first half of the project technology options were evaluated based upon state of the art and a workshop held with industry specialists to gather important stakeholders’ requirements. From these inputs, Key Performance Indicators (KPI’s) were developed setting the objectives for further development of the BASSE system. The BASSE system as defined comprises three main elements: A sandwich panel solar collector; A heat pump system including energy storage; A control and management system. A range of concepts were developed relating to each of these subassemblies and for the system as a whole. These were evaluated, using various methods including thermal analysis, against the key performance indicators, the expertise present within the project partners and the consideration of the existing steel sandwich panel manufacturing process. A BASSE system description including the above components was developed for a residential building, to show a real world scenario for the integration of the proposed BASSE system. A prototype of the system was developed, manufactured and installed on the Kubik test facility in Derio, Spain. The installation was used to validate the theoretical models developed to predict the system performance and refine the installation procedures for the system.

  • Published: 2019-05-21
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Garay, Roberto ; Perry, Tim ; Lindahl, Michael ; Bertucelli, Luigi ; Francesconi, Guido ; Harper, Colin ; Elguezabal, Peru ; Vairo, Guiseppe ; Holmberg, Ted ; Fuster, Almudena ; Gisbert Rueda, Jorge ; Svensson, Holger ; Toledo, Consuelo ; Simpson, Kevin ; Boudjabeur, Samir ; Rodriguez, Pilar ; Chica, Jose Antonio
  • Subject: building insulation, building materials, building technique, heating, housing, iron and steel industry, physical process, project evaluation, research report, special steels, steel
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  Seismic PROtection of INDUSTRial plants by enhanced steel based sYstems (PROINDUSTRY)
  Final report

  The PROINDUSTRY project developed and set up innovative seismic protection systems, both for the design of new industrial plants and for the retrofit of existing ones, based on seismic isolation and energy dissipation techniques. In order to reach these goals, a detailed study of the state-ofthe...

  The PROINDUSTRY project developed and set up innovative seismic protection systems, both for the design of new industrial plants and for the retrofit of existing ones, based on seismic isolation and energy dissipation techniques. In order to reach these goals, a detailed study of the state-ofthe- art concerning the analysis of risk associated to seismic event for different types of process plant was preliminary carried. A suitable procedure for the non linear-analysis of the selected case study was then studied and adopted for the seismic vulnerability assessment of 12 selected case studies through Incremental Dynamic Analysis (IDA). On the base of the peculiar vulnerability sources of each structure, three different devices were proposed: i) one innovative Isolation System (IS), obtained substituting the restrainers with a variable friction surface, ii) an asymmetric Steel Self Centering Device (SSCD), obtained introducing a supplemental pretensioning cable, iii) a torsional damper based on the MARTI system already developed by Maurer. The 12 case studies were retrofitted adopting the proposed systems and their effectiveness assessed through IDA. Considerations regarding inspection, maintenance and repair of the developed system are exposed, together with some technical drawings illustrating a possible retrofit solution of one case study were also proposed. To assess the actual behavior of the proposed devices, experimental tests were carried out and numerical/analytical models developed together with linear procedures for the design of structures retrofitted or designed with the examined systems.

  • Published: 2019-01-25
  • Corporate Author(s): Directorate-General for Research and Innovation (European Commission)
  • Personal Author(s): Hoffmeister, B ; Butz, C ; Morelli, F ; Kanyilmaz, A ; De Pasquale, E ; Gigliotti, R ; Mordant, C ; Castiglioni, C ; Medeot, R ; Rossi, E ; Georgi, J ; Tesi, M ; Gouveia Henriques, J. A ; Bellos, J ; Moretti, M ; Faggella, M ; Pinkawa, M ; Anastasi, N ; Bakas, N ; Laguardia, R ; Degee, H ; Braga, F ; Salvatore, W
  • Subject: earthquake, industrial infrastructure, industrial research, innovation, modernisation of industry, report, research project, special steels