Beneficial research by Swerea -...

Beneficial research by Swerea– a selection of good examples 2014

Research for industrial benefit

Swerea has more than 3,000 national and international customers. Together with our customers and public sector funding bodies, we take part in some 4,000 projects each year. Swerea’s goal is to strengthen companies in their capacity to apply new knowledge from research findings and create competitive advantage for industry.

With the examples highlighted in this publication, we wish to present several results from projects in which our more than 500 employees have actively created benefit for industry and, ultimately, for society and the environment. The principal industrial focus areas in which we work are materials, process and manufacturing engineering and product engineering. Energy and environmental aspects of these industrial research areas are an important part of this work.

Swerea works with applied research and is backed by a broad spectrum of industrial know-how and experience of how research findings are applied in practice. To enable this, Swerea has advanced testing and demonstration facilities, where industry and the research community can meet to test new technologies and materials. These include both virtual and experimental facilities.

Via our national and international networks we also participate in international research and development projects. For example, in 2013, Swerea participated in some ninety EU-sponsored projects.

The examples given here are intentionally brief and focus on the benefit accruing to indu-stry and society. If you wish to find out more about a specific example or are interested in learning how Swerea can help, please feel free to contact us. We have extensive members’ programmes for various sectors and partnership agreements with several companies. More information is available on our website, www.swerea.se.

We hope you have an interesting and enjoyable read.

Göran CarlssonCEO, Swerea AB

4 swerea brandbook del 1

G ooD ExAM plES pAG E Ar EA B rAnch

Table of contents Beneficial research by Swerea

Contents 1] 3D scanner measures with high precision. ................................. 6 product engineering Industry

2] new process saves energy................................................... ......... 7 Energy Steel

3] Future aerospace demands thin cast-steel products...............8 Materials development Aerospace

4] new technology for aluminium recycling...................................... 9 recycling Industry

5] Smart garments used in the healthcare sector. ....................... 10 Materials development Textiles

6] Bio-oil reduces steel-industry emissions ...................................11 Environment Steel

7] new operating mode saved SEK 6.5 million ...........................12 process development Steel

8] Elpex ski rolls best ...........................................................................13 Materials development Steel

9] Substitutes for hazardous flame retardants ..............................14 Environment Society, Environment

10] Foundry sand becomes bricks .....................................................15 recycling Foundries

11] new model solves problems in continuous casting ...............16 process development Steel

12] lower prices on cold winter days ................................................17 Energy Society, Environment

13] Future demand for light products ................................................18 Materials development Steel

14] The future is here – 3D-print in sand!. .......................................19 process development Foundries

15] Simulator creates complete overview of continuous casting .20 process development Steel

16] right temperature gives the right properties ............................21 Materials development Steel

17] higher speed for increased productivity ...................................22 process development Steel

18] hot on the outside, cool on the inside .......................................23 Materials development Textiles

19] The right coal reduces costs ........................................................24 Environment Steel

20] lifecycle assessment reveals lack of knowledge ....................25 Environment Textiles

21] Swedish manufacturing engineering is world-leading ...........26 Manufacturing engineering Industry

22] 3D scanning assures the right geometry ..................................27 process development Industry

23] lean creates value for the customer...........................................28 Manufacturing engineering Industry

24] preventing corrosion in stainless steel. ......................................29 Materials development off-shore

25] Vehicle corrosion seminar gathers industry people ................30 networking Vehicles

26] Great job prospects for the long-term unemployed. ..............31 Training and education Industry

27] new foundry concept reduces costs .........................................32 Manufacturing engineering Foundries

28] Scania pleased with paint center ...............................................33 process development Industry

29] new sun deck for lighter riverboat. .............................................34 Materials development Ships

30] Flue dust becomes blast furnace fuel ........................................35 recycling Steel

31] companies get help with environmental permitting ...............36 Environment Industry

32] Seminars aid knowledge transfer.... ............................................37 networking Society, Environment

33] Guidance simplifies laser work... .................................................38 Work environment Industry

34] new ultrasound camera technology. ..........................................39 process development Industry

35] predicting polymer service life.. ....................................................40 Materials development Steel

36] commitment is just as important as knowledge.. ...................41 operational development Industry

37] coating improves material wear resistance ............................42 Materials development Steel

38] network leads the way to Europe.. .............................................43 networking Industry

39] Team work and tenacity boosted production efficiency ............. 44 Manufacturing engineering Industry

6 Beneficial research by Swerea Example 1 • 2014

Lars-Olof Ingemarsson, [email protected], Swerea IVF

3D scanner measures with high precisionWith a 3D scanner, complex geometries can be measured with a high degree of precision.

In collaboration with Swerea IVF, SSpA has used the technique for quality assurance of

model propellers.

ssPa sweden ab provides advanced consultancy services and works with applied research in the maritime sector. In a joint project with swerea IVF, the company has had the opportunity to use a 3d scanner to quality-assure propellers used in model testing trials at the research facility in Gothenburg.

ship propellers often have complex geometries and must meet tough requirements on tolerances. Measuring and evaluating propellers by means of conventional methods is difficult and time-consuming. ssPa was quick to spot the potential when swerea invested in a 3d scanner seve-ral years ago. with the aid of the scanner it was possible to capture a complete, detailed image of the propeller surface.

The fact that the method is also rapid is a bonus for ssPa, whose international clients always demand shorter lead times from design through testing. ssPa now enlists swerea's services for 3d scanning on an ongoing basis.

optical 3d scanning is a technique that enables measure-ment of physical models with very high precision. The technique is used, for example, in the manufacturing industry, for deformation measurement and quality assurance in production. The method is also ideal for reconstruction or replication of objects, as well as for creating new products e.g., in prototyping.

Beneficial research by Swerea 7 Example 2 • 2014

Ulf Sjöström, [email protected], Swerea MEFOS

New process saves energy outotec has developed a process for hot magnetic separation of metallic fine-grained

concentrates and products. The process has been verified with the aid of

Swerea MEFoS’s pilot plant.

Foto: Outotec

outotec has developed PyroMagTM, a process that can separate magnetic materials under high temperatures. Pilot trials were conducted at swerea MeFos to verify the process.

In the process of direct reduction of iron ore using coal as a reductant, with outotec's reduction process, a fraction with ferromagnetic properties and a non-magnetic fraction are formed. by separating these magnetically directly in the hot state (over 700 degrees Celsius) significant energy savings can be made. The metallized magnetic fraction is charged hot in the next process stage, while the carbon in the non-metallic fraction is recirculated.

The equipment used in testing was built by outotec in Germany, and then shipped to swerea, where it was as-sembled, modified and tested. The process was run con-

stantly with up to 4 tonnes of hot material per hour. The targeted 48 hours of continuous operation at high tempe-rature and designed capacity was reached.

Max dieter Laumann from outotec in Germany says, "The high professionalism of swerea MeFos’s operatio-nal and maintenance group under the leadership of Ulf sjöström, and the excellent cooperation between the swerea MeFos and outotec teams made this test a full success."

outotec will now commercialize the PyroMagTM process. Customers will thereby gain access to equipment that ena-bles both energy and cost savings, which ultimately brings environmental gains.

Published with the permission of Outotec.


Martin Risberg, [email protected], Swerea SWECAST

Future aerospace demands thin cast-steel productsnew solutions and lighter components are essential for reducing emissions from future

air transport. The outcome of an EU project points to great potential for replacing

costly titanium engine parts with lighter cast-steel components.

emissions and environmental impact are key considera-tions for companies like Gkn aerospace in Trollhättan. Gkn and other participants in the eU-funded project Clean-sky are aiming to reduce emissions from future air transport. but meeting future environmental restrictions and global competition will demand new initiatives and solutions for aviation.

"Producing future aircraft with reduced environmental impact is a challenge that will require thinner cast-steel engine components," explains anders sjunnesson at Gkn aerospace. Creating thinner components has therefore been the focus of Clean-sky. The Clean-sky project has yielded new knowledge concerning casting of complex thin cast-steel parts for aero engines, in both existing alloys and potential future alloys.

The results indicate that it is possible to make a cheaper component using steel instead of titanium, knowledge that has been of great benefit to Gkn.

TPC, a company that also participated in the project, has improved techniques for casting thin components in a controlled and repeatable manner.

"Collaboration with swerea has had a direct impact on how we simulate our preparatory work and has helped to improve efficiency,” says Peter edman at TPC.

new knowledge has emerged in the project by developing and improving the simulation tools used to predict casting results in ultra-thin geometries. as well as conducting research, swerea sweCasT has coordinated the project.


Jonas Gurell, [email protected], Swerea KIMAB

New technology for aluminium recyclingScrap metal can be analysed at a recycling facility with the aid of laser technology. The

technique has been adapted for steel, but Swerea KIMAB is also developing a method for

aluminium recycling. A trip to Brazil last year generated new contacts in this area.

For several years swerea kIMab has been developing laser technology for scanning/analysis and identification of various materials. The method, laser-induced break-down spectroscopy* (LIbs), has been adapted for use with steel. In 2013 a project concerning use of the technique in aluminium recycling was initiated.

as part of the project, swerea and acreo swedish ICT ab visited brazil last year. The aim was to open the way for future collaboration with brazilian partners in the area "scrap analysis for improved aluminium recycling”.

Thanks to the visit to brazil, several new contacts were generated. Vinnova and the brazilian funding entity Finep also signed a collaboration agreement.

Joining the visit was swedish Minister for enterprise, annie Lööf, who voiced her support for the agreement.

"This agreement is testament to the fact that sweden and brazil have long enjoyed close cooperation, but it also pre-sents new possibilities for even closer "said annie Lööf.

* laser Induced Breakdown Spectroscopy

LIBS operates by focusing the laser onto a small area at the surface of the specimen; when the laser is discharged it heats up a very small amount of material, which generates a plasma plume. Because all elements emit light of characte-ristic frequencies when excited to sufficiently high tempera-tures, LIBS can (in principle) detect all elements.


Erik Nilsson, [email protected], Swerea IVF

Smart garments used in the healthcare sectorFibres with piezoelectric properties can measure body movement, respiration and heart rate.

The fibres are sewn into garments that can in some cases be used in healthcare to replace

conventional electrodes.

swerea IVF has developed a fibre that can be used in texti-les to monitor heart rate, respiration and body movements on patients or athletics. The fibres are sewn into the fabric and no extra electrodes need to be applied to the body, since the fibres in the garments act as sensors. This impro-ves patient mobility and comfort.

one other possible application is monitoring of sleep disorders or stress. This type of study is often done over a long period of time and when the patient is asleep or resting, which means that the comfort of the garment is very important. The development of smartphones also presents new possibilities for analysing and presenting data in mobile apps. This has contributed to the develop-ment of so-called wearable electronics, in which sensor fibres are a necessary component for data collection.

other important applications include, for example, monitoring the respiration rate of babies, and thereby preventing sudden infant death, or for studying how muscles, limbs or organs function with an aim to impro-ving athletic performance. However, athletic garments of this kind are currently rather expensive. a training sing-let in which the necessary function is incorporated would cost perhaps ten times as much as a normal singlet.

when the piezoelectric fibres in a garment are stretched, an electrical current that can be registered is generated. Hopefully, the advent of wearable devices will improve the future competitiveness of the swedish textiles industry.


John Niska, [email protected], Swerea MEFOS

Bio-oil reduces steel-industry emissionsUse of bio-oils can reduce the steel industry’s carbon dioxide emissions from fossil fuels.

This was demonstrated by pilot trials at Swerea MEFoS.

The effect of bio-oils on mill scale formation was studied with a termobalance built into Swerea MEFOS’s chamber furnace.

In pilot trials in swerea MeFos's chamber furnace, researchers studied bio-oil combustion characteristics and the effect on the steel and the furnace refractories. Combustion of the bio-oil gave low carbon monoxide levels and lower fossil fuel-based carbon dioxide emissions.

For the trials, a liquid bio-fuel based on vegetable oils was chosen. different types of fuels in both liquid and gas state can be studied in the pilot plant facility. These fuels are expected to cause fewer problems with, for example, ash build-up, as compared to solid fuels.

In addition to carbon dioxide emissions, the effect of bio-oil on oxidation of the material surface, so-called scaling, was also studied. different steel grades were studied with the aid of a built-in thermobalance. Mill scale formation during combustion of bio-oil was comparable to that

observed when firing with conventional fossil fuels.

swerea also studied the content of nitrogen oxides and was able to demonstrate that these are comparable to levels observed in combustion with conventional fuel oil. The bio-oil used also worked well with the burner equipment that was tested and trials showed no negative impact on either steel or furnace lining.

The bio-oil was preheated, since it is more viscous than conventional light fuel oil. The oil was vaporized with pressurized air, but vaporization with steam is also an option.

Pilot trials were conducted in collaboration with Gefa systems ab, a company that developed the arctic Heat burner, and with support from IUC norrbotten.


Chuan Wang, [email protected], Swerea MEFOS

New operating mode saved SEK 6.5 millionA change in hot stoves’ operating mode has resulted in a reduction in coke consumption in

the blast furnace at SSAB. costs have been reduced by SEK 6.5 million per year.

Photo: SSAB/Bo Björkdahl

Together with researchers from ssab oxelösund and aGa Linde, swerea MeFos has developed a new opera-ting mode for the hot stoves at blast Furnace no.4 in oxelösund. a shift from parallel to serial mode has resul-ted in lower coke consumption in bF4 and, consequently, cost reductions amounting to sek 6.5 million per year.

Hot stoves produce hot blast, which provides thermal en-ergy and gases for smelting reduction in the blast furnace process. Preheating equipment is a key component for blast furnace iron production.

The work has been conducted within the framework for the PrIsMa research programme. Modelling and simula-tion showed that the serial operating mode would result in a high hot blast temperature and, thereby, energy and cost savings. This was confirmed by data from production

trials. The hot stoves operating mode was changed in May 2012.

erik olsson, who is in charge of research at bF4, explains why the project has been successful.

"This has given us the necessary theoretical background for changing the hot stoves’ operating mode. This may seem like an obvious choice but, since the impact on the process is so significant, it is good to have an external eva-luation," says erik olsson, continuing, "work within the PrIsMa programme helps us to demonstrate the overall effects for the whole plant, and not just our own depart-ment, something which is difficult for us who mainly work with the blast furnace. This means we can avoid subopti-mization, which is a common pitfall in a steelworks.”


Erik Sandlund, [email protected], Swerea SICOMP

Elpex ski rolls bestTogether with Swerea SIcoMp, Elpex has developed a new rollerski with a unique

suspension system. compared to other brands on the market, the ski is an obvious

winner in tests.

elpex ab in Piteå is a world-leading brand and manufac-turer of rollerskis. The company has developed a comple-tely new and revolutionary technology for its rollerskis. The ski consists of a composite body together with a so-called PU (polyurethane) suspension, which prevents vibrations from the asphalt from reaching the feet. The ski, marketed under the name elpex evolution, was designated overall winner in one of sweden's biggest rollerski tests, arranged by rullskidor.nu.

swerea sICoMP has played a central role in evaluating mechanical properties, such as material strength under repeated mechanical loads. during strength testing the skis have been equipped with strain gauges and loads have

corresponded to what the skis would be subjected to under hard, intensive skiing.

"we have simulated 8,000 km of diagonal riding with a toe pressure corresponding to 200 kg," says Johan Öberg, a co-owner of elpex.

The skis have been tested at swerea's mechanical testing laboratory.

"The skis have undergone extensive testing and swerea's superior resources for mechanical testing played a decisive role in our development work," says Johan Öberg.


Dag Andersson, [email protected], Swerea IVF

Substitutes for hazardous flame retardantsSome brominated flame retardants can be replaced with less detrimental products. This is

the outcome of a recently concluded EU project, in which several alternatives have been

studied.

brominated flame retardants are used as a fire-retardant agent in many different products. Unfortunately, some of these substances have a negative impact on both hu-man health and the environment. better alternatives are available on the market, but comprehensive information about their negative effects is still lacking. swerea IVF has participated in the eU-funded project enFIro, in which various alternatives have been investigated.

Halogen-free flame retardants were compared with bro-minated flame-retardant agents with respect to hazards, exposure, flame-retardant properties and performance in applications. The project demonstrated that halogen-free flame retardants meet set requirements as regards flame retardancy. They also displayed several other advantages,

for example, lower smoke emissions during fire, lower maximum temperature and fewer toxins in smoke. Half of the selected alternatives were less hazardous to health and showed lower accumulation in the food chain. For all studied polymer systems, functional non-halogenated alternatives were found.

Hazard and consequence analyses were conducted for14 halogen-free flame retardants as substitutes for the bro-minated substances decabromodiphenyl, TbbPa and brominated polystyrenes. Flame retardants were studied for five application areas: circuit cards, electronic compo-nents, injection moulded products, textile coatings and intumescent paint.


Anna Lundberg, [email protected], Swerea SWECAST

Foundry sand becomes bricksDespite in-house recycling, foundries often have large amounts of surplus sand that must

be disposed of. Together with the foundry industry, Swerea SWEcAST has found new

application areas for the sand. one successful application is in bricks.

For decades, surplus foundry sand has either been land-filled at foundry sites or used as cover material for muni-cipal garbage dumps. as more and more of the country's landfill sites are closed, new solutions for sustainable and cost-effective use of surplus sand must be found.

Collaboration between swerea sweCasT and the norwegian foundry Ulefos nV resulted in just such a solution. an alternative that proved to be both environ-mentally and economically sound was to use the foundry's surplus sand as raw material for brick produc-tion at a nearby brickworks.

Foundry sand is mixed with natural sand, after which shavings and clay are added. sand from Ulefos nV is very well suited for the purpose and one of the new bricks in the product range has even been named after the foundry.

brick manufacture is an example of successful recycling of residual products. This shows how it is possible to conserve resources while at the same time reducing costs. determined long-term efforts to find new uses for residual and surplus products pay off in many ways.


Pavel Ramirez Lopez, [email protected], Swerea MEFOS

New model solves problems in continuous castingA new computation model helps steelmakers to reduce waste and improve quality. The

model was developed by Swerea MEFoS.

Photo: Swerea MEFOS

swerea MeFos conducts extensive research on continu-ous casting. Much of the research focuses on problems that arise in the mould, such as cracks and lack of slag lubrication. Part of the research has resulted in the deve-lopment of a new computation model.

researchers can achieve a fundamental understanding of the entire casting process by combining outputs from the model with data from real trials. with the model it is possible to determine conditions that lead to cracks and defects, or to predict other phenomena that are difficult to study in the steelworks. Costly experimentation can thereby be avoided, and problems with casting can be alleviated or eliminated.

The model describes how the metal flows and how heat is distributed in the mould. It includes information about the

casting machine; for example, the geometry of the mould and input system, including the tundish and casting nozzle, the composition of the steel and casting powder, operator practice and the oscillation of the mould.

during casting a ceramic powder is added which melts to slag, thereby forming an insulating layer between the steel and the atmosphere. This also functions as a lubricant. ensuring an appropriate consumption of powder is important to achieve a product free of defects. The swerea MeFos model takes this into consideration.

swerea's collective expertise is now being applied to broaden this area of research, as well as for testing new and modified steel grades and casting powders. This gives steel producers new possibilities for improving their continuous casting process.


David Bellqvist, [email protected], Swerea MEFOS

Lower prices on cold winter days Swerea MEFoS is helping to gain an overall understanding of the district heating system in

luleå from a broad perspective. This is part of a collaborative effort between luleKraft and

luleå Energi, the aim of which is to reduce environmental impact and costs.

Photo: Maria Åsén

Lulekraft's cogeneration plant produces both heat, which is sold to district heating company Luleå energi, and electricity. Production is controlled by several factors; for example, weather, fuel prices and heating demand from customers.

To increase revenue, it may in some circumstances be best to increase power production. but if power production is increased, then heat production must decrease and heat must therefore be produced by other plants using other fuels. even if increased power production yields higher returns and is the best strategy in that respect, it may not be optimal in a broader sense. Process integration is a way of improving production systems by adopting a holistic perspective, instead of merely focusing on the individual processes.

Currently, a process-integration survey of Lulea’s district heating system is being conducted and swerea MeFos, Lulekraft and Luleå energi have developed a systems model. work has resulted in a better understanding of cost-effective and environmentally sound production, as well as pointing to the need for close collaboration among the companies involved. a comparison of produc-tion data revealed that there is potential for savings of up to sek 300,000 on cold winter days.

Lulea’s district heating network is 400 km long and serves 31,000 households and several large industrial and commercial customers. The district heating system has five production units which run on process gases from ssab, wood pellets, electricity and oil. about half, or 2000 Gwh, of all process gas from ssab's integrated steel production is used to produce district heat, electricity and process steam.


Stefan Gustafsson Ledell, [email protected], Swerea SWECAST

Future demand for light productsBy combining steel and composites in a truck beam, the weight of the structure can be

reduced by 70 percent. This was the outcome of a project within the lIGhTer programme.

a steel beam was joined with a composite beam for a truck rear axle. This resulted in a weight reduction of 70 percent, which in turn can translate into heavier payload or lower fuel consumption for the vehicle.

This is the outcome of a project within the lightweight arena LIGHTer, of which two overall objectives are to re-duce environmental impact and improve resource effi-ciency. Cost-effective methods for joining metal and lightweight composites have been developed, giving swedish industry a head start in the field of lightweight engineering.

LIGHTer, which is led by swerea, is one of five initiatives within Vinnova's strategic innovation areas. LIGHTer was initiated in response to the need to meet environme-

ntal requirements and emissions restrictions. For the transport sector, for example, the target has been set to achieve 75 percent lower carbon dioxide emissions by 2050. by promoting the manufacture and use of lighter products, this will contribute to a reduction in carbon dioxide emissions and, ultimately, to a more sustainable society.

In the future, cost-effective and reliable methods for joining metal and fibre composites will be a key factor for reducing vehicle component weight. ever greater de-mands are being placed on weight efficiency, as well as on safety and integrated functionality. This applies to many industries, not least of which are the vehicle, aerospace and marine sectors.


Sten Farre, [email protected], Swerea SWECAST

The future is here – 3D-print in sand!In component casting, as in all product engineering and manufacturing, there is an increa-

sing demand for shorter lead times. now, lead times can be shortened, thanks to a method

of casting directly in a sand mould printed out from a cAD file.

The competitiveness of swedish industry owes much to our capacity for flexibility and automation. In addi-tion to these factors, short lead times are decisive for the customer's choice of supplier.

smålands stålgjuteri ab in eksjö is a family-owned business that is investing heavily in new technology and efficiency improvement in all of its processes. The company was therefore quick to benefit from knowled-ge gained from the pre-study sPÖk, in which casting trials were conducted with excellent results. The pre-study showed that there is good potential for shortening lead times, something that can give the swedish foundry industry significant competitive advantage.

Per Ytterell, Ceo of smålands stålgjuteri, explains that ongoing implementation of new technology is essential

both for maintaining competitiveness and for staying in the game when it comes to tendering for future work in an increasingly demanding engineering industry. after the casting trials, Per Ytterell said, "now, we don't need to simulate castings; all we have to do is print out a mould and core, and then cast. right away, we have a real com-ponent that we can analyse."

swerea sweCasT has worked with the project and the goal has been to investigate just how far the technology for 3d printing of moulds and cores has progressed. The focus has been on determining how well and how quickly the technology can take components from a digital environment into a physical one.

sPÖk is a Vinnova-funded project.


Pavel Ramirez López, [email protected], Johan Björkvall, [email protected], Swerea MEFOS

Simulator creates complete over-view of continuous castingSwerea MEFoS has developed a simulator for studying important relations during

continuous casting. The simulator provides an overall view of the casting process.

although extensive research concerning the behaviour of molten steel in the mould during casting has been conducted, not all flow relations can be described. It is difficult to study the metal in a real casting machine or to build one in pilot scale. often, water models are used; but molten steel and water do not behave similarly when it comes to pressure and flow.

swerea MeFos has therefore created a full-scale physical model of a continuous casting machine complete with a stopper rod, casting tube and mould. only the tundish has been reduced in size as compared to that of a real casting machine. an alloy with a low melting point (137 degrees Celsius) has been selected as a suitable medium for simulating steel flow. The model is equipped for gas in-jection via the stopper rod, which corresponds to normal practice in industry.

The alloy's properties are similar to that of steel and it is non-toxic. Its electrical properties make it ideal for stud-ying devices such as electromagnetic stirring or braking. In addition, an oil layer can be applied to simulate how slag behaves in a real casting machine. Metal flow rate is measured with various sensors, while a video camera monitors the surface of the mould.

The equipment enables better understanding of the im-portance of the multiphase flow (steel, slag and argon) in continuous casting. The model provides a clear overall view of the continuous casting process. studies with the model have also resulted in two patent-pending methods.


Patrik Sidestam, [email protected], Swerea MEFOS

Right temperature gives the right propertiesThe right steel temperature reduces energy use and results in better material properties.

Swerea MEFoS has developed a program that gives steel producers answers to important

temperature-related questions.

Photo: Jernkontoret/Stig-Göran Nilsson

The STEElTEMp® program suite includes:

STEELTEMP® 2D: for temperature and heat-transfer analysis during casting, cooling, stripping, heating, rolling and forging.

STEELTEMP® GR: used in rolling and cooling of long products.

STEELTEMP® 3D: computes temperatures in reheating furnaces.

How long should the steel be heated to have a homoge-neous temperature without being heated unnecessarily? what is the temperature of the steel after rolling and how quickly does it cool? These are important questions for steelmakers. The answers give an indication of the opti-mal temperatures for influencing steel characteristics and energy use.

with the help of sTeeLTeMP® software, steelmakers can get the right answers and use the information in various analyses. The outcome is lower energy use, higher productivity and the right material characteristics. The program computes temperatures during casting, heating, rolling, forging and different cooling regimes. swerea MeFos, Jernkontoret, norwegian IFe and the nordic steel industry have long been collaborating on develop-

ment of the program. To facilitate its use there are training courses, a built-in material database and an adapted user interface. The program is also linked to FoCs, the Furnace optimising Control system, which is used to minimize energy use and to increase productivity. FoCs has been developed by swerea and has resulted in productivity increases of up to 28 percent in the nordic steel industry.


Patrik Wikström, [email protected], Swerea MEFOS

Higher speed for increased productivityTo increase productivity during hot wire-rod rolling, higher roller speed is necessary. But

higher speed results in an increased deformation heat, entailing a risk for melting. Swerea

MEFoS has developed testing equipment to better simulate rolling.

Hot wire-rod rolling is done under both high temperature and at high speed. during the process considerable de-formation heat is generated. There is risk that, if this heat is not conducted away from the material, local heating will occur. at worst, heating will result in local melting and, subsequently, failure.

To address this problem, swerea MeFos has developed testing equipment that enables simulations at high speed while also maintaining good precision. The aim is to in-crease rolling speed.

The project is funded by Vinnova and involves the participation of swerea kIMab and Luleå University of

Technology, LTU. swerea MeFos and LTU are respon-sible for material testing at high elongation rates, while swerea kIMab is in charge of testing at lower elongation rates.

To achieve good analysis results, it is very important to have good knowledge of the wire's mechanical proper-ties. Test methods have therefore been developed to enable characterization of the mechanical response under the same conditions that prevail during wire-rod rolling. Finite element analyses have been done, allowing the process to be studied virtually.


Bengt Hagström, [email protected], Swerea IVF

Hot on the outside, cool on the insideprotective clothing worn during forest or grass firefighting is often cumbersome and un-

comfortably warm. Swerea IVF has therefore developed textile fibres that provide good

protection against heat, while at the same time making the garments cool and comfortable.

Throughout the world, grass and forest fires are increa-singly more frequent and more intensive. a glowing cigarette end carelessly tossed into a dry patch of ground is all it takes to cause an uncontrollable raging inferno. Combating these fires requires both knowledge and good protective clothing. For example, in southern europe, where summer temperatures can rise to 30–40 degrees Celsius, volunteer organizations have a great need for protective clothing that not only withstands heat from fires but is also cool and comfortable to wear.

one way to improve protection against heat radiation is to increase its insulation capacity. However, a garment with more insulation is, for obvious reason, not suitable for continuous work under hot summer temperatures. swerea IVF recently concluded the eU-sponsored safe-

protex project, in which textile fibres incorporating so-called phase-change materials (PCMs), which change phases at different temperatures, were developed. during a phase change, energy is either liberated or stored in the fabric. The aim has been to achieve adequate protection against radiated heat, but without creating a garment with high insulating capacity. with the help of a special lining, the incoming radiated thermal energy is captured in the form of latent heat. This prevents the temperature nearest the body from increasing.

The jacket was successfully tested by a volunteer team in spain. It was reported to be cool and comfortable under normal heat conditions, but also allows the wearer time to escape to safety in the event of a rapid fire-front ad-vance. This has also been confirmed in laboratory tests.


Joel Orre, [email protected], Swerea MEFOS

The right coal reduces costsA study done by Swerea MEFoS demonstrates the importance of choosing the right coal

in each situation to reduce costs and environmental impact.


Considerable gains in terms of both cost and environment can be made by using and adapting the most suitable coal, depending on the situation. For example, theoretically, charcoal is a good injection coal that is carbon-dioxide-neutral. This makes it a good alternative for reducing carbon dioxide emissions. on the other hand, it is consi-derably more expensive than other fuel sources.

swerea MeFos has conducted a systems study for ssab in oxelösund to analyse how costs, energy requirements and carbon dioxide emissions influence the choice of injection coal for the blast furnace. The study shows that there is great potential for realizing both cost and environmental savings by adapting the coal according to the desired production rate.

Johannes Larsson, who manages bF4 at oxelösund, sees the benefits of the study.

"The result provides a basis for future testing with alterna-tive injection fuels. we have gained an understanding of "value in use" for the various types of coal," he says.

Coal injection accounts for one-fifth of the reducing agent requirement, or 400-500 tonnes of coal per day in the blast furnaces studied at ssab in oxelösund. owing to the great amount of coal that is used, from both an economic and environmental point of view, there are good reasons for using the most suitable coal, depending on the situation.


Sandra Roos, [email protected], Swerea IVF

Life cycle assessment reveals lack of knowledgeconsumers and public authorities are challenging the global textile industry to use more

environmentally friendly raw materials. But how can a company ensure that the materials it

uses meet the requirements for good environmental performance?

Conventional cotton is today the leading renewable fibre raw material in clothing fabrics, but it is largely produced using pesticides, artificial fertilizers and irrigation. on the internet and in other media we see innumerable misleading claims about the alternative fabrics that are available. It is difficult to discern a genuine scientific basis for these statements in this welter of fact, fiction and opinion one explanation is that the environmental impact of a material can differ substantially from one supply chain to another.

by letting an independent research institute like swerea IVF conduct life cycle assessments, companies can be assured of the facts. That is exactly what wiges ab did with their bamboo viscose, Life wear bamboo. results show that, in terms of chemical load and water use, Life

wear bamboo garments has considerable advantages over comparable wiges garments in cotton, and that it is just as good when it comes to climate impact and use of land and energy. The results have also been reviewed by a third party, bureau Veritas ab.

wiges is very pleased with the result and can now provide its customers with scientific facts to back environmental arguments for its products.

wiges is a knowledge-based company in the textile and garment industry, located in kinna, near borås. The company imports and sells products to retailers and works with the entire supply chain from design to finished product. wiges is now working strategically to produce environmentally friendly substitutes for cotton.


Arne Melander, [email protected], Swerea KIMAB

Swedish manufacturing engineering is world-leadingThe xprES initiative is promoting the advancement of Swedish research in manufacturing

engineering. The goal is for Sweden to place in the top five in Europe within advanced

manufacturing. Thanks to xprES, Volvo cars has implemented new virtual engineering

methods in its production planning.

The government-sponsored initiative for excellence in Production research, XPres, is a joint initiative with the participation of the royal Institute of Technology (kTH), Mälardalen University and swerea.

In one of the XPres projects a doctoral student has deve-loped methods for optimizing spot-welded joints with the aid of simulations. In production planning, several trial series are normally produced to attain the optimal process parameters. However, thanks to the new methods, planning can instead be done virtually with the computer. as a result, Volvo Cars in Torslanda has introduced these methods in its production planning.

annual funding to XPres amounts to 20 million kronor. several of the externally funded projects in which swerea is participating concern production methods for light-weight vehicles, such as laser welding for future light-weight vehicle bodies and new, stronger vehicle transmis-sions.

within XPres, the focus is on three areas:• Manufacturing of new materials, and new technologies• Lifecycle assessment for product engineering• reconfigurable and rapidly adaptable manufacturing

systems


Kenneth Strand, [email protected], Swerea SICOMP

3D scanning assures the right geometrySatmission uses 3D scanning to create images of its antennas and to verify the production

process for these antennas. This technology offers a very high degree of precision and the

company can therefore assure the quality of its antennas, which facilitates product approval.

optical 3d scanning is a technique that is used for imaging and measuring physical objects. due to its very high degree of accuracy, the technique is used in, among other applications, quality control in manufacturing.

satmission ab develops and sells equipment for the com-munications and telecoms industry. They have used 3d scanning to verify the manufacturing process for their carbon fibre parabolic antenna. Carbon fibre parabolic antennas are both lighter and more rigid than antennas made of other materials, but manufacturing these pro-ducts places high demands on tool and die geometry and process parameters, since the component must retain its shape during manufacturing.

swerea sICoMP has assisted satmission with measu-rement of the parabola's geometry. The 3d scanning

technique has been used to scan the tool geometry, which has then been compared with the geometry of the finished parabolic antenna. The tests can be done in a laboratory setting and the results facilitate approval of the products for use in satellite transmission.

"This has saved a lot of time and money, since we have had no need to do long and costly tests with satellite transmissions," says Conny Hedman at satmission.

Swerea SICOMP's optical 3D scanner is an ATOS Compact Scan 5MP from the German company GOM. In addition, Swerea has other optical metrology equipment, including ARAMIS for measuring elongation and displacement fields on three-dimensional surfaces, and ARGUS for visual 3D measurement of elongation.


Mikael Ström, [email protected], Swerea IVF

Lean creates value for the customerA better overview, a clearer idea of the company’s competence and structured problem-

solving. These are some of the benefits Autotube has realized since the company introdu-

ced lean in its operations.

”Some call it lean product development. We see it as an enjoyable way of working that brings great benefit to our customers.” Photo and caption: Autotube

Lean manufacturing or, simply, "Lean", is a production practice that aims at creating value for the customer and managing resources efficiently. Companies that imple-ment Lean in their operations learn to find the causes be-hind waste and can work continuously to follow up on, and improve, their processes. small efforts can yield big gains. autotube, a company that introduced Lean in its business with the help of swerea IVF, is well aware of this. among other things, this led to improved management of multiple projects. This entails writing up all projects on a single planning board. brief meetings are held in front of the board, which gives co-workers a better overview of ongoing activities and which problems need to be solved. In addition, each project has its own mobile board with detailed visualizations of targets and the status of the individual project. as a result of the Lean effort, knowledge within the company has become clearer, problems are now

solved according to a structured model and customer con-tacts have been made visible.

The project was funded by Vinnova and managed by swerea together with Chalmers. at the first meeting auto-tube did a self-assessment and used it as a basis for setting various targets. subsequently, there were several meetings on theory and discussions about possible improvements. The research group also gathered data on the outcomes of improvement proposals and the results were published in scientific publications. In all, six concrete improvements were implemented in the company's processes, all of which were validated in the project. autotube is now continuing with the process on its own. Company development manager, Jan olofsson, had this to say: "Look for know-ledge gaps and avoid delegating. always go to the source and look!"


Dominique Festy, [email protected], Institut de la Corrosion

Preventing corrosion in stainless steelDuplex stainless steels are more susceptible to hydrogen embrittlement than carbon steels

when they are subjected to cathodic corrosion protection. This is one of the findings from a

project in which Institut de la corrosion studied steels used in seawater.

swerea kIMab's subsidiary, Institut de la Corrosion, in France, has investigated how cathodic corrosion protection can be applied to duplex stainless steels used in seawater. The objectives of the project have been to assess:• cathodic protection criteria for duplex stainless steels

in a real environment• aluminium–gallium as an anode material for corrosion

protection• the risk for hydrogen embrittlement in duplex stainless

steel and high-strength carbon steel (HsCs).

results showed that hydrogen development on stainless steel is more common than on carbon steel, which implies that stainless steels are more susceptible to hydrogen embrittlement.

The project also revealed that the capacity of aluminium alloys was 25 percent lower in a real environment as com-pared to theoretical values and that aluminium–gallium was strongly influenced by temperature. The cathodic protection for stainless steel structures also appeared to be largely dependent on environment.

The findings will be applied in the oil industry to assess cathodic protection criteria for duplex stainless steels for use in deep-sea applications.

due to the risk of environmental disasters, exploitation of oil and gas reserves at great depth is subject to stringent safety requirements. Corrosion gives rise to problems that can jeopardize safety and cathodic corrosion protection is one way of safeguarding the material.


Bo Rendahl, [email protected], Swerea KIMAB

Vehicle corrosion seminar gathers industry peopleEvery three years Swerea KIMAB arranges a large seminar for companies and industries

that work with issues related to corrosion and corrosion protection of vehicles. This is one

of few seminars where industry people from around the world can gather to network and

exchange knowledge in this field.

In May 2013, swerea kIMab arranged the 5th Interna-tional seminar in the Field of automotive Corrosion. The seminar is widely appreciated and is an excellent opportunity for companies to meet for two days of net-working, discussions and presentations on the theme of automotive corrosion.

The seminar was held at swerea kIMab in kista, near stockholm. The seminar attracted 65 participants from Japan, south korea, austria, belgium, the Usa, england, France, Germany, norway and sweden.

Two topics of great interest were corrosion testing and new materials in the automotive industry.

13 presentations were given at the seminar, whereof swerea kIMab and Institut de la Corrosion held five. other presentations were given by specially invited spea-kers from the automotive industry.


Conny Gustavsson, [email protected], Swerea SWECAST

Great job prospects for the long-term unemployedIn Småland, in southern Sweden, there are many new arrivals that have not entered the labour

market. These people are important both for regional industry and for the smaller communities

that are experiencing depopulation. The InGJUTA project made everyone a winner.

The project has attracted interest throughout sweden, and arbetsförmedlingen (the labour market placement service) is amazed at the results. InGJUTa is a training programme that has successfully equipped young people with immigrant backgrounds for employment in the foundry industry. eight of twelve participants in the first session of the programme found jobs.

"Thanks to InGJUTa, the students have demonstrated that they are employable and have the prerequisites for working with us," confirms Martin boigs, personnel manager at Tenhults Pressgjuteri, one of the participating host companies.

Many recent arrivals, especially young people, have great difficulty entering the labour market. at the same time, many companies in small communities often find it hard

to recruit people with the right vocational training. This prompted the Municipality of sävsjö to initiate a project and procure a six-month vocational training program-me. swerea sweCasT and skandinaviska Gjuteriskolan (scandinavian Foundry school) won the contract.

In the project, people aged 18 to about 30 with immigrant backgrounds and who, for various reasons are in need of vocational training, have been trained. each week, students study work-related swedish for immigrants and practical foundry technology, as well as working on an internship basis at the host-company foundries.

both host companies and arbetsförmedlingen participate in the recruitment process. according to arbetsförmed-lingen, normally, only one or two people find jobs during the corresponding period.


Håkan Fernström, [email protected], Swerea SWECAST

New foundry concept reduces costsValmet has reduced its costs through better and more continuous flows in its processes.

The company is well on the way to achieving the long-term goal of lowering manufacturing

costs by 20 percent.

Valmet ab faces major challenges and demands for bet-ter cost-efficiency. The goal is to reduce manufacturing costs by at least 20 percent over a three-year period. The company has now taken several important steps towards that goal. The new foundry concept has so far resulted in a whole new planning tool, buffers with set minimum and maximum limits, and an initial step towards process automation.

a greater degree of automation is often cited as a universal solution when a company wants to achieve better produc-tion efficiency and competitiveness. but that is simply not enough; if a company automates an ineffective process, the losses from that process will only multiply. The sensible

approach is to create a balanced, even flow throughout the entire production apparatus. achieving this requires a thoroughgoing inventory of production-related facts and figures, which is exactly what swerea sweCasT and Valmet have worked with. swerea has presented an ana-lysis of the company that points to potential for balancing the processes and creating a continuous, even flow that will lead to cost reductions.

The development work has been conducted by sub-project groups that have been manned cross-functionally with personnel from both Valmet and swerea. Thanks to this effort, a new concept for automation has been presented.


Cecilia Groth, [email protected], Swerea IVF

Scania pleased with Paint CenterAt paint center, companies can test new materials, prepare for new installations or monitor

the stability of processes without disrupting their ongoing production.

when scania ab in oskarshamn installed new robots in their body paint shop they made good use of the Paint Cen-ter test facility at swerea IVF. Together with robnor ab and paint supplier PPG, scania tested their process and pre- tuned the equipment for different types of process parame-ters. Thanks to Paint Center, the principal contractor, rob-nor, was able to ascertain critical process parameters and train personnel. Joakim Heimer, project manager at rob-nor, thinks that collaboration has simplified the processes.

"Collaboration with swerea has given us the means to more quickly and easily develop existing and new customers' processes. after a few months at swerea we did a pre-in-stallation on-site in oskarshamn to finalize all robot path planning and settings. In just four weeks, in the middle of the holiday period, we were able to finalize the installation and bring it online at scania." scania's project manager,

Ulrik Lindgren, is also pleased, and he claims that the major advantage was the possibility of using several people with specialist competence in their respective areas.

"Utilizing Paint Center allowed us to bring more specialists into the development project. at most, seven people were involved. This enabled us to identify and solve problems in all aspects of the production apparatus," says Ulrik Lindgren, continuing, "The installation and production start-up progressed smoothly and production was up and running, as planned, after the summer holiday."

Swerea IVF’s paint center

At Paint Center, companies can test different pre-treatment and coating methods, chemicals and paints. Paint Center works with spray-painting of metal, plastic and wood, and has contacts throughout the entire value chain from suppliers and producers to end-users.


Erwan Juin, [email protected], Swerea SICOMP

New sun deck for lighter riverboatTogether with Meyer Werft and Blatraden, Swerea SIcoMp has developed a new type of

riverboat sun deck in composite material. The result is a boat that is both lighter and cheaper

to maintain.

The sun deck, which replaces an existing version in steel, is used on a riverboat built by the German shipyard Meyer werft GmbH. The new sun deck in composite material reduces both the overall weight of the boat and mainte-nance costs.

In the project, swerea sICoMP optimized and compared twelve different types of structures with respect to weight and cost. The sandwich-type structures were based on a core with varying materials and the outer layers were of either fibreglass or flax-fibre-based.

The project also included design of a beam system. design of each structure began with a simple weight optimization of the sandwich panel with respect to limits for load, stress

and deformation, as well as reasonable limits for material thicknesses. optimization was performed using 2d finite element analysis. The finite element method (FeM) is a numerical technique that can be used, for example, to calculate strength. In the next step, the entire deck was modelled in 3d to verify the results from the first step. The best design was selected and a prototype was built by blatraden. It will be tested under real conditions at the Meyer werft shipyard.

The sun deck was developed within the eU-funded programme THroUGHLIFe – “development and proof of new approaches for through-life asset management based on next generation of materials and production technology”.


Lena Sundqvist Ökvist, [email protected], Swerea MEFOS

Flue dust becomes blast furnace fuelBy recirculating flue dust as fuel in the blast furnace, both raw-material costs and

environmental impact can be reduced. The method is now used at SSAB in oxelösund.


The idea of using blast furnace dust and sludge as a fuel supplement in the blast furnace was conceived as early as the late 1990s. Flue dust is a residual product from iron production, containing fine-grained particles of coke, pellet fines and slag formers. Thanks to several years of joint development by swerea MeFos, ssab and Lkab, the method is now used in industrial scale by ssab in oxelösund.

Flue dust is normally recirculated via blending with sinter feed. However, sweden has no sintering plants, so the material is instead briquetted before recirculation to the blast furnace process. The method works well, but when flue dust is added to briquettes the cost increases, since flue dust impairs the mechanical strength of the briquet-tes, necessitating a greater addition of binder agent.

In light of this, injection of fine-grained material to the blast furnace is an interesting alternative. In that case, the flue dust is injected directly; however, this causes excessive wear and tear on equipment, which must be adapted.

successful co-injection trials using a blend of flue dust and pulverized coal have been conducted in Lkab's ex-perimental blast furnace, as well as with separate lances adjacent to the coal injection lance in ssab's no. 4 blast Furnace in oxelösund. results show that transport of flue dust directly from the off-gas cleaning system to the injection plant is a satisfactory method. Coke breeze in the flue gas effectively replaces some of the coal and coke. In addition, environmental impact is reduced, since landfilling of the dust is avoided. The method is used in industrial scale at ssab in oxelösund and will also be used at ssab in Luleå.


Martin Wänerholm, [email protected] Swerea SWECAST

Companies get help with environ-mental permittingMany growing companies need to apply for new environmental permits. The permitting

process is often long-drawn and can entail significant losses for these companies. Swerea

recently helped a company that risked closure due to the delay in permitting.

when a company expands or otherwise changes its opera-tions, a new environmental permit is required by law. app-lying for these permits can take years and the lengthy app-lication process places companies at risk of considerable financial loss. swerea therefore helps different companies to apply for permits and write environmental impact as-sessments. recently, one company risked closing down operations while awaiting permit approval, but thanks to rapid processing and submission of the right documents to county authorities, closure was avoided. after swerea submitted the application, the county administrative board requested no supplementary documentation, which is rather unusual.

"a short, concise and concrete application makes it easy for us to find everything we need to know in the documen-tation. Here, consultants and lawyers should take note,"

commented the county clerk, emphasizing that much can be learned from an application like the one submitted by swerea.

The Land and environmental Court, which also reviews environmental permit applications has remarked on an-other of swerea's submissions. "If it had reached the court, it would have received an immediate stamp of approval."

swerea sweCasT has longstanding experience of helping companies with permit applications and environmental impact assessments. Companies planning to expand existing operations or start new ones are required by law to apply for a permit, and application is made to the county administrative board or the Land and environ-mental Court.


Margaretha Sönnergaard, [email protected], Swerea KIMAB

Seminars aid knowledge transferTo facilitate the exchange of experience and knowledge concerning current and cutting-

edge research, Swerea KIMAB often arranges seminars on various themes.

swerea kIMab holds regular seminars in many different areas. seminars provide an excellent opportunity for people from the academic world, companies and resear-chers to meet, listen to presentations on current topics, exchange experiences and discuss problematic issues.

Two interesting seminars arranged by swerea in 2013 were "Innovative total solutions for pool facilities in sustainable cities" and "Materials in Contact with drinking water".

The seminar on indoor pools revealed that many of sweden's indoor pools are experiencing problems with corrosion and moisture and are therefore in need of reno-vation. researchers and representatives from industry and the public sector met to discuss problems, future needs and opportunities. one issue that was avidly discussed was the importance of knowledge transfer; everyone that

works with indoor pool facilities must have the benefit of researchers' experience and knowledge to be able to select the right materials, modify ventilation systems or solve other problems in an effort to create better indoor pools.

The seminar "Materials in contact with drinking water" also gave occasion to engage in discussion and hear several presentations. erik Gravenfors from the swedish Chemi-cals agency presented a study on the presence of bisphe-nol a in drinking water from relined pipes. Pipes are often cleaned and relined, instead of being replaced. He also gave an account of how the european reaCH regulation can be applied with respect to materials. kenneth M Persson from Lund University discussed new medical findings concerning health hazards associated with plastic pipes, while karin Jacobson, swerea kIMab, explained what happens to pipes when they are disinfected.


Martin Lindahl, [email protected], Swerea SWECAST

Guidance simplifies laser workSwerea has produced guidelines and checklists that help companies to perform risk

assessments for work involving lasers and sources of optical radiation.

work involving potential exposure to optical radiation is subject to requirements for usage, equipment and safety. The swedish work environment authority has issued directives concerning risk assessment, but many find them complicated and feel that specialist knowledge is necessary for assessing risks and exposure.

swerea sweCasT and sP Technical research Institute of sweden have therefore carried out a study concerning artificial optical radiation in swedish industry. The working group has conducted reference measurements for a number of well-defined industrial operations and the results serve as a basis for the guidelines and check-lists that have been produced.

Guidelines include diagrams that indicate current expo-sure levels in relation to applicable limit values. There are also recommendations for personal protective equip-ment. swerea and sP have also produced checklists for work involving lasers and optical radiation. Together with the checklists, the guidelines will be used to assess working conditions relative to the requirements set out in the swedish work environment authority's directive 2009:7 “artificial optical radiation”.

bharat Forge at kilsta ab has used the reference material and feels that it has been "a great help" in making work-site assessments.


Tomas Luksepp, [email protected], Swerea IVF

New ultrasound camera technologyDophiTech has developed a new technology for its advanced ultrasound camera. Swerea

IVF has assisted with development of the manufacturing process, which has led to a near

doubling of the sensitivity of the camera.

dolphiTech as in raufoss, norway, offers advanced ultra-sound cameras for materials testing and inspection. The company's recently launched dolphicam is optimized for analysis of carbon fibre composites. Impact on composite materials can cause internal defects, even though the sur-face appears to be undamaged. The dolphicam system features a unique, patented ultra-sound transducer design. an ultrasonic transducer sends an acoustic pulse towards a surface and registers the echo which is returned. by measuring the time interval and intensities between the sent signals and the received echos, the extent of internal damage within an object can be estimated. The technique provides high-resolution images and the capability to visualize suspected damage areas.

swerea IVF has helped the company to develop and quality-assure the method by which the transducer is manufactured by adhesive bonding. Performance in terms of sensitivity, uniformity and repetition has been significantly improved. Function, low weight and compact format, as well as the possibility for dry coupling on surfaces make the camera easy to use. The camera has also attracted great internatio-nal interest from both the aerospace and automotive indu-stry. The camera has recently been included in the non destructive testing manual for boeing 787 dreamliner.


Karin Jacobson, [email protected], Swerea KIMAB

Predicting polymer service lifeSwerea KIMAB has produced new corrosion data and an improved test method for fibreglass

reinforced polyester in some corrosive environments. This will make it easier to determine

the service life of the material and prevent premature replacement of material that is still

serviceable or exclusion of material that might be appropriate.

For accurate determination of material service life it is important to have access to reliable corrosion data. such data are often available for metals but largely lacking for polymeric materials.

There is an increasing demand for corrosion data for polymers and swerea kIMab has been working for quite some time to address this issue. In a recently concluded project, swerea kIMab has helped Materials Technology Institute (MTI) to develop a method for producing rele-vant corrosion data for fibreglass reinforced polyester (FrP).

Unlike existing systems which consider chemical resis-tance and maximum temperature, the method is based on a corrosion approach. This provides a better means of

determining service life. Materials that were previously not approved for use have been found to be acceptable in certain well-defined environments.

The test method has been verified via accelerated testing of the material in six different environments. outcomes agreed well with observations from practical experience.

FrP is used in, among other applications, chemical storage tanks. Here, new data can help to more easily answer questions concerning functional reliability and safety.

swerea coined the term Corrosion approach for Polyme-ric Materials. Large-scale implementation of the method testifies to its success.

Beneficial research by Swerea 41Example 36 • 2014

Richard Berglund, [email protected], Swerea IVF

Commitment as important as knowledgeIt may seem paradoxical, but technological development involves more than just technology.

To drive technological advancement, committed personnel are just as important as know-

ledge. Autoliv is well aware of this.

Åsa Beronius, HR manager, Anders Svantesson, quality manager, and Daniel Åhlström, centre director, in front of the performance board.

"Committed co-workers" is cited as a success factor in virtually all company presentations. at Tech Center, autoliv ab in Vårgårda, commitment is a self-evident starting point for success. but working systematically with this "soft" issue is not always easy. one way for autoliv to boost commitment is to highlight good performance and for each group within the company making the challenges for the year more tangible.

swerea IVF has developed a method of working with commitment that has been introduced to all managers of the Center. The method is based on a web-based question-naire, interviews, several seminars with management teams and the creation of a programme of measures that will improve the prerequisites for employee commitment.

Commitment within Tech Center's organization was already high, but there was still room for improvement.

working with swerea has also given managers a means of discussing this important management aspect. For daniel Åhlström, who is both centre director and techni-cal director, commitment within the company is vital.

"we regard commitment as a cornerstone of improvement and a decisive factor for the success of our company", continuing, "we are very pleased and proud that the level of continuous improvements has increased during our journey of commitment together with swerea."


Henrik Borgström, [email protected], Swerea SWECAST

Coating improves material wear resistancepVD coatings are used mainly within tool applications to give tools better wear resistance.

new application areas include coating on machine components in nodular cast iron.

Photo: Oerlikon Balzers Sandvik Coating AB.

swerea sweCasT has worked with a project of which the goal has been to find new application areas for so-called PVd coatings. PVd coatings are used primarily to coat tool surfaces. The coating gives improved wear resistance, makes coated surfaces less susceptible to corrosion and has lower friction.

as a result of the project, oerlikon balzers sandvik Coa-ting ab will now offer customers PVd coatings for so-called adI material (austempered ductile Iron). adI is an austenitic ductile iron that is used to treat, among other things, components in vehicles, mining and mineral pro-

cessing equipment and gearboxes for wind turbines. steel has long been favoured over adI, but by using adI, weight can be reduced by up to ten percent in cases where the material is used to replace steel in a structure.

swerea has coordinated the project and researchers have studied various pretreatments that enable coating of machine components made of adI. work has resulted in better knowledge of how residual stresses and topography influence the PVd coating's adhesion after various pretreatments.


Christin Vännman, [email protected], Swerea IVF

Network leads the way to EuropeEnterprise Europe network is the largest network helping Swedish companies seeking for

international collaboration and business contacts. Thanks to the network, cleanergy found

many new interesting European contacts.

Cleanergy is the world’s leading supplier of sustainable energy solutions based on the stirling engine based in Åmål. The company develops small solar power units that are driven by solar energy captured using a proprie-tary parabolic mirror. Ideally, several thousand such units could be linked to a single solar power plant which could then be connected to the power grid.

Last autumn, when Cleanergy needed a solution for de-icing the solar mirrors, the company came in contact with swerea IVF and enterprise europe network. The net-work is the world's largest source of information and ad-vice for small and medium-sized enterprises that wish to grow in europe. Via the network, swerea helps companies to find partners for development in europe.

Cleanergy entered its company profile in the network's database, which yielded at least ten serious enquiries for collaboration with european companies. The company also took part in a seminar on how small businesses can participate in eU projects.

Cleanergy was also able to get in touch with specialists in different fields. swerea has helped with assessment of ceramic linings for the power units, as well as questions concerning geometric verification.

Cleanergy is now growing quickly and is well equipped for meeting an increasing global demand for green power.


Kalle Persson, [email protected], Swerea IVF

Team work and tenacity boosted production efficiencyIn 2013, after a few weak years in the wake of the financial crisis, Elektromontage engaged

in the production leap initiative. The company’s order book is now bulging.

elektromontage ab is located near the bridge over the Göta kanal, in söderköping. Here, it is not uncommon for visitors to be greeted by flags from many nations.

"what drives our company is the sense of hometown pride we feel when we welcome customers from other parts of the world," says roberth karlsson, president of a 45-years-old family business that has lifted once again after a few weak years in the wake of the financial crisis.

Part of the recipe behind the company's recent success was the Production Leap in which swerea IVF helps compa-nies to improve efficiency of their operations according to Lean principles. since elektromontage strives to offer a high degree of service, improved delivery performance to customers is very important. when the company esta-blished a new key performance indicator (kPI) they call

"Lead-time critical material ordered on time", a dramatic improvement was realized in six months. This kPI helps to ensure that the right material is ordered on time and that subsequent production and deliveries also take place on time. Co-workers have reached consensus as to improve-ment and work methods. The outcome is better flow and efficiency and that the improvement work is continuously visualized on so-called improvement boards. several work areas have been organized more rationally, which allowed the work group to reduce the area used by 42 percent, while some lot sizes could be reduced from 25 to 2.

elektromontage has conducted the process of change while at the same time increasing business volume during 2013 by nearly 50 percent. Thanks to tenacity, team work and the insight that improvement work can never rest, elektromontage has started a successful journey.


Luleå

Linköping

GöteborgJönköping

Stockholm

Piteå

Oslo

Brest

St Etienne

Here are our operating locations

www.swerea.se

Swerea IVF – production efficiency, industrial product development and eco-design. Process and materials development within the fields of textiles, polymers, metals and ceramics. www.swereaivf.se

Swerea KIMAB – Process and alloy development, the material’s properties during manufacture and use, and corrosion and corrosion protection with metals, polymers and surface coatings.www.swereakimab.se

Swerea MEFOS – Process metallurgy, heating, metalworking, recycling, environmental engineering and energy efficiencies for the ferrous and base metal industries. www.swereamefos.se

Swerea SICOMP – Composite materials – materials technology, process and production technology, design technology. www.swereasicomp.se

Swerea SWECAST – Cast materials – efficiencies in processes, products, environmental technology and energy. www.swereaswecast.se

The Swerea GroupThe Swerea Group creates commercial benefits for its members and customers by developing, refining and communicating new research results within the following areas: material technology, process technology, production technology and product development.

This improves the overall competitiveness and in-novativeness of Swedish industry.

Swerea is owned by around 500 companies via owner associations (57%) and by rISE holding – the state-owned company for shared owner-ship in Swedish research institutes (43%) .

The Swerea Group, which comprises around 550 research scientists, consists of the following research institutes:

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