1/09

How to secure a 15 m tall rock devouring giant – heavier than a dozen jumbo jets

Read more on page 18 – 21

O f f i c i a l L o c t i t e ® C u s t o m e r M a g a z i n e no.

10 The next generation of gasketing.Providing more flexible solutions. Read more on this topic on page 10

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Dear Readers, Have you ever wondered how to drill a hole into a mountain? If so, the story of Martin Herrenknecht and his rock-eating submarines might interest you. Maybe you were the kind of child who took grandpa’s mechanical alarm clock apart to see how it works? In this case, Rudolf Neumayer and his Tear Down Centre could be just what you are looking for. What we would like to do in the first issue of “Loctite® at work”, our new customer magazine, is to take you on a journey behind the scenes of some of the world’s most successful and sophisticated high-tech companies. This is why we gave this issue the title “Reliability at work”. We want you to share our fascination when we look over the shoulders of engineers constructing the world’s largest tunnel boring machines destined to drill the way through the Alps or building propellers that move tankers and cargo ships through the ocean. We believe that curiosity and an interest in how things work are the basis for creativity and innovation, two values that Henkel and the brand Loctite® stand for. That’s why in the first issue of “Loctite® at work” we are putting the spotlight on two out of the many companies that embody those values, to show how they can impact on the practice and the success of a business. In our Trend Report, we will track the evolution of energy over the last 150 years and give an outlook on how the future of this most important resource of all might look like. And of course, with Henkel and Loctite® you'll ride shotgun in the Dakar Rally with the Loctite® brand. So, lean back and enjoy the ride.

Yours sincerely,

Highlight: Dakar 2009Come along to the bivouac and learn more about the heroes of the Dakar.

Side GlanceEnergy – the breath of civilisation.

Reliability Report 1: Berg PropulsionMarine propulsion systems. High tech and maximum precision, hand made. Breathtaking technology from Sweden.

Reliability Report 2: HerrenknechtTunnel boring technology from Germany. How does Loctite® provide design support?

RD&E insightsAdhesives aren't invented. They are carefully developed. Read more to find out how.

Handy HintsInsights online – the new web-platform from technicians for technicians.

Advanced TechnologiesThe Tear-down process provides insights and creates new options.

OutlookSome of the topics for the next issue of Loctite® at work.

Content

Vice President Loctite Industrial Group Henkel Adhesive Technologies EMEA

Cédric Berthod

Cédric Berthod

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Editorial | 3

A cloud of dust on the horizon. A VW Touareg approaching at breathtaking speed. The towering mountains and dunes of the Atacama desert rising up all around Copiapo, in the northern part of Chile. The Copiapo – Copiapo special is a pretty tough challenge: 476 kilometers of the steepest dunes, deep sand and stony tracks. According to the drivers it‘s the toughest one in the history of the Dakar.

The Touareg whizzes by only a metre away at top speed, the air filled with the powerful roar of the new turbo-diesel engine, a sound that makes every off-road fan‘s heart beat faster. Next the field of competitors arrives hot on the heels, in rapid succession: the great Mitsubishi, Hummer and BMW X-Raid desert racers. And then, following a short distance behind, the monster trucks rumbling by, making the ground shake. Thick clouds of dust have engulfed the terrain. The Atacama desert is said to be the driest in the world, with places where it hasn‘t rained for 400 years.

Conditions for the drivers are tough: Rough terrain, difficult navigation, extreme temperature differences and, most of all, the dry and dusty conditions, push all competitors to the limit. Vehicles are continually subjected to hard shocks and flying stones, the steep dunes demand the highest level of performance from the engines. That day the stage finishes at the Copiapo bivouac, the northern most point of the rally. The “Desert Knights” – Henkel engineers, better known as the “Loctite® Charlies”,

are also ready for action: Jean Gaborit from France, Célio Renato Ruiz and Demetrio Santos from Brazil. The Dakar Service Center, set up as a common platform for Euromaster, BF Goodrich and Loctite®/Pattex, is easily visible from a long distance. Loctite® banners are snapping in the wind – and the red Renault truck is parked in its slot. It is fully loaded with products for repairing all kinds of vehicle damages: Teroson plastic repair and window glazing adhesives, Pattex Power Tapes, and the indispensable threadlockers, sealants, retaining compounds and instant adhesives from Loctite®, used for maintenance and overhaul of the mechanical assemblies on engine and gearbox.

Just now, as dusk is falling, the Henkel Team is busy, working at full steam: many of the drivers coming “home” – mainly the private competitors not accompanied by a service armada of their own – urgently needing support to get their vehicles going again for the next day. “There were several difficult situations during this rally where my machine was quickly back in shape thanks to the Loctite® Team‘s professional repair service. This helped me save valuable time when every minute counts”, says Miran Stanovnik, a Slovenian KTM rider in the top 20, sponsored by Loctite® since 2005.Right now there are three bikers dragging their fairings to the Loctite® service tent, where Célio Renato Ruiz and

Live from the 2009 Dakar Rally

Meeting the Loctite® “Desert Knights” in the Copiapo bivouac

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Highlight|4

Demetrio Santos are busy doing a plastic repair on a BMW body part. Their daily work and many exciting insights into the heart of the rally are documented on the Loctite® live blog www.dakaradventure.com

Chief Charlie Jean is nowhere in sight. I finally discover him with the Hummer team! Robby Gordon‘s box-shaped race vehicle is almost completely disassembled, sitting on the repair stand like a skeleton. Jean is explaining to the chief mechanic how to use Loctite® 243, a medium strength threadlocker that is capable of withstanding severe vibration but allows parts to be dismantled whenever required. “You need only a few drops to make sure that

VW – The new Dakar winner

Innovative solutions for racing champions

Hummer H3 in action Loctite® repair area in the bivouac

threaded assemblies such as motor mounting bolts remain safely and reliably locked – all the way to the finish line”, is Jean Gaborit‘s expert advice. This is truly “Reliability at work”, or, using rally parlance: “Dakar proven!”

The rally finished successfully on 18th January, with a great winners‘ ceremony in the heart of Buenos Aires. A double victory in the car category makes VW the new hero of the Dakar: Both Giniel de Villiers and Mark Miller maintained their lead after Carlos Sainz‘ withdrawal from the race, and they were more than enthusiastic: “For sure: this is the toughest rally in the world - and we had the best marathon team in the world! I am overwhelmed by the surge of feelings at the finish line”, as de Villiers put it in moving words, “I am proud to be part of it, proud of what the team has achieved”. And his team colleague, second placed Mark Miller, adds: “De Villiers is a great champion. He deserved to win! For me as an American it‘s a dream

to finish the rally in second place, and finish as the best American. Our team did a fantastic job.

We will gather new strength from this victory!”

Third position was claimed by Robby Gordon driving

a Hummer, the eye catching race car

from USA with rear mounted,

7.0 liter V8 engine. He lost ground to VW as a result of several roll-over crashes during the rally. In the interview he stated: “Our only goal was to make it safely across the finish line. And we did. The rally was an incredibly tough challenge. We will now work on improving the chassis to get an even better result next year”. Marc Coma secured victory in the motorcycle class Second and third positions went to Frenchmen Cyril Despres and David Fetigne. Chilean motorcycle rider Francisco Lopez finished fifth and was celebrated as a national hero by his compatriots and ardent local fans.Loctite® KTM bikers Miran Stanovnik, Annie Seel and Norman Kronseder successfully mastered the tough challenge and reached positions 13, 76 and 82. Loctite® triumphed in the truck category! Another double victory was achieved in the truck competition with Russia‘s Team Kamaz , supported by Loctite® since 2007. The two front runners fought a spectacular fight, finally decided by Vladimir Chagin‘s tire damage. Firdaus Kabirov finished just 30 seconds ahead to win overall victory.

The Dakar winners

Henkel – Official Partner to the Dakar Rally

First time participation: 2005

Team: "Loctite Charlies": Service team with 3 – 6 international engineers

Brands: Loctite®, Teroson, Pattex

Products: Adhesives, Sealants, Surface Treatment

Major applications: Threadlocking, Gasketing, Sealing, Retaining, Plastic Repair, Windscreen Replacement, Glass Repair, Instant Bonding

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Highlight | 5

High-tech from Sweden The rays of the morning sun reflect on the calm surface of the sea, before they reach the white lighthouse that has been operating for more than a hundred years. The small sailing boats are quietly bobbing up and down in their moorings, wooden houses with the characteristic low roofs line the waterfront and the cries of the seagulls are the only sounds that the wind carries.

Production in Öckero Berg Propulsion headquarters Propeller blades ready for assembly High precision meets high-tech

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Reader recruiting Reader|6 |6 Reliability Report 1

What sounds like the beginning of a bad novel or a holiday brochure for travellers with a taste for maritime nostalgia, actually describes the location of a modern production plant: The island Öckerö, off Sweden‘s West coast, is home to the ship propeller manufacturer Berg Propulsion, one of Sweden‘s leading high tech companies.

Ensuring reliability with Loctite®

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Reader recruiting Reader | 7Reliability Report 1 | 7

Cleaning the hydraulic pipes with Loctite® 7063

Loctite® 243 – securing the propeller´s steering mechanism

Locking & sealing the threads with – Loctite® 638

End cap fixing on hub shaft with Loctite® 243

A dowel pin controls the propeller blades. Secured by Loctite® 243

The hydraulic system is embedded into the shaft

After only one hour the system has to withstand 70 bar of oil pressure

All the blades are

assembled and the

propeller is ready

for use

Assembly of the pipes – securing it with Loctite® 243

No room for errorFrom modest beginnings, the company was founded as a shipyard for fishing vessels in 1912, Berg Propulsion has developed into a multinational company constructing propellers for all kinds of vessels. Tankers, containers, cargo ships and luxury yachts, to name just a few, all rely on the experience and the craftsmanship of Berg Propulsion.

The demands placed on the reliability and durability of Berg‘s CP (Controllable Pitch) propellers are enormous: Once the propeller is fitted to the vessel, alterations become extremely difficult and the propellers are in use for 25 years or more. There is no room for error, because the safety of the ship and the vessel depend on the quality of the product. Money is another aspect; every day that a ship has to remain in the dock for repairs costs the owner between $15 and $20,000 a day, explains Berg‘s Managing Director Anders Christoffersson. (see interview)

Family businesses gone globalTechnological progress has made its mark on every aspect of life, and the manufacturing process at the plant on the idyllic island of Öckerö is no exception to this rule. A lot has changed since Johann Wiktor Berg manufactured the first CP Propeller for a wooden fishing vessel in 1929; one of those changes is the use of Henkel‘s Loctite® products. Berg Propulsion and Henkel, the

global leader in adhesive technology, have a lot in common: Both started as family businesses with an emphasis on high-quality products and both have developed into successful companies operating on a global scale.

Henkel had the opportunity to observe the production process at Berg‘s island plant. The gigantic propeller, with a diameter of more than 9 metre, dwarfs the men standing next to it. The shining bronze propeller blades appear almost menacing in their shining perfection. At every stage of the manufacturing process Loctite® products have an important role to play: The threads of hydraulic pipes responsible for controlling the individual b lades

Customer: Berg Propulsion, Sweden

Task:Securing hydraulic systems to assure reliability for 25 years and more

Products: Loctite® 243Loctite® 638

Reliability at work

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|8 Reliability Report 1

What is your position at Berg Propulsion? I am Vice President of our technical division Berg Propulsion Technology. And we are developing Berg’s products of tomorrow.

You use Loctite® threadlockers and thread sealants to secure assemblies in the hydraulic system and in the propeller hub. Can you tell us more about the specific requirements applicable to these areas? The requirements which our systems must meet are that they have to be sealed, and this applies especially for our hydraulic systems, they have to be pressure resistant. Then in our threaded assemblies we have to lock the bolts and screws against vibration loads.

In which way can Loctite® be of help in those situations? Loctite® increases reliability of our products.

Why do you use Loctite® products in this application? This gives us a quick and easy assembly.

Which products do you mainly use? We use threadlockers 243 and 2701, for retaining it is 638 and 603.

Which benefits do you get, besides the technical reliability? We can reduce inventories for mechanical locking devices and we have fewer item numbers, which gives us big savings in warehousing

Why is reliability so important for Berg Propulsion? Reliability is important as Berg has safe and dependable products. Our customers expect ship propulsion systems with highest availability at all times. If there is some failure in the propulsion system, the boat can no longer earn money. And in this case, we talk about high amounts of money. This varies from 15 – 20 thousand US Dollars per day. This is not unusual.

Do you make use of Loctite‘s technical service today? Yes, we use Loctite® technical support daily in the form of calculations and application solutions. Then, we also get ongoing product training for our technicians and engineers.

Do you know more about the brand Loctite®, e.g. the history or the other product ranges? Yes, concerning the history I know that it is a company from the 50's, and we’ve started to use Loctite® in 1964. It was a colleague, Erik Berg, son of the founder of Berg Propulsion. He was in England and came home with a Loctite® product as replacement for the locking washer. And it worked. Since then we have used Loctite® products and other products; those we know among others are your lubricants and flexible adhesives and instant adhesives.

What do you think are the most important characteristics and benefits of Loctite® products today? Loctite® products have a lot of benefits. But the most important one for us is reliability and the technical support which Loctite® gives us.

are retained with Loctite® 638. They have to withstand pressures of more than 70 bar, which equals twice the force the blades will have to bear on the ocean.

Developing tailor-made solutionsThe adhesive sealing has to create a hermetic seal after an hour, because then the hydraulic pipes are embedded into the shaft. Another example for applied technological progress is the production of the spacer that protects the propeller‘s control units. The spacer is fitted to the units with 4 screws, locked with Loctite® 243. “Loctite® increases the reliability of our products. We co-operate closely with Loctite‘s technical department during the development and the production process” says Christofferson.

Lars Andreasson, from Loctite‘s Industrial Engineering department explains: “We can assist the customer by calculating the pressures the product has to withstand, for example. It‘s a form of team-work. Our goal is to assist the customer by developing tailor made solutions.”

The manufacturing process of ship propellers has come a long way. What is interesting to note about it, is the fact that there is something like a conspiracy theory about the origin of the technology. There is a possibility that the Englishman Francis Smith, who took credit for the invention was actually preceded by the Austrian enthusiast Josef Ressel. Unfortunately, however, that issue wasn‘t resolved in Ressel‘s lifetime and he never received the credit that in retrospect appears to be due to him. While technological progress is unstoppable, like the co-operation of Berg Propulsion and Henkel on idyllic Öckerö shows, issues with intellectual ownership seem to be here to stay.

Anders Christofferson, Managing Director Berg Propulsion Technology AB

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Reliability Report 1 | 9

The stories behind inventions tend to have something romantic, something co-incidental about them: Archimedes allegedly had his big idea in the bath tub and Einstein is said to have been sunbathing in the park when the special theory of relativity occurred to him. If you listen to Martin Smyth and Peter Wrobel from the Henkel Technology Centre in Dublin, however, there seems to be little room for the picturesque co-incidents that make for a good urban myth about inventions.

No room for mythsIt rather seems to be an efficient, well-organised process that leaves very little to chance. “We have something called Single Customer Project, which allows us to react very quickly to customer needs,” says Smyth. In this particular case, a customer needed an adhesive that cured on nickel-plated substrate with an extreme speed. The initial screening phase took about a month. After another month, during which three employees of the centre in Dublin devoted themselves full time to the project, the first prototype was ready. “It met 90% of their requirements, but it needed some fine-tuning,” says Smyth. By that point, market research had already shown there was a broader market for Loctite® 276, the new addition to the Loctite® product family.

Co-adapting to industrial evolutionPeter Wrobel’s story is an example for a more long term project. It was a 2 year process that led to the development of Loctite® 5188, a flange sealant aimed primarily at the automotive industry. “We are basically co-adapting to the evolution of car engines,” says Wrobel. “There is a shift from steel to aluminum in the industry, and accordingly, we constantly improve Loctite® sealants in order to work well with that material.” Before Mr. Wrobel and his team embark on such a project, though, there needs to be a solid business case. “If a successful commercial application seems less than probable, we don’t go into the lab, because that’s very cost-intensive,” explains the team-leader. Wrobel is a trained chemist, but he has acquired a good feeling for the business side of things through customer visits. While there is still a place for the coincidence and the power of the subconscious, after all success and failure is still down to people, individuals with their strengths and weaknesses, innovation depends today on to a large extent on exact planning and efficient use of resources.

Peter Wrobel, Senior Development Scientist, Automotive Product Development Dept. Henkel Technology Centre Europe

RD&E insightsThe evolution of new adhesives

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|10 RD&E insights

Achieving fast fixture on passive metal substrates – such as nickel- & other plated surfaces – is quite a challenge for an anaerobic threadlocker, especially if requirements

also call for good sealing performance and high strength, as well as very good thermal and shock resistance.

Finding the optimal solution: Loctite® 276, one of the latest innovations to come out of the Henkel R&D labs, meets all of these requirements. Originally developed in as little as two months within the scope

of Henkel's so-called Single Customer Project in reaction to an urgent customer need, the product was fine- tuned to give an optimal combination of characteristics for the market environment. And, there could be no compromise where performance was concerned, because a high production output is one of the key criteria. Mission accomplished: Loctite® 276 is a high-strength anaerobic threadlocker that achieves fast fixture even on passive metal substrates. It provides locking and sealing of threaded assemblies. It cures reliably even at low temperatures but can withstand up to +150 °C. Loctite® 276 carries the European gas approval according to EN 751-1. Available in 50 ml and 250 ml bottles.

Flexibility – a challenge in gasketing

High-speed threadlocker

Loctite® 5188, the first anaerobic gasketing material offering excellent flexibility even after heat aging, can be used for many applications in the automotive and industrial area. Typical applications include metal-to-metal flange assemblies such as gearboxes, housings, covers, etc.

Anaerobic gasketing technology has revolutionised flange sealing of rigid flanges in the automotive industry, and the assembly of heavy equipment. Anaerobic sealants remain liquid when exposed to air, but cure when the metal parts are assembled and the adhesive is confined between mating flanges. OEMs and subsuppliers have long been enjoying the technical and economic benefits of anaerobic gasketing materials, and Loctite® 5188 takes this technology to a new level. The use of aluminium to produce light-weight automotive castings has gained wide acceptance, and Loctite® 5188 meets the flexibility requirements of these modern concepts. The product is designed to function in the most demanding applications. It has very good

adhesion to metal surfaces, especially to aluminium, and provides immediate low pressure sealing. Resistance of the cured product to thermal and chemical stress is excellent. It provides elongation to compensate for micro-movements resulting from vibration, pressure and temperature changes. Because Loctite® 5188 allows flanges to come together with metal-to-metal contact, tolerances can be more accurately maintained, and the correct clamp load is ensured throughout the life of the assembly. Loctite® 5188 has improved oil tolerance, allowing it to seal through slight oil contarmination. To suit all needs, the product is available in three sizes: 2 l bag-in-box, 300 ml cartridge, and 50 ml accordion.

Reliability at work

Reliability at work

Benefits – Overview:

Provides locking and •sealing

Ideal for gas pipes, •valves & connectors

Allows higher •production output

Benefits – Overview:

Suitable for light-•weight design flanges

Can tolerate • micromovements on highly stressed flanges

Ideal for engine •compartment applications

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RD&E insights | 11

Have you ever felt the urge to take a washing machine apart to see how it works? Or an oven? A fridge, maybe? If your answer to any of the above questions is yes, you will probably envy Rudolf Neumayer: Because that’s what he does for a living. The friendly Bavarian lights up when he starts talking about taking things apart.

“Taking things apart” is not his official job description, of course. Rudolf Neumayer is Manager of European Technical Service and Engineering for Henkel in Munich. He works out of Henkel’s Innovation Centre in Munich and is part of an interdisciplinary team of specialists that is responsible for what Henkel calls the “Teardown Analysis”, also known as taking things apart.

Tearing it downWhat is the rationale behind such an analysis, apart from the sheer joy it seems to bring to the people involved in the activity? A Tear Down analysis is a form of Value Engineering,

i.e. the attempt to look at each component of a

finished

product, to see whether the value of the product can be enhanced or the cost of manufacturing can be cut.

“Value Engineering or Value Analysis was conceived in the early 1940s by Lawrence D. Miles while he was employed by General Electric, a major defense contractor which was facing the scarcity of strategic materials needed to produce their products during World War II, according to a paper published by the International Value Society in 2007.

From those humble beginnings, Value Engineering has come a long way. One of the paths the development of the method has taken is the Tear Down Analysis practiced by Neumayer and his team. “In the last 3 years, we have worked on over 60 projects with a broad range of major international companies,” explains Neumayer. Since the customers enter a very confidential relationship with Henkel, giving access to manufacturing sites and construction plans, it is understandable then Neumayer guards their identities very carefully and refuses to even hint at them during the interview.

Tear Down analysisimproving industrial processes

Rudolf Neumayer

Manager of European Technical Service and Engineering, Henkel, Munich

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Advanced technologies|12

Dreaming of windmillsWhat he does talk about is in what way

he and his team have achieved some quite stunning results on some of the projects: Adhesives,

aka glue, are something else that Rudolf from Bavaria seems to feel passionate about. “It is a problem that in many vocational trainings, people aren’t taught enough about the possibilities that modern adhesives open up,” he says in English. Surprisingly, his English sounds a lot more polished and difficult to place than his German. The fact that he is responsible for the whole European area and speaks English most of the time seems to have taken its toll.

“To give you an example: For a major customer (we only deal with customers that do mass-production, otherwise our process wouldn’t make any sense) we managed to replace a step in the production process of his washing machine by using Loctite. That way, the production has become cheaper and the customer was able to fit a larger drum inside the washing machine. So, it’s good for everybody: Good for us because we have a new customer for Loctite, good for the manufacturer because they raise their margin, and good for the consumer because they get a larger drum,” he explains enthusiastically and it is hard to disagree with him.

And it doesn’t stop here, at least not for Rudolf: “We have only just started, we have just scratched the surface of what’s possible,” he says and his eyes gleam.

Team play and interplay of our various technical specialists at the ETS in Munich brings all relevant facts and figures on the table.

And what kind of machine would he like to tear down next? “A windmill would be nice,” he says, with a dreamy look in his eyes…

Value engineering

Enhanced product

value

Tear Down analysis

Lower production

costs

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Advanced technologies | 13

Energy – the breathof civilisationWith every breath we take, according to Traditional Chinese Medicine, we receive our share of Chi, the universal energy keeping us alive. Normally we are not aware of breathing. Normally we are also not aware of the energy, equivalent to 120,000 TWh, produced and used each year around the world to keep our society alive, except when our cities stay dark, oil becomes too expensive or there is no gas for heating.

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Side Glance|14

Watt – the man who brought the dawn of endless opportunity

In 1776 James Watt installed the first industrial standard steam engine. This was the dawn of our modern, technology-driven society that soon became inseparably linked to and dependent upon a continuous and growing supply of energy. From these very first days, energy production and transport became a global network, as unobtrusive as it was reliable, always available and ready to work. The impact energy has on daily life, the way energy characterises society becomes apparent when malfunctions occur; only when cities remain dark, or when oil, gasoline or natural gas run short or become unavailable do we fully understand our lifestyle’s dependence on energy. Without an energy supply there is no mobility, no media, no information technology, no commodities nor a food supply; medical care and hygiene is reduced instantly, and in the worst-case-scenario there is iciness.

Sources and uses of energyFor more than a hundred years, the world’s energy consumption has increased rapidly. Today the demand for energy is nearly twenty times greater than in 1900 and twice as big as in 1970. Of the energy consumed globally, 58 % is produced by oil and coal, 24 % by natural gas, and 18 % by biomass, renewable energy and atomic power plants. In the distant past, coal was a less-than-ideal solution for those who could not afford wood and had to use these putrid, smoking stones for cooking and heating. But the growing demand for metal, and James Watts’ steam-engine paved the way to a coal-driven era. Soon large cities like London, Boston, New York and Berlin were illuminated by coal-produced town gas. From 1800 to 1850, coal consumption grew from 10 million tons (mt) to 76 mt. In 1900, 760 mt of coal were used in a single year. In those days, coal covered 90 % of global fuel needs.

Share of world energy

consumption 2007,

percentages.

Source: BP

Timeline of energy demand

by sources.

Source: Exxon

Others

Africa

India

Middle East

Latin America

Japan

Russia EU

China

USA

oil

gas

nuclear power

hydropower

firewood

coal

(Mtoe)

(Year)

2118

17

1665

5

5

43

10,000

9,000

8,000

7,000

6,000

5,000

4,000

3,000

2,000

1,000

1860 1880 1900 1920 1940 1960 1980 2000

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Side Glance | 15

The rise of industrial nations would not have been possible without the combined power of coal and the steam engine. Even today, coal production is still rising. Due to the increasing demand for energy, especially in China, coal production was at an all time high of 5.4 bn tons in 2007 – equivalent to a 1.4 kilometre cubic block of coal, and an increase of more than 30% within only five years.

The rise in demand for crude oil started with an ingenious marketing campaign. To sell more petroleum, J.D. Rockefeller gave away free oil lamps. So people bought his oil instead of expensive and rare whale oil. Some years later, refined oil played a key role in developing the newly invented motorcar, and oil became the basis of mobility. From then onwards, a global distribution network was introduced that included drilling rigs, pipelines, crude oil vessels, refineries and gas stations. Since 1960, crude oil has been the most important fossil fuel, covering one third of world energy consumption. A 60% share of oil production is used for traffic and transport. In 2008 the average daily production and use of crude oil was 85 million barrels (one barrel =159 litres) a day or 31 bn barrels a year, which is 4933 bn litres or 4.9 cubic kilometres – this would make a cube with sides 1,68 kilometres long.

Natural gas has been available since the beginning of oil production, was mainly considered as an unimportant and dangerous by-product. In the 1980s, natural gas became established as a basic energy resource for industrial production, the production of electricity, and for households. This economic breakthrough was founded

on the convenience, warmth and cosiness that natural gas offered as a replacement for coal-produced town gas. Today, natural gas is still a major fuel for generating electricity and for residential domestic use. The total worldwide amount of natural gas extracted in 2007 was 2940 bn m3 – this time enough to make a cube with 14 kilometre-long sides.

However, progress was followed by adverse effects. In total, burning oil, coal and gas produces 26.100 bn tons (13.300 bn cubic kilometres) of carbon dioxide a year – imagine a cube with sides 23.7 kilometres long. This is the problem of growing energy consumption – nature cannot recycle all the man-made CO2 and so the atmosphere is becoming overloaded with this gas. In addition, fossil resources are limited but in the future there will be a vital need for these precious raw materials – for synthetics as well as for life-saving pharmaceuticals and hundreds of other products derived from crude oil. Dependency on fossil resources has also become an economic and a political source of crisis. The Cold War as well as power games with and between main oil-producing countries has led to economic imbalances. Long-distance transport routes, volatile prices, geopolitical instability, trouble spots and economic dependency on a few energy providing countries are causing a worldwide re-evaluation of energy systems.

The breath of the sun – light, heat, windIn contrast to fossil energy production, atomic energy, hydro power, biomass and renewable energy represent only one fifth of world energy production. Nevertheless, the

A 1.7 kilometre cube in

New York, equivalent to

the world oil consumption

each year.

Source: SDI-Research

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Side Glance|16

hope for an enduring and stable energy supply depends on renewable resources such as the wind, sun, biomass and water. The reason is obvious; in only three hours the sun sends as much energy as the whole world needs in a year.

Therefore only 3 % of the Sahara‘s land area would be enough to cover the world’s usage of electricity. Only a fraction of available solar energy is used now even though solar power capacity increased from 2 Petajoules (Pj) to 13 Pj in the period from 2004 to 2008. In 2008, wind energy plants, mainly in Germany, the USA and Spain, produced 94.000 MW of electricity. A huge potential remains untouched. The overall potential of renewable energy also depends on technical as well as geographical and economic conditions. Only a fraction of the solar energy we receive is usable but the figures are still impressive:

Type of Energy Amount of world energy consumption covered

Solar Energy 3,8x

Wind 0,5x

Biomass 0,4x

Geothermal Energy 1,0x

Tidal Power 0,05x

Hydrogen Power 0,15x

Less is more – power efficiencyThe largest power plant does not produce any energy; it is designed to save energy by intelligent and efficient usage. On the road from power production to the end-user there are often losses of up to 90% measured against energy input. There are losses within the power-plants, losses of transmission and distribution, and losses in power conversion, for example:

A bulb converts only 3 % of electric energy into visible •lightOnly 13 % of gasoline energy reaches a car’s wheels.•80 % of heating and climating losses in buildings could •be avoided by efficient thermal insulation.

The reduction of losses is multiplied as the energy travels

back to power plants. If losses cause a reduction of energy from say 100 produced units to 10 units output, an increase of efficiency from 1 unit on the output side will save 10 units on the input side. Therefore energy efficiency is the most promising power source of the future.

The Evolution of TechnologyFor more than 150 years the increasing availability of energy has improved access to resources and the production and supply of food. It has enabled unprecedented mobility, information availability, communication, and the usage of sophisticated technical devices. New technologies evolve whenever existing applications turn out to be too costly to resolve new problems. Old technologies will either be optimised or gradually substituted by their successors, unless the problem itself is altered or changed by new perspectives and solutions. It is obvious that an environmental and socio-economic driven change in energy-technology lies ahead. It is also obvious that essential technologies already exist or are in development, ready to compete to provide useful and practical solutions. Even now there are numerous inventions and innovations, such as new technologies to produce and save energy or efficient production solutions to preserve natural resources. New materials, components and drives are steadily reducing the energy demands of industry and transport. New concepts of mobility will evolve to a essential criteria. The final goal should be, as Traditional Chinese Medicine advises, to keep the flow of energy alive – with every breath we take.

Dr. Oskar Villani, SDI-Research

A fraction of the area of the Sahara could cover the world’s energy demands Source: TREC

Only a fraction of primary

energy is used.

Source: Paeger

Primary energy 100 %

transport

Conversion in power plants,

refineries etc... Conversion loss

22.5 %

Private consumtion, loss of power

5 %Non-energetic consumption

7.5 %

Consumer consumption

36 %

Final energy 65%

Useful energy

WorldEU 25 D

Reliability at work

Technical Glossary

bn:billions 1 billion =1,000,000,000 =1x109

barrel:1 barrel = 159 litres or 42 US Gallons

CO2:Carbon Dioxide

PJ:Petajoule1,000,000,000,000,000 J ~ 278,000,000 kWh,unit of energy

MW:Megawatt = 1,000,000 Watt

Mtoe:million tons (of) oil equivalent, unit of energy. 1 Mtoe = 11,630,000,000 kWh

Km:Kilometre, 1 Km ~ 0.62 Miles

kWh:kilowatt-hour = 1,000 Wh, unit of energy

at work | no. 1/09

Side Glance | 17

A German masterpiece Imagine a 82 m long, rock-eating submarine with four floors, as tall as a high rise building with 20 floors lying on its side. This monster is heavier than a dozen 747 jumbo jets and creeps forward through the earth behind a more than 9 m tall rotating cutting face. Sounds a little outlandish to you? Product of a hyperactive imagination? If you thought that, you were wrong. This is not Hollywood, this is the Discovery Channel.

Engineering Know-How from Germany for the whole world

Every mm counts – even when 9t of steel are waiting at the hook

82 m of pure power – ready for action This threaded fitting has to resist up to 350 bar oil pressure

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Reliability Report 2|18

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Reliability Report 2 | 19

The main drive of a tunnel boring machine is an assembly of no less than four large gear units that are bonded and bolted together. Flange faces are coated with Loctite® 586 using a roller, which increases friction 2 to 2.5 times.

Insane pieces of engineeringIf you are the kind of person that doesn‘t like science-fiction, because you are interested in reality, Allmannsweier in Baden-Württemberg is the place for you.

Allmannsweier in Baden-Württemberg is one of the more pleasant regions of Germany, famous for its good food and the friendly locals. It‘s also the home of Herrenknecht, the world‘s leading manufacturer of tunnel boring machines. And it‘s those machines which dwarf the imagination of your average Hollywood screen writer. It’s not surprising that the company and its charismatic founder, Dr Martin Herrenknecht has attracted a lot of attention from the global media lately.

“An insane piece of engineering” is how the American Discovery Channel describes the Herrenknecht machine that drilled a 5.4 and a 3.9 kilometer tunnel in Kuala Lumpur in 2006.

The defining project of Herrenknecht‘s career and one of the greatest public works of any kind is the Gotthard Base Tunnel. The tunnel, which has been under construction since 2002, will run from the village of Erstfeld, in central Switzerland, to Bodio, in the southeast, a distance of more than 57 kilometers. When completed, in 2017, it will be the longest traffic tunnel in the world; it is also one of the most geologically challenging, The Gotthard crosses nine geological zones. It cuts through granite and quartz, along fault lines and beneath a sugar like layer of dolomitic marble – a challenge to anything going through it.

No rock too hard, no mountain too high: Loctite® and Herrenknecht

Herrenknecht has been growing ever since its foundation in the 70s. It now employs around 3000 people worldwide and sales reach 1 billion Euro for the first time in 2008. This impressive success story is partly due to the fact that Herrenknecht took advantage of the opportunities offered by globalisation. China is one of the countries which Herrenknecht focused on early and in 2008 they were able to celebrate the delivery of the 100th machine to the power-house of the world economy. Completed main drive waiting

for the assembly into the machine.

Forget Star Wars, forget Star Trek, forget the Matrix.

Wherever one of the machines operate, Malaysia, China, Switzerland or Brazil, Henkel‘s Loctite® products always play an important role during the construction of those insane pieces of engineering. Loctite® threadlocker 243 is used to lock all the screws in the machine, which has to withstand enormous pressure while it eats its way through the rock.

Another application which makes good use of the reliability that Loctite® stands for, is the machine’s rotating cutting head. The cutting head's power unit relies on a variable number of single engines. The superstructural part's flange ring and main bearing as well as transmission case and main bearing are cemented repeatedly in a laminary fashion, using Loctite® 586. This process allows to transmit more than twice the turning movement that would be possible otherwise. The cementing with Loctite® enhances the reliability and allows the power unit to withstand the forces that can come to bear on it underneath the earth.

Loctite® Sales Engineers are also involved in the planning process of the machines, liaising with the various Herrenknecht departments in order to meet the customer’s construction needs as early as possible. Henkel and Loctite® are ideal partner for Herrenknecht’s tunnel-boring machines, which never quite know what kind of rock they will have to taste next. Loctite’s Rapid Response Process (see Product Development Article), allows us to respond to new requirements in a matter of weeks.

The next stop for the tunnel boring machines is Paris, where the new tunnel for the Metro 12 has to be drilled.

Reliability at work

Customer: Herrenknecht, Germany

Task:Securing flanges on the main drive with a 2 to 2.5 times higher friction coefficient within it.

Products: Loctite® 7070 Loctite® 586Loctite® 243

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Reliability Report 2|20

InterviewWolfram Lais, Head of Subassembly, Herrenknecht AG

Christian Draeger, Traffic Tunnelling Sales Department, Herrenknecht AG

You're using Loctite® products for a wide variety of applications in the manufacturing process of your equipment. What Loctite® products do you use in the manufacture of tunnel boring machines? Mr. Lais: In our department we mainly use Loctite® 586 for bonding flanges and 577 for thread sealing, 243 for threadlocking and Loctite® 7070 as a cleaner.

Where do you use Loctite® adhesives on your machines? Mr. Lais: We use Loctite® mainly on the cutting wheel drive. We apply product 586, to increase friction.

In general, what parts of a machine are most severely stressed during operation of the equipment? Mr. Draeger: The cutting wheel and the main drive are subjected to very high loads. Just imagine that the cutting wheel is moving through the ground, encountering a variety of soil types and loading conditions. There may be hard rock or loose rock. In the case of hard rock it's mainly the

pressure and the force to be transmitted by the cutting wheel when it's carving away the rock.

With loose rock, it's mainly the torques, the rotating or twisting forces that act there and

cause very high stresses.

How does such a tunnel boring machine get from this production facility to its final destination ? Mr. Draeger: The tunnel boring machine is fully assembled right here in the factory. But, to move the machine to the construction site, it must be disassembled again. That's why the machine is completely modular in design, and modules are assembled with bolts. We will disassemble these bolted joints to get accurate structures which we can transport to the construction site. Once they have arrived at the construction site, these structures are then re-assembled, tightened with bolts or welded.

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Reliability Report 2 | 21

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at work | no. 1/09

Handy Hints|22

Discover reliability in the most extreme racing conditions. Learn more about the Porsche Mobil 1 Supercup and Loctite's technology partnership with the fastest one make cup in the world.

... coming soon

Come along and visit the “kings of earth”. Discover the plant of TEREX in Scotland. Get insights into the production of 100 ton rigid trucks.

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Outlook | 23

Imprint

Publisher Henkel AG & Co. KGaA Adhesive TechnologiesHenkelstraße 67 40191 Düsseldorf Germany www.henkel.com Editorial DepartmentMarketing Department EMEA: Christian Scholze Andreas Engl Beate Schneider Isabelle Feix Erik EdelmannFrank Fischer ContactAndreas Engl (Project lead) Phone: +49-211-797-6758 Andreas.Engl@henkel.com Creationblösch.partner Werbeagentur GmbH www.bloesch-partner.de

Henkel LimitedWood Lane End Hemel Hempstead Hertfordshire HP2 4RQ Tel. 01442 278100 Fax 01442 278071

www.loctitesolutions.com/uk

® designates a trademark of Henkel AG & Co. KGaA or its affiliates, registered in Germany and elsewhere © Henkel AG & Co. KGaA, 2009