ARCEO : acier et ruptures technologiques par Jacques Pélerin | Liege Creative, 09.10.12
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ARCEO : acier et ruptures technologiques par Jacques Pélerin | Liege Creative, 09.10.12

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Le monde des matériaux est en pleine évolution. L’acier n’échappe pas à la règle. Dans le domaine des traitements de surface et de revêtements, le développement des procédés de dépôts ...

Le monde des matériaux est en pleine évolution. L’acier n’échappe pas à la règle. Dans le domaine des traitements de surface et de revêtements, le développement des procédés de dépôts sous vide, notamment par plasma, constitue une véritable rupture technologique en ce qui concerne l’acier et ouvre la voie à de nouveaux produits présentant des fonctionnalités originales ou des performances nettement améliorées. C‘est aussi de nouvelles solutions en matière de procédés et produits respectueux de l’environnement.

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ARCEO : acier et ruptures technologiques par Jacques Pélerin | Liege Creative, 09.10.12 Presentation Transcript

  • 1. Parole d’expertARCEO : acier et ruptures technologiquesJacques PELERIN - Arceo | ArcelorMittal
  • 2. Avec le soutien de :
  • 3. ARCEOLiège CreativeColonster9 octobre 2012
  • 4. FROM STEEL TO NANOMATERIALS09/10/2012 1
  • 5. PVD in world industryPVD process is widely used for several years (20-30) in differentindustrial fields : –  Small area coatings (CD ROM, DVD, mechanical tools, medical equipments, …) Large area coatings (glass, plastics, …) BUT NOT YET IN STEEL INDUSTRY 09/10/2012 2
  • 6. Plasma Vacuum CoatingsObjective of the ProjectThe objective of the project is to revitalize the offering in the fieldof Flat Carbon and Stainless Steels by developing new products,with improved margins, by industrializing the environment-friendly breakthrough technologies Plasma Vacuum Coatings09/10/2012 3
  • 7. Strengths of « Plasma Vacuum Dispositions » (PVD)•  A revitalized offering –  Strong capability to develop a wide range of coatings (nano- to micrometrics) of various types (metallic, alloys, multilayers, oxide, organic, …)•  New high-value products with : –  - improved properties (corrosion resistance, paintability, esthetic aspects, …) –  - or/and new functionalities (high reflectivity, anti bacterian, self cleaning, self lighting,…)•  Sustainable Development –  Green Process / Green Product•  Competitiveness –  Driven by cost reduction and added value 09/10/2012 4
  • 8. ARCEO / PVD STORY•  1990 : Exploratory Research ( universities)•  1995 : R&D Team in CS dedicated to PVD•  1999 : R&D Pilot Line Merge CS Usinor Arcelor ArcelorMittal•  2004 : ARCEO Creation•  2006 : ARCEO Starting Focus on « NANO »•  2009 : ARCEO Technology Extention To « MICRO » (JVD) ARCEO Engineering Creation•  2012 : Preparation of Investments in ARCELORMITTAL +Development of « NICHES »09/10/2012 5
  • 9. PVD UPSCALING From Laboratory PVD Reactor09/10/2012 6
  • 10. … through R & D pilot line … Arcelor Research Liege09/10/2012 7
  • 11. … to Arceo Prototype Line09/10/2012 8
  • 12. Arceo (etching equipment)09/10/2012 9
  • 13. PVD Technology for steel "Physical Vapour Deposition (PVD)” processes constitute a family of vacuum techniques for coatings and surface treatments. The different steps are the creation of a metallic or non metallic vapour (by sputtering or evaporation), transportation under vacuum of atoms (with or without plasma assisted) and condensation on a substrate. 540 mbar 55 mbar 1 mbar 5 10-5 mbar Ar+ Strip e- Me Me+1000 mbar Cathode (-) Ion bombardment by Sputter Etching device to clean the 200 mbar 5 mbar 10-2 mbar metallic surface is essential to get a good coating adhesion. Air to air coater is the manufacturing design of Thick Thin process line for deposition on metal strip coating. or coatings coatings Cathode (-) Jet Low pressure e- Ar+ High pressure … and micrometric coating Me Air to air coater is the manufacturing design of + Me of metal or alloy by “Jet process line for deposition on metal strip coating. Vapour Deposition”. Me Me Me Me Me Me Me Me Me bande (+) Induction heating: closed crucible Deposition of nanolayer to functionalize metal strip can be achieved by Sputtering Deposition … 09/10/2012 10
  • 14. Breakthrough PVD Surface and CoatingTechnologies for SteelMicrometric coatings VPD (Vapor Polymer Deposition) ity C.CV SIP (Self Induced Plating) matur rialization D ndust "New family lines"I JVD (Jet Vapor deposition) ional MODULAR O perat ss ge In pro ars GREEN > 2-3 ye COMPLEMENTARY PACVD l.p. (Low or high vacuum/ With or without Plasma/ Nanometric films Physical or Chemical,…) PACVD h.p. Sputtering DBD plasma cleaning Surface preparation & cleaning Etching 2005 2010 2015 09/10/2012 11
  • 15. Vacuum Coatings: Guidelines for industrialization rative ColoredDeco ic Metal Look tEsthe 1000 hrs salt spray Target 2 Target 3 Auto Adhesion New multi layers (metallic/organic) concept int « Provider » HTL/LL/ETL Prepa ineering Organic layers g Reen Al cathode (-) Electrical connection (-) Absorber OLED GREEN LIGHT FROM OLED Reflector PhotovoltaïcLight ement Glass + ITO (Anode +) gMana Self-cleaning antibacterial Antidirting Scratch resistance TiO2 Coating Antibacterian and Active surfaces t Smar New surface treatments r kets Environment/Cost reduct. Modules on coating lines All ma Before UV After UV 09/10/2012 12 2005 2010 2015
  • 16. Technology Upscaling And Product Development Processes and Products DefinitionFrom LabScale Technology ConceptionThrough Product /Process DevelopmentR & D Pilot Investment (Conception/Realization)To industrialization Product/Process Window/Reliability Product Homologation/Commercialization Simultaneous and interactive developments Reduction of Time to Market and Risk Management 09/10/2012 13
  • 17. Specifics of the project Management of a « double breakthrough » (Products/Technologies) Risk Management –  Phasing: product and process development, investments, …) –  Upscaling through R & D Pilot line –  Arceo (start-up concept/prototype) –  “Open” to a wide range of new products and new applications (thickness : 0.17-1.5mm ; width : 1500 mm) –  Modularity and flexibility –  Commercial “push” –  Financial partnership (risk capital) 09/10/2012 14
  • 18. ArceoCompany Profile•  Identity Ø  Arceo S.A. founded in June 2004 Ø  Production starting 2006 Ø  Subsidiary of ArcelorMittal (Start-up) Ø  Partnership with Sogepa•  Key figures Ø  50 Employees Ø  Turnover = 15 millions EUR•  Location : Ø  Ivoz - Ramet (Liège) Ø  Belgium (Europe) 09/10/2012 15
  • 19. ArceoLigne description•  Painting line with a Plasma Vacuum Deposition section•  Width: 700 to 1500 mm•  Thicknesses: from 0.15 to 1.5 mm•  Multi «substrates» : flat carbon, stainless steels, Cu, Al, Zn•  Multi layers products Cleaning PVD coatings Painting 1 Painting 2 Vacuum09/10/2012 16
  • 20. Arceo Strategic Priorities•  « Scale up » Technologies (PVD, Roll Coating) ex : JVD ( Preparation of investment in « High Speed » line).•  Development of new products and markets09/10/2012 17
  • 21. Zn Mg by PVDMicrometric coatings è (Arceo Phase 2) Mg Zn PVD Thermal Treatment Zn2Mg Zn2Mg Zn Fe EG Steel Steel • Better corrosion performance (for example perforating corrosion for auto) • Cost reduction 09/10/2012 18
  • 22. ArceoStrategic « Niche » markets and productsI. Renewable Energy-Solarceo ®-Luminance®-ShieldarceoII. Active surfaces and esthetic products Ambient® Hairclyn® AFP Colour Coatings09/10/2012 19
  • 23. RENEWABLE ENERGY09/10/2012 20
  • 24. Solarceo Description produit et marchéü  Description du produit. ü  Revêtement sélectif (grande absorption et faible émissivité) sur aluminium et cuivre pour fabrication de collecteurs solaires thermiques09/10/2012 21
  • 25. SOLARCEO09/10/2012 22
  • 26. Light & Energy : OLED Light source PERFORMING SOLAR REFLECTORS CONCENTRATORS ARCEO L&E SOLAR PHOTOVOLTAICS ABSORBERS ENERGY ARCEO CONTROL (EC) 09/10/2012 23
  • 27. 09/10/2012 24
  • 28. 09/10/2012 25
  • 29. Innovative lighting systemsSolid-state Lighting LED Lighting technology timeline Gen.2 Reflectors Gen.1 OLED Gen.3 Gen.4 •  Gen 1 : Fire (700.000 years ago) à Fire is tamed (Oil lamp : 2500 years ago) •  Gen 2 : First stable Light bulbs with electricity – J.W. Sawn & Th. Edison (1879) •  Gen 3 : Light source are made more efficient (Luminescent Tube : 1937, Reflectors) •  Gen 4 : Fire vanish and light only prevails : SOLID-STATE Technologies LED (2003) & OLED (~ 2010-2015) 09/10/2012 26
  • 30. Shield Arceo : Heat shields applications09/10/2012 27
  • 31. ACTIVE AND ESTHETIC SURFACES09/10/2012 28
  • 32. Esthetic : Ambient Platinium & Silverline 09/10/2012 29
  • 33. 09/10/2012 30
  • 34. 09/10/2012 31
  • 35. Esthetic : Ambient Stainless09/10/2012 32
  • 36. Self-cleaning and antimicrobial•  Development of active surfaces in order to propose new functionalities. ü  Based on TiO2 (< 100 nm) ü  Superhydrophilicity ü  Photo-degradation of organic compounds, stain and microorganisms (bacteria,… ) ü  Combining Ag-oxyde thin films for improved antimicrobial effectUV-induced hydrophilic stainless surface … but also aesthetic aspectsEvolution under UV light of a palmitic acid on anatase coated glass 09/10/2012 33
  • 37. Easy-cleaning Steel (TiO2) Normal PPS PPS easycleaning 09/10/2012 34
  • 38. Partenaires : 23 Budget Global : 22 Millions € Créations d’emplois annoncées : 450 Durée du projet : 4 ans09/10/2012 35
  • 39. Arceo- Experience and Learning Management of a Very complex project•  Breakthrough•  Whole new technologies, products, applications and markets•  « Double Looping »•  360° innovation for steel (purchasing,engineering…)•  Open Innovation•  Operational difficulties (multi missions)•  Flexibility and adaptation (BP, Substrates, valorisation of whole technological potential (PVD + organic coatings)). 09/10/2012 36
  • 40. Arceo-Experience and Learning Start – up = « right way » to scale up•  Governance , team spirit,raise of financings,…•  Stop to dream,stop to search,focus on business•  Spin-out in big company (adaptation,flexibility)•  Right financing to start (development costs,…)•  Products and technologies Business•  Markets steel and « out of steel »•  Technological platform 09/10/2012 37
  • 41. Arceo-Experience and Learning Human Challenge•  Leadership•  Team (skills,motivation,..)•  Long term run•  Coordination with R&D,Engineering,Commercial,Corporate,…•  Manage team evolution 09/10/2012 38
  • 42. ARCEO JUST DO IT!09/10/2012 39
  • 43. Arceo – Experience and Learning GO THROUGH09/10/2012 40