Optimization and New Product Development
Metal Pass LLC
www.meta4-0.com (Industry 4.0 Metaverse)
5. A New-Generation Level 2 and the development of new products
(1) Demand of the New-Generation
Level 2 System
High alloyed steel (e.g. Stainless
steel) or other high alloyed material is usually with good quality, but it is
expensive. It is found that by adding a small amount of alloy element, or better
by adding a combination of alloy elements, and by deforming the material with
higher reduction and lower temperature, and then by quick cooling of the hot
formed materials, the mechanical properties such as strength and hardness, etc.
would be improved in a great deal, even though only a small portion of the cost
in increased. Currently it is very common to add alloy elements such as Ni, V,
Ti, Cr, Mo and Cu, etc., together with theromechanical processing in above
mentioned ways. There are very few pure steels/materials, but mostly with
micro-alloyed steels/materials. Therefore, traditional Level 2 system needs
mechanical models to integrate to it. This is why the Level 2 system needs
metallurgical models. About 20 years ago, we in Metal Pass as the earliest in
the world to add metallurgical model into the Level 2 system. We also fixed
intelligent learning problems and add advanced software engineering into the
software, so for example, we let the Level 2 system understand engineering (e.g.
steel) business. Several dozens of publications can be seen in
The Level 2 system
with metallurgical model, intelligent learning and advanced software
engineering, is called by Metal Pass team as the New-Generation Level Level 2
(2) Development and application of the New-Generation
Level 2 System
In the steel industry the equipment software is
mainly reflected in the Level 2 System, in particular Level 2 Model.
The new-generation Level 2 System is particularly suitable for development of
new material grades, as a center portion of high-precision performance
forecasting package associated with thermomechanical forming.
In a steel mill, the Level 2 System is the nerve system, while the Level 2 Model
is its brain. New Level 2 System package installation accounted for only 0.2% of
the equipment investment, and Level 2 System upgrade accounted for only
0.01-0.02% of the equipment investment; it can, however, revolutionize equipment
performance, increase equipment price by 200-1000%! (World Fortune 500 AMER
Group has a case, in which it is 600%).
The team has developed a New-Generation Level 2 System and filled technology
gaps in the world, because the other suppliers do not contain metallurgical
models in Level 2 System in TMCP scheduling, or is very weak in this aspect.
The new generation Level 2 has particular strength in development of new
products, such as to reduce alloys usage: while material properties are
improved, alloy usage can be decreased and thus great saving in material costs
For example, development of new steel grades is not just the chemical composition design, but
to design a complete range of controlled rolling and cooling process
specification as well, in order not only the properties but also the shapes can
be achieved. With the metallurgical Level 2 System, microstructure changes of
different chemical compositions can be fully calculated and thus, the chemical
composition is optimized.
<To Be Continued>