February 2024 Volume 6

MATERIALS

this predictability translates into confidence—confidence that the steel will respond to consistently deliver the desired mechanical properties and characteristics during their heat treat process. This helps prevent forgers from having to grapple with uncertainties stemming from diverse material responses and reduces the necessity for extensive trial-and-error endeavors. And it is why the steel making industry remains committed to establishing a dependable foundation, enabling forgers to dedicate themselves to honing their craft without being hindered by substandard raw materials. Automation and AI: Enhancing Precision In the realm of steel manufacturing, standard grades serve as foundational elements that underpin various applications. However, evolving demands have heightened the necessity for specialized engineered steel that surpasses traditional applications. Recognizing this transformation, many leaders in the industry are harnessing the power of automation and artificial intelligence (AI) to customize standard grades, catering to the distinctive needs of pivotal sectors such as aerospace, automotive, energy and defense. Traditional steel manufacturing processes involve intricate variables, from raw materials composition to temperature controls during melting. The integration of automation and AI represents a paradigm shift, enabling real-time monitoring, analysis and optimization of these processes. Machine-learning algorithms empower steelmakers to glean insights from extensive datasets, identify patterns and make data-driven decisions to ensure consistent quality across batches. While many mills can meet basic steel chemistry requirements, the incorporation of automation and AI extends the range of services and control, resulting in highly optimized responses that align with stringent application requirements. Steel manufacturers are embracing automation to streamline processes and reduce reliance on manual intervention. Today, a highly automated, driven process offered by Metallus effectively manages inclusion size, shape and distribution, ensuring consistent material quality and mitigating the risk of premature fatigue failures. Continuing AI advancements are enhancing this capability for the future. Reflecting an industrywide trend toward greater efficiency, there currently is a strategic emphasis placed on achieving a higher reduction ratio and employing the largest initial section size when producing a hot rolled bar. Starting with a larger size offers forgers advantages beyond scale alone; it facilitates more extensive hot working, leading to a finer grain structure and heightened steel strength. This proves instrumental in supporting the forging process by minimizing the need for aggressive forging, extending the life span of dies and fostering operational efficiency.

Controlled melting expertise helps forgers reduce their total ownership costs. In many steel plants, automation has expanded to encompass the loading and unloading of furnaces, enhancing control over the production environment. Additionally, material handling is optimized with robots equipped with sensors, mitigating the risk of human error and guaranteeing precision in the handling of raw materials and finished products within facilities. Symbolizing the joint quest for innovation and advancement in the broader steelmaking community, the transformative influence of automation and AI ultimately emerges as a pivotal driver for customization, empowering forgers to acquire precise quantities of specialized engineered steels tailored to their specific requirements. Local Supply and Service: The Strength of Domestic Partnerships Forgers highly value the strategic advantage of a reliable local supply chain, and within the steelmaking industry, companies with longstanding legacies consistently champion domestic manufacturing. Amidst transformations, the enduring commitment to a robust local supply chain remains a focal point across the industry. This commitment is not just a nod to historical roots but a pledge to forgers who prioritize strong partnerships and consistent delivery. Acknowledging the complex challenges presented by global supply chains, particularly in the aftermath of recent disruptions such as the COVID-19 pandemic and hyperinflation, manufacturers like Metallus are persistent in their dedication to upholding a domestic supply chain. They recognize the success of steelmaking depends on the success of the forgers as a key player in domestic manufacturing. This commitment is grounded in the recognition that proximity can serve as a powerful ally for forgers. It brings forth numerous key benefits, including enhanced control over the manufacturing process and quality control measures. This, in turn, instills confidence in forgers, enabling them to meet demanding production schedules and respond promptly to market needs.

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