arceo : acier et ruptures technologiques par jacques pélerin | liege creative, 09.10.12

Parole d’expert

Jacques PELERIN - Arceo | ArcelorMittal

ARCEO : acier et ruptures technologiques

Avec le soutien de :

ARCEO Liège Creative Colonster 9 octobre 2012

1 09/10/2012

FROM STEEL TO NANOMATERIALS

2 09/10/2012

PVD in world industry PVD process is widely used for several years (20-30) in different industrial fields :

–  Small area coatings (CD ROM, DVD, mechanical tools, medical equipments, …)

Large area coatings (glass, plastics, …)

BUT NOT YET IN STEEL INDUSTRY

3 09/10/2012

Plasma Vacuum Coatings Objective of the Project

The objective of the project is to revitalize the offering in the field of Flat Carbon and Stainless Steels by developing new products, with improved margins, by industrializing the environment-friendly

breakthrough technologies Plasma Vacuum Coatings

4 09/10/2012

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

5 09/10/2012

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 »

6 09/10/2012

PVD UPSCALING From Laboratory

PVD Reactor

7 09/10/2012

… through R & D pilot line …

Arcelor Research Liege

8 09/10/2012

… to Arceo Prototype Line

9 09/10/2012

Arceo (etching equipment)

10 09/10/2012

Deposition of nanolayer to functionalize metal strip can be achieved by Sputtering Deposition …

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.

Ion bombardment by Sputter Etching device to clean the metallic surface is essential to get a good coating adhesion.

… and micrometric coating of metal or alloy by “Jet

Vapour Deposition”.

1000 mbar

200 mbar 5 mbar 10-2 mbar

540 mbar 55 mbar 1 mbar 5 10-5 mbar

1000 mbar

200 mbar 5 mbar 10-2 mbar

540 mbar 55 mbar 1 mbar 5 10-5 mbar Ar+

Cathode (-)Me

Me+e-

StripAr+

Cathode (-)Me

Me+e-

StripAr+

Cathode (-)Me

Me+e-

StripAr+

Cathode (-)Me

Me+e-

StripAr+

Cathode (-)Me

Me+e-

Strip

Air to air coater is the manufacturing design of process line for deposition on metal strip coating.

Ar+

Cathode (-)

MeMe+

e-

MeMeMeMeMe MeMeMeMe

bande (+)

Air to air coater is the manufacturing design of process line for deposition on metal strip coating.

Ar+Ar+

Cathode (-)

MeMeMe+Me+

e-

MeMeMeMeMeMeMeMeMeMe MeMeMeMeMeMeMeMe

bande (+)

Air to air coater is the manufacturing design of process line for deposition on metal strip coating.

Jet

High pressure

Low pressure

Induction heating: closed crucible

Thick coatings or Thin

coatings

11 09/10/2012

Breakthrough PVD Surface and Coating Technologies for Steel

2005 2010 2015

Etching

Surface preparation &

cleaning

Nanometric films

Sputtering

DBD plasma cleaning

PACVD h.p.

PACVD l.p.

Micrometric coatings

"New family lines" MODULAR

GREEN COMPLEMENTARY (Low or high vacuum/

With or without Plasma/ Physical or Chemical,…)

Industrialization maturity

Operational

In progess

> 2-3 years

C.CVD

VPD (Vapor Polymer Deposition)

C.CVD

JVD (Jet Vapor deposition)

SIP (Self Induced Plating)

12 09/10/2012

Vacuum Coatings: Guidelines for industrialization

2005 2010 2015

Colored

Target 3 Target 2

Adhesion

Reflector OLED

Photovoltaïc

Self-cleaning antibacterial

New surface treatments Environment/Cost reduct. Modules on coating lines

Antidirting

Decorative

Esthetic

Auto

Prepaint

Reengineering

Light Management

Active and

Smart surfaces

New multi layers (metallic/organic) concept

All markets

Metal Look

« Provider »

Absorber

Scratch resistance

Before UV After UV

Electrical connection (-)

Glass + ITO (Anode +)

Al cathode (-)

GREEN LIGHT FROM OLED

HTL/LL/ETL Organic layers

TiO2 Coating Antibacterian

1000 hrs salt spray

13 09/10/2012

Processes and Products Definition

Technology Conception Product /Process Development

Investment (Conception/Realization) Product/Process Window/Reliability Product Homologation/Commercialization

From Lab Scale

To industrialization

Through R & D Pilot

Simultaneous and interactive developments Reduction of Time to Market and Risk Management

Technology Upscaling And Product Development

14 09/10/2012

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)

15 09/10/2012

Arceo Company 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)

15

16 09/10/2012

Arceo Ligne 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

16

Painting 1 Painting 2

Cleaning

PVD coatings

Vacuum

17 09/10/2012

Arceo Strategic Priorities

•  « Scale up » Technologies (PVD, Roll Coating) ex : JVD ( Preparation of investment in « High Speed » line). •  Development of new products and markets

18 09/10/2012

Fe

Zn

Zn2Mg

Steel

Zn

Zn2Mg Thermal

Treatment

Steel

EG

Mg

PVD

Zn Mg by PVD Micrometric coatings è (Arceo Phase 2)

• Better corrosion performance (for example perforating corrosion for auto) • Cost reduction

19 09/10/2012

Arceo Strategic « Niche » markets and products

19

I. Renewable Energy -Solarceo ® -Luminance® -Shieldarceo

II. Active surfaces and esthetic products Ambient® Hairclyn® AFP Colour Coatings

20 09/10/2012

RENEWABLE ENERGY

21 09/10/2012

ü  Description du produit. ü Revêtement sélectif (grande absorption et faible émissivité) sur

aluminium et cuivre pour fabrication de collecteurs solaires thermiques

Solarceo Description produit et marché

22 09/10/2012

SOLARCEO

23 09/10/2012

ARCEO

Light & Energy :

PERFORMING REFLECTORS

PHOTOVOLTAICS

ENERGY CONTROL

(EC)

SOLAR ABSORBERS

SOLAR CONCENTRATORS

OLED Light source

L&E

ARCEO

24 09/10/2012

25 09/10/2012

26 09/10/2012

Lighting technology timeline

•  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)

Gen.2

Gen.4

LED

OLED Gen.3

Reflectors

Gen.1

Innovative lighting systems Solid-state Lighting

27 09/10/2012

Shield Arceo : Heat shields applications

28 09/10/2012

ACTIVE AND ESTHETIC SURFACES

29 09/10/2012

Esthetic : Ambient Platinium & Silverline

30 09/10/2012

31 09/10/2012

32 09/10/2012

Esthetic : Ambient Stainless

33 09/10/2012

•  Development of active surfaces in order to propose new functionalities.

Self-cleaning and antimicrobial

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 effect

… but also aesthetic aspects UV-induced hydrophilic stainless surface

Evolution under UV light of a palmitic acid on anatase coated glass

34 09/10/2012

Easy-cleaning Steel (TiO2)

Normal PPS

PPS easycleaning

35 09/10/2012

Partenaires : 23

Budget Global : 22 Millions €

Créations d’emplois

annoncées : 450

Durée du projet :

4 ans

36 09/10/2012

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)).

37 09/10/2012

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

38 09/10/2012

Arceo-Experience and Learning

Human Challenge

•  Leadership •  Team (skills,motivation,..) •  Long term run •  Coordination with R&D,Engineering,Commercial,Corporate,… •  Manage team evolution

39 09/10/2012

ARCEO

JUST DO IT!

40 09/10/2012

Arceo – Experience and Learning

GO THROUGH