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CORUS' FRACTIM BRINGS COST SAVINGS TO AUTOMOTIVE SUPPLY CHAIN
Fractim represents several years of research and development work by Corus Engineering Steels and follows consultation with European forgers, machinists and vehicle manufacturers. Used mainly in the production of engine con-rods, Fractim's unique chemical properties have improved the product's machinability over traditional steel bars. The steel chemistry also allows the forger to manufacture the connecting rod in one piece, which can then be split along a pre-determined fracture line to separate the end cap from the rod. Importantly, the traditional and expensive heat treatment process that follows forging can be eliminated allowing the industry to make significant reduction in manufacturing costs. Machinists, too, can achieve additional cost savings through drilling and tapping efficiencies as well as through the savings in processing that fracture splitting technology affords. The fracture splitting process ensures a perfect fit between the two halves of a con-rod, resulting in additional engine performance benefits for vehicle manufacturers. Commenting on how Fractim allows forgers to produce connecting rods that help meet increasing performance specifications, Corus project manager Steve Kinsey said: 'Fractim is 100 per cent pearlite, which ensures that the material can be split - or fractured - in a precise manner. In connecting rod applications, it is critical that the split is created quickly and without deformation, so that when it is placed around the crankshaft, the fit is perfect. Any deviation can have a detrimental affect on the vehicle's performance levels, resulting in excessive engine noise and vibration.' Mr Kinsey continued: 'Engine efficiency can also be reduced if the fit is not perfect as the conversion of the piston's downward stroke into rotational motion is not as efficient as with a perfect fit. Alternative processes based on conventional machining produce flat surfaces for mating that need careful alignment, whereas fracture splitting creates mating surfaces which align perfectly.' Mark Adams, chief executive of Kidderminster-based forger SDF Forgings Ltd added: 'Over many years Corus has been working closely with us to better understand the needs and issues facing the forging industry today. Fractim represents the results of this relationship and we look forward to enjoying the sales generated by the increased performance benefits of this new product.' Repeated cyclic loadings means that the demands on connecting rods are high. Fractim has undergone an extensive and rigorous test programme and has been shown to offer the same fatigue life as existing materials on the market. Mr Kinsey concluded: 'Fractim is just another example of how Corus is using its expertise to offer the automotive industry material solutions to meet the challenges it faces today. The new material will allow connecting rods to be designed to be thinner and lighter while exhibiting additional strength allowing automotive engineers to take vital weight out of the next generation of engines without losing any performance. Underlining this commitment, Corus technical teams are already working on the next generation of steel bars, which are expected to yield even more benefits for forgers. '
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