Case Studies

Summary: MST Steel, a certified Tier 1/Tier 2 supplier, dramatically transformed a challenging scenario for a customer who faced a 40% waste rate in their roll-forming operations. By identifying that the customer’s use of martensitic CR1500T/1200Y steel was leading to quench pockets and material deformation, MST Steel introduced a game-changing solution. Utilizing their specialized shape correction rolling mills, they not only improved the geometry of the square tubing but completely eliminated the need for material rework and scrap. The result was a significant reduction in waste and improved operational efficiency for the customer.

Industry: Automotive Manufacturing
Category: Process Optimization
Processes: Shape Correction Rolling, Material Analysis, Process Engineering

An MST Steel customer was confronting a critical problem that was impacting their bottom line and operational efficiency. Employing a roll-forming process, they were shocked to find that an alarming 40% of their material needed to be reworked or scrapped. Unknown to them, the martensitic CR1500T/1200Y steel they were using was prone to creating quench pockets, severely deforming the metal and causing an array of production challenges.

Desperate for a solution, the customer reached out to MST Steel for expert guidance. Recognizing the gravity of the situation, we immediately performed an in-depth review of the customer’s metal forming process. It was evident that the formation of quench pockets was the primary culprit affecting the quality of the square tubing.

Drawing upon our extensive expertise, MST Steel proposed a tailored solution by employing our state-of-the-art shape correction rolling mills. The mills were specifically designed to rectify issues like quench pockets by altering the steel’s internal stresses while improving its shape. After implementing the new process, the difference was stark and immediate. The issue of quench pockets was entirely resolved, and the geometric quality of the square tubing was noticeably enhanced.

The results spoke volumes. The customer’s waste rate was eliminated, completely eradicating the need for any rework or scrap. This transformative solution not only saved the customer significant material costs but also drastically reduced their production cycle times, adding enormous value to their operation.