Research and development

The Outokumpu research centres in Tornio, Finland and Avesta, Sweden focus on process, product and application development. Some process and technology development work is also carried out in production units. The R&D function operates in close cooperation with the Group's commercial organisation and customers, and direct feedback regarding customer needs serves as input for further product development. In 2009, the R&D function employed almost 200 professionals and investments in R&D totalled EUR 19 million.

Avesta focuses on special grades

At the Avesta Research Centre, the focus is on special grades including duplex grades, high-alloyed corrosion-resistant austenitic grades and heat-resistant alloys. Much effort has gone into developing duplex grades, which offer a good combination of strength and corrosion resistance with lower nickel content. Ideal applications for the use of duplex grades are large heavy-wall tanks where weight savings of some 20% can be achieved. Customers have shown a growing interest in LDX 2101^®, Outokumpu's own development of Lean Duplex. New applications are continually being developed and related production technology has been improved.

In high-alloyed corrosion-resistant austenitic and heat resistant grades, Group R&D has also been actively involved in technical marketing aspects of older developments such as 254 SMO^® and 253 MA^®.

Outokumpu research centres in Finland and Sweden focus on process, product and application development.

Tornio develops ferritic grades

The Tornio Research Centre develops non-nickel-containing ferritic grades which offer the biggest opportunity to reduce the effects of varying nickel prices on raw material costs. The R&D function at Tornio has investigated optimum process parameters and product properties for standard ferritic grades at production scale, with the primary focus being on surface quality, formability and corrosion resistance. Four different grades, mostly for use in indoor applications, kitchen utensils, domestic appliances and the transportation segment, are now part of the Group's product portfolio.

Manganese-alloyed grades (200-series) are the third opportunity to reduce the quantities of nickel used and also represent an interesting alternative in many applications. The most common product of this type is commodity grade 201, whose chemistry has been modified by Outokumpu. With corrosion-resistant properties almost equal to those of standard austenitic 304 (Cr-Ni), other properties of this grade include higher strength and good formability.

Application development focus is on process industries

The traditional focus of application development has been the process industries, where stainless steel plays a dominant role in the manufacture of industrial equipment used in the pulp and paper, oil and gas, desalination and chemicals segments. Outokumpu's R&D experts provide advice to the Group's commercial organisation and customers on product properties and material selection.

Stainless steel's high strength and good formability have resulted in its use as a construction material being investigated in the architectural, building and construction and transportation sectors - its lower weight and low life-cycle costs make it an excellent substitute for many other materials. Potential new automotive application were studied is the Next Generation Vehicle project, a cooperative project involving European stainless steel producers, car manufacturers and engineering companies which was completed in 2009. In crash tests, passenger-car components made of high-strength stainless steel have yielded very promising results.

Active participation in international associations

In addition to participating in EU cooperation projects, Outokumpu experts are active members of many international associations such as ISSF and EuroInox. Together with other steel and engineering companies and universities, the Group is also actively involved in new FIMECC (Finnish Metal and Engineering Competence Cluster) research programmes in Finland. During 2009, Outokumpu experts gave several presentations at international conferences on stainless steel manufacturing, material properties and the selection criteria for different applications.

The 10th edition of the Outokumpu Corrosion Handbook was published in 2009. Regarded as an authentic guide to the corrosion resistance of stainless steel for more than 60 years, the handbook provides essential information for metallurgists, design engineers and fabricators all over the world, as well as serving the needs of stainless steel users, academics and students.

Development of efficient and environmental friendly production processes

In addition to new products and new applications for stainless steel, the Group's R&D operations focus on innovative and energy-efficient manufacturing processes that reduce costs, result on lower emissions, shorten lead times and improve quality levels. The main subject of environmental research in 2009 was slag utilisation, and studies on both the properties of different slag products and the development of applications continued.