Textron Aviation 3D-Printed Engine

With the rise of new technologies, innovative ideas in the aviation industry are taking off in an effort to streamline manufacturing processes and improve the aircraft performance. In 2016, Textron Aviation unveiled its new 10-person business aircraft, the Cessna Denali, powered by a propeller engine that consists of 3D-printed titanium and steel components.

The Cessna Denali’s propeller engine that consists of 3D-printed titanium and steel components (Source: Textron Aviation)

The engine, which was developed by GE and Textron Aviation after a decade of research and development, features the benefits of a private jet but at an entry-level price. Engineers were able to reduce 855 separate parts down to just 12 components and also reduced the number of steps to make the engine.

There are numerous benefits that come with this 3D-printed engine. As 3D-printed parts and materials weigh significantly less than traditional parts, airline manufacturers can benefit from fuel-efficiency gains. The engine can burn up to 20 percent less fuel and achieve 10 percent more power compared to other engines of the same class. Also, the engine eliminates the risk of losses and leakage as the 3D-printed parts have no joints. A test flight is planned to take place in early 2018.

Virgin Atlantic Green Jet Fuel

As major contributors of carbon emissions, more and more airlines are choosing to go cleaner and greener. In partnership with LanzaTech, Virgin Atlantic has derived 1,500 gallons of low carbon jet fuel from waste industrial gases from steel mills. The carbon used to make the fuel, Lanzanol, is made from ethanol, which is captured through a fermentation process during steel production.

Virgin Atlantic’s Jet fuel made out of waste gases from steel mills (Source: Virgin Atlantic)

This innovative low carbon fuel project is expected to reduce the aviation industry’s reliance on oil. According to LanzaTech, the process could be retrofitted to 65 percent of the world’s steel mills, producing 30 billion gallons of ethanol worldwide. It will ultimately cut emissions by 65 percent compared to using standard petroleum-based fuel.

Dr Jennifer Holmgren, chief executive of LanzaTech, said “We can now truly imagine a world where a steel mill can not only produce the steel for the components of the plane but also recycle its gases to produce the fuel that powers the aircraft.”

Other airlines are also turning to greener solutions. While Airbus is collaborating with Siemens to introduce a range of hybrid passenger planes, Boeing is working with NASA to curb emissions through slimmed down aircraft wings.

Thanks to these innovative aviation projects taking off, commercial jets are becoming greener and more technologically advanced. If engineers can make 3D-printed parts to lightweight an engine and use waste from steel mills to fuel planes, one can only wonder what forthcoming innovations will further empower the aviation industry.

But to fully enjoy those winter sports, you need to have the right equipment for the season. Playing on the ice requires skates, while sliding down the snow-covered slopes requires skis – or even a bobsled or luge, for the serious winter sports enthusiast.

All these sports require steel. So let’s take a look at the role steel plays in bringing our favorite winter sports to life.

Slashing Across the Ice with Steel Skates

Whether it’s for ice hockey, figure skating or just a leisurely recreational skate, a pair of skates and a big sheet of ice is one of the most popular ways of having fun during the winter.

Actually, the oldest known skates are around 5,000 years old, and were made from the leg bones of large animals. But around the 14th century, people in the Netherlands started using iron runners, which were attached to people’s shoes with leather straps. Back then, people used poles to push themselves over the ice, but with the invention of double-edged blades around the year 1500, people gained the ability to push and glide directly with their skates. Finally, in the 19th century, steel began to be used for skates, giving them the strength needed for modern winter sports.

For today’s skates, typically the blades use tempered carbon steel that has been heat treated, and then covered in chrome – although some also use aluminum or stainless steel, and others even use titanium. The more high-end blades use better grades of steel than less expensive types. Because an important part of skating well is the blade’s edge, stronger grades of steel help hold the sharpness of the edge longer, so can go longer between sharpening.

Skate blades are thin – for hockey, usually just over 3 millimeters, while goalie and figure skater skates can be a bit wider. Surprisingly, though, the blades are not just a flat piece of metal. In fact, skate blades have a concave groove or “hollow” in them, so each blade actually touches the ice in two spots. This gives each blade an inside and outside edge, making them faster and more powerful.

Skis and Other Downhill Devices

Recently, we looked at how steel has proven pivotal for downhill fun as it is the main material in ski lifts. But in addition to helping people get up those big, snow-covered hills, steel also helps them come down again.

That’s because the serious downhill sports go seriously fast, and that means major stress on the equipment (and on the rider). Skis and snowboards typically have a thin strip of steel around the edge to strengthen the board and help carve the snow and ice better while turning.

In bobsledding, teams used to have a lot more latitude for coming up with their own sleds, so they would experiment with different alloys for the blades. But since 2006, the bobsledding governing body announced a set of standards for the steel blades, so now everyone uses the same type of metal.

Luge and skeleton are two more high-speed sleds, but much smaller than the bobsled. Their frames are made of steel, and brakes are forbidden in the competitive models. Only on the luge do participants start sitting on the sled, whereas for the skeleton and bobsled they take a running start. For luge, they travel feet-first, while skeleton is head first. The luge also comes in one-person and two-person versions.

The sleds do vary a bit in their steel blades, though. Skeletons have tubular steel blades, which have a larger surface area and slow the sled a bit, whereas luge blades are sharped steel, for maximum speed. But for all these sports, steel blades form the connection between the rider and the ice, creating the foundation for their incredible speeds (lugers can reach 140 kilometers per hour).

Snow Machines

Sometimes to get through the deep snow – when you don’t have a big, steep slope handy – you need an engine to power you along. One of the most popular machines of winter, for those living in the great outdoors, is the snowmobile, which can be both practical and fun.

Of course, steel has long been an integral part of the internal combustion engine. In addition, snowmobiles rely on steel for a variety of other parts. The skis at the front of the snowmobile can be made from a variety of materials, including steel. Studs, which go through the track to create traction, are usually made from steel, too, providing strong, durable traction in the snow and ice.

There is also another steel machine that is as slow as the snowmobile is fast, but it is vital for skaters so they can enjoy an ice rink – the resurfacer (commonly known as a Zamboni). Weighing some 2,500 kilograms, a resurfacer needs to carry upwards of 380 liters of water, along with the blades and other equipment it uses to clean the ice and lay down a new coating of water. A resurfacer needs steel for the strength to support such a heavy machine plus the durability in cold conditions.

Winter is an exciting season with a whole range of special games and sports. And thanks to steel, there are even more fun things we can do.

Conquering Mountains with Steel

Be sure you never miss any of the exciting steel stories from The Steel Wire by subscribing to our blog.

GM plans to launch its plug-in hybrid car (PHEV) “Bolt” during the second half of this year. PHEV is a hybrid car that runs on an electric motor, which can be recharged by plugging it into an electrical power source. It switches to run on the combustion engine when the batteries are depleted.

POSCO ICT plans to build EV-charging stations at 120 key locations as the business partner of GM Korea and will also implement a related membership program.

As POSCO ICT has been selected as the producer of EV chargers for GM Korea, it plans to provide charging services with public charging stations at 120 key locations. Locations will include after-sales centers, GM sales stores, and big marts.

On top of public stations, it is building home charging stations for drivers of GM’s EV and is also implementing a membership program. Through this program, drivers can use the existing charging stations available at big marts, cinemas, and department stores across the country in addition to newly built stations.

 Expansion of the facility to 300 stations to become largest privately-owned infra

Apart from the 120 stations to be built under the deal with GM, POSCO ICT will increase the number of its own stations from 250 to 300 by the end of the year, making it the owner of the largest privately-owned EV charging infra.

It will build and run the infra by targeting the facilities that drivers visit often and spend time at. Drivers will be able to charge their car by driving only 4 to 5 km each time.

The Ministry of Trade, Industry and Energy recently announced that it would build high-speed charging stations, one within each 2-km radius, at key locations such as petrol stations, large supermarkets and parking lots in Seoul and Jeju by the end of this year. A total of 490 charging stations will be established. Since the Ministry will also build a total of 30,000 slow chargers at 4,000 apartment complexes across the country, the spread of electric vehicles in Korea is likely to be accelerated.

The interest in the electric vehicle is increasing due to climate environmental issues and the strive towards energy reduction. POSCO ICT will further expand its cooperation with electric car manufacturers in order to grow the charging infrastructure, no longer hindering the spread of electric vehicles within the country.

Be sure you never miss any of the exciting steel stories from The Steel Wire by subscribing to our blog.

Of the total volume of the 2,108 cars to be exported, 408 units were loaded under the Government to Government (G2G) contract signed by POSCO Daewoo, the Ministry of the Interior of Peru and the Korea Trade-Investment Promotion Agency (KOTRA) in December of last year.

The intelligent patrol cars supplied to the Peruvian government are equipped with a communication system which allows for the direct sharing of real-time data from the field with the central control center of the Peruvian National Police.

POSCO Daewoo’s business of exporting intelligent patrol cars to Peru has been realized as the company has made localization efforts, offering technical support that meets local needs, building maintenance depots and supplying parts. POSCO Daewoo exported around 800 units in 2013 as part of the first export project.

POSCO Daewoo provides additional services in nine Peruvian cities including supplying equipment for building maintenance depots, parts for maintenance of patrol cars and engine oil. It also recruits local technical personnel and offers technical training through special equipment companies.

As the supplier under the contract, POSCO Daewoo will provide the Ministry of the Interior of Peru with 2,108 patrol cars by September. The vehicles will be used in 17 cities.

POSCO Daewoo is the largest police equipment supply business in Korea. The company looks forward to making additional business contracts with the Peruvian government and to further expanding its market into Central and South America

Be sure you never miss any of the exciting steel stories from The Steel Wire by subscribing to our blog.

 Before the Revolution

Before the Industrial Revolution, most people lived in small, rural communities where their daily lives revolved around farming. Life for the average person was difficult, incomes were barely sufficient and malnourishment and disease were common. People lived from making their own food, clothing, furniture and tools.

Before the invention of machine tools, metal was worked manually using basic hand tools. It was tedious and expensive. Because of this, before the new technology in steel production was discovered, most tools were made of wood.

Urbanizing the World

The Industrial Revolution marked the transition to new manufacturing processes. New chemical manufacturing and iron production, water power, steam power, machine tools and the rise of the factory system all contributed to the urbanization of the world. The volume and variety of factory-produced goods raised the standard of living for many people, particularly for the middle and upper classes.

The availability of cheaper iron and steel was fundamental in the growth of several industries. The development of machine tools made precision iron working possible. Other changes included improved roadways, waterways and railways. Raw materials and finished products could be moved more quickly and cheaper than ever. Improved transportation also meant as people moved to new places, ideas and information spread. This was the beginning of globalization.

One of the defining impacts of the Industrial Revolution was the rise of cities. By 1850, for the first time in world history, more people Great Britain lived in cities than in rural areas. By 1920, the majority of Americans lived in cities. The new industrialized cities grew the economies of their nations.

The Industrial Revolution changed materials production, standards of living, labor conditions and population distribution. Job opportunities in growing factories resulted in a population shift from rural areas to the cities, creating the world’s first urban populations.

Changing Societies

The Industrial Revolution marks a major turning point in history; almost every aspect of daily life was influenced in some way. Average income and population growth began to experience unprecedented sustained growth. The standard of living for the general population began to increase consistently for the first time in history.

Prior to this era, most of the working population were land owners, tenants or laborers who worked on farms. With the growth of factories, workers began to move from working on farms to working in cities. The Industrial Revolution also created a middle class of professionals, lawyers, doctors, industrialists and businessmen, rather than a class nobles.

For the first time in history, there was a simultaneous increase in population and in per capita income. Life expectancy of children increased dramatically. A dramatic decline in the death rate cab be attributed to a decline in famines, warfare and illnesses.

Steel production was the major driving factor of the Industrial Revolution, which is one of the periods of greatest change in history. Steel helped drive industry, globalization and urbanization.

It is perhaps the latter element that is the most essential in this epic car chase of a movie. The film’s footage embellishes an exceedingly creative procession of real steel automobiles tearing through the desert at rip-roaring speeds, symbols of power and objects of worship in a desperate time when even humans have been reduced to commodities valued only for their utility. (Source: Warner Bros. via http://bit.ly/1JhMUa0)

Behind the Design

Because the vehicles play such an important role in Mad Max, their designs were not taken lightly. Envisioned by production designer Colin Gibson, under the direction of George Miller, one of the film industry’s most innovative visionaries, the creation of the movie’s iconic automobiles began in 2003, when the project was slated to be filmed in South Africa.

Considering the setting of the movie—a post-apocalyptic wasteland—Gibson built the cars by repurposing found objects, the way that they would most likely be built after the collapse of civilization. He spent years scouring the junk yards of Australia and Nambia, searching for vintage pieces and parts that possessed the same personality attributes of the characters that would be driving the titanic vehicles.

The automobiles were built in a workshop next to the art department and set decoration so that a team of creatives, artists, mechanics and even a steel department could easily collaborate and collectively bring them to life. In the end, 88 cars were used in the movie, but 150 were made in total. Of these, half were blown up, flipped or split in half during filming. (Source: Warner Bros. via http://bit.ly/1Ll2Sjk) 

Putting the Pieces Together

Despite the large number of vehicles created, careful attention was paid and much consideration was given to each model. For example, for the War Rig, the most important and central vehicle of the bunch, Gibson generated 41 drawings of the colossal truck, working alongside Mark Gatt, Steel Department Supervisor. The steelwork required fabricating, rolling, welding and cutting to modify and build the beast, which incorporated spikes, vents and lighting panels in its inventive design.

The Doof Wagon, which leads Immortan Joe’s troops to battle, and transports the Doof Warrior, a flame throwing guitarist, and his band of drummers, steals the show. The vehicle, seemingly straight out of a heavy metal concert, was constructed from a stripped down eight-wheel-drive rocket launcher truck, and utilizes a supercharged V8 engine, a wall of speakers and steel air-conditioning ducts from the insides of a number of large buildings as drums. (Source: Warner Bros. via http://bit.ly/1CrGLjO )

Yet the most terrifying looking vehicles of Mad Max belong to the Buzzards, a scrap merchant tribe that seeks to consume the remains of the old world, and are encapsulated in a rusty shell of metal spikes. One of these vehicles, the Buzzard Excavator is a MAN 6×6 tractor covered in 1,757 steel spikes hand-fabricated from old car panels. Coincidentally, this just so happens to be the same number of quills on the Australian anteater, an animal native to the area where the movie was shot.

As simple and as fundamental as steel is, it’s certain that Mad Max: Fury Road would not be the cinematic masterpiece it is without the metal. Furthermore, the film’s impressive cars are also a testament to the power and importance of steel in a time when nothing else exists. And while Earth may not experience an apocalypse anytime soon, in the case that one does happen, we can rest assured knowing steel will still be as reliable as ever. (Source: Warner Bros. via http://bloom.bg/1zXlvqD )

Please Give Us A Brief Introduction And Your Account At POSCO!
Since my entrance to POSCO in 2010, I have been working in the auto steel plate sales team and actively participating in field sales activity. Before joining POSCO, I was an engineer in charge of developing an engine in automobile company. However, as I start new at POSCO, I jumped into marketing with a strong passion in mind. Maybe it is due to my destiny with automobiles, I am now conducting automobile steel plate sales business! Until about a month ago, I was in charge of sales targeted to GM Korea. Because of my responsibility to handle contract issues, I had frequent meetings with client companies. My major work revolves around managing and signing of the key contracts that are vital in achieving corporate’s annual sales goal. Hence going on 100+ business trips a year became the norm to maintain good relationships with the existing clients and to meet new clients. Now I can breeze through a business trip from Seoul to Bupyeong.

Looking Back On Your Past Experiences, What Do You Consider As The Most Essential Quality Of A Marketing Manager

From five years of my past experiences, I believe that the basic quality required for a marketing manager is ability to ‘scratch the itch that they can’t reach’. For instance, the quality of products must be impeccable and they need to be provided in timely fashion. Every tiny detail that our clients might demand must be handled with scrupulous attention. As we build trust through sincere endeavors to enhance in every aspect, we were able to fully experience the true communication with our clients.

Automobiles Are The Outcome Of Constant Cooperation Between POSCO And Its Clients! Is There A Special Motif That Sparked Your Interest In Automobiles?
I don’t recall a significant motif but I’ve been realizing many fascinating aspects of automobiles ever since I started working as an automobile engineer. One of the biggest charms is that automobile is the product of collaboration of a number of professionals from various industries and companies. Also, despite its high price as a consumer goods, I believe it is wonderful that automobiles can provide a topic for any conversation with anyone at anywhere.

What Is The Sales Status Of Auto Steel Sheets In Regards To GM Korea?
Even in the current status of increasing foreign steel products, POSCO Auto Steel Sheet Marketing Team has led to a situation where a large portion of GM Korea’s steel products are being supplied by POSCO. Also, we have recently established a global process which provides high-quality products with competitive price and continue to participate in technical collaborations required for developing a new automobile prototype.

What Is The Biggest Difficulty You Are Facing As A Salesman?
From last month, I have been managing steel sheet sales targeting Renault Samsung Motors and SsangYong motors. Though I am very excited about encountering new clients, when we consider increasing competition of production cost in the current market, I am always contemplating the best approach to accomplish a Win-Win outcome for both POSCO and the clients.

What Do You Wish To Do At POSCO In The Future?

Currently, I am in charge of domestic business at POSCO, but I would like to work on overseas export in the future. Although automobile companies and steel companies are already cooperating in various aspects, I believe that there are many more opportunities and possibilities to lead to an enhanced collaboration from production to completion. Therefore, I wish to continue the cooperative efforts with numerous more companies and people in the future.

According to Mr. Hyun-ju Lee, he always reminds himself of the very first day he started working as a ‘salesman’. By reading about Mr. Lee who is constantly striving and learning from past and present, we hope everyone can feel positive and motivated as you reach the end of this post!

Successful companies have three factors in common: 1) A goal that all members share together, 2) empathy for a unified ideology, 3) sharing strategies to achieve a goal. POSCO has been sharing the vision of ‘POSCO the Great’ with all employees and striving to enhance its corporate value. Thus, based on their shared innovation agendas and management ideologies, ‘POSTIM’ was newly established as a powerful execution engine.

1. POSCO’s Unique Innovation Model, POSTIM

POSTIM, which stands for POSCO Total Innovation Model, is based on the participation of all POSCO employees and subsidiaries, as well as integration of work and innovation. By establishing a specific solution to the previous problems and systemizing the accumulated procedures and capabilities through POSTIM, POSCO will make its way to realize ‘POSCO the Great’.

2. Four Basic Principles of POSTIM

POSCO established four basic principles with the goals of increasing profitability, creating a Great Work Place, and enhancing job commitment. The specific principles are: 1) striving to generate profits by integrating work and innovation, 2) offering a reward corresponding to voluntary participation and employee performance, 3) creating a work environment in which employees are committed to creative activities and jobs, and 4) fostering and giving preferential treatment to talented individuals with technical and problem-solving skills.

3. POSTIM’s engine for implementation

POSTIM consists of PWS, QSS+, and SWP activities. Each activity will act as an engine for implementation to practice the management ideologies – One POSCO, Creative POSCO and Top POSCO – and fulfill POSCO’s innovation agendas. POSTIM is expected to contribute greatly to accelerating the fulfillment of ‘POSCO the Great’ by systemizing the accumulated organizational competences, such as innovation methodologies, human resources and systems within a unique innovation model

• PWS (Project-based Working System)A business method in which employees find new projects to increase profitability, attain qualitative goals, and concentrate on producing outstanding results

• ŸQSS+ (Quick Six Sigma Plus) in every corner of the siteActivities to improve Quality, Stability and Safety by evolving a unique method suitable for steelworks with a focus on operating facilities. Accordingly, steel mill sites such as STS steel manufacture and quality-technology departments, are accelerating the realization of ‘POSCO the Great’ by having proclamation ceremony for QSS+ and holding an information session in each department. POSCO expects QSS+ to root down firmly in every corer of the sites and contribute as a stepping-stone for unprecedented innovation activities.
• SWP (Smart Work Place)A series of activities carried out to enable employees to concentrate on their jobs by performing high value-added tasks and generating creative ideas based on a harmonious and positive organizational culture.

[box]

Notes from CEO

 “Let’s develop POSTIM as POSCO’s unique innovation model”

If the innovation methodology that POSCO has been promoting was in a physically mixed condition, the new POSTIM is the result of chemical bonding of innovation methodologies. For example, we utilized TESAL and Six Sigma individually in the past. However, as TESAL’s good methodology is applied to Six Sigma, POSTIM is a systemized model that is not limited to a certain methodology and allows combined application. Through this new model, POSCO is able to apply the majority of the existing methodologies with further convenience and can choose the part to include in POSTIM if a better methodology is developed in the future. Let’s develop POSTIM as POSCO’s unique innovation model.

[/box]

Peter Marcus said in his lecture, “POSCO was able to succeed as a global steelmaker because it has its own unique corporate culture,” emphasizing the importance of continuously developing POSCO’s unique and great corporate culture.

In addition, he mentioned the importance of continuous R&D investment activities to maintain competitiveness, explaining, “5 companies globally, POSCO, NSSMC (Nippon Steel & Sumimoto Metal Corp), JFE, CSC (China Steel), and Baoshan Iron & Steel, are showing competitive R&D activities.”

He also pointed out that the steel industry today is facing an extremely difficult environment, forecasting that the growth engine from China will be exhausted while the remaining power for new growth of BRICs will not be sufficient, thus the downcycle of the steel industry will continue until around 2018.

In the long term, scrap production supply from China will increase rapidly while DRI (Direct Reduced Iron) competitiveness will recover due to shale gas, leading to distinct competition between iron sources forecasting a decline in material costs such as iron ores, DRI, and HBI (Hot Briquetted Iron).

In the mid- to long-term, increases in steel demand will be prominent in the Middle East regions rather than China, where steel production will increase 1.5% annually from 1,574 million tons in 2013 to 1,873 million tons by 2025.

Lastly, Marcus forecast that there is a high chance that the increase rate of steel demand in China will stagnate at less than 1% until 2025, and that the increase rate of annual steel production will reach 7.9% until 2014 but only 0.59% for the ten years after 2015.

Marcus explained that this is based on the decrease of GDP growth rate, decline in demand due to the depreciating construction economy, and weakened export competitiveness due to a strong Chinese yuan value.