POSCO hosts 50th global technology convention ‘World Steel Association Technology Committee (TECO)

TECO is a global convention in which global steel companies share their current status of technology development and discuss the current issues that the steel industry is facing. POSCO hosted the 50th TECO for a second time following its first hosting of TECO back in 2010, to celebrate its 50th anniversary this year.

At this convention, more than 60 experts from steel and related industries such as ArcelorMittal, NSSMC, Tata Steel and Voestalpine and also Secretary-General of the World Steel Association joined to shine the conventions. This convention held in Gyeongju, South Korea from April 23rd to April 26th.

Since sustainability has become main global issue, the main focus of the convention was carbon dioxide emissions and energy. The participants in the convention expressed their own perspectives related to the development of iron and steel manufacturing, rolling process technology and development of innovative products and digitalization that lead positive impacts on environment.

Wonderful opportunity to spread POSCO’s world premium technology

POSCO’s own technology that may shine in the convention is ‘high-manganese product and manufacturing technology that is invented first in the world. This unique technology was one of the driving forces of POSCO become world leading company.

Additionally, participants had a great opportunity to experience Pohang Steel Works, the FINEX plant, smart factory and rolling system and then visit POSTECH to see world’s 3rd 4G synchrotron accelerator.

* 4G synchrotron accelerator: ‘Ultra-high-performance gigantic microscope’ that observes the microscopic structures and reaction of materials using synchrotron radiation when accelerating electrons at the speed of light.

The World Steel Association, founded in 1967, is the most authoritative organization in the steel industry, which promotes the understanding and interests of the steel industry. Currently, as many as 170 steel companies, related associations and laboratories around the world are listed as members. The World Steel Association and the Technology Committee shares the technologies developed by individual steel companies in every year to propose joint research on steel technology and encouragement of cooperation.

Prime Minister Modi revamped India’s economy with his “Make in India” initiative. (Source: LinkedIn)

Most notably, Prime Minister Modi launched the “Make in India” initiative in September 2014, showing his resolve to revamp the manufacturing industry in India. Under the initiative, domestic as well as foreign companies are encouraged to manufacture their goods in India with the goal of increasing the makeup of the manufacturing industry to 25 percent of GDP by 2025.

At the heart of the initiative is the government’s efforts to ignite the steel industry. The National Steel Policy (NSP) 2017 declared that India will become self-sufficient on domestic steel supplies by increasing its steel production capacity from 122 Mt in 2015 to 300 Mt in 2030. However, the steel industry currently only makes up 1.04 percent of the country’s GDP.

Challenges Ahead for India’s Steel Industry

Despite India’s promising potential and robust government support, the steel industry has not met the government’s high expectations and growth has been modest. According to researchers in volume 4 of the Asian Steel Watch, there are deep structural flaws within India’s steel industry that need to be addressed before the country can reach its full potential.

One of the industry’s biggest challenges is its growing debt – In 2016, the steel industry surpassed INR 3 trillion in debt. Most of the country’s steel and infrastructure projects are financed by the government. What India needs is more private sector involvement, but private players are hesitant due to complex regulations, a lack of business models and no guarantee on returns on investment (ROI). The government has also been slow to secure FDI because, over the years, India’s steel industry has displayed poor planning and management of projects as well as a mismanagement of funds.

India’s mining industry will directly affect the success of the steel industry. (Source: Pinterest)

Another major challenge has to do with India’s natural resource management, as mining companies do not have fair access to the country’s abundant resources. The mining industry is subject to heavy tax burdens including the royalty, local area development tax, forest development tax and much more as it is a profitable business for the government. Plus, the costs of meeting international environmental standards are passed directly onto mining companies. Thus, the price of iron ore and other minerals do not reflect the abundant supplies available, and the higher prices ripple into the steel industry.

Moreover, the government regards the steel industry as the backbone of India’s economy, but in reality, the times are changing.

Technological advances in the manufacturing industry is making the steel production process more efficient and less labor intensive. (Source: South China Morning Post)

In the past, 70,000 workers were required to produce 1.5 Mt of steel. Today, it takes about 3,000-4,000 workers to make 5 Mt a year. The steel industry is just not what it used to be in terms of the positive effects it had on the economy as a whole. The industry requires intensive capital and the only way it will survive is with low labor costs and maximum manpower productivity.

India needs to take full advantage of the country’s abundant resources and capitalize on its competitiveness to reach its full potential. In order to do so, India can start by examining other steel industries that served as the main driver for national economic growth, such as Korea’s.

Takeaways from Korea

After the Korean war in 1953, Korea had to build its economy up from scratch. Like India, the government chose to stimulate its steel industry and spent its war reparations payment from Japan to build POSCO’s steel mill in 1969. Since then, the state-led steelmaker has been a primary engine for Korea’s miraculous economic growth.

The construction of POSCO’s headquarters began in May 1968.

So how did Korea manage such growth?

The government allocated much of its resources to infrastructure construction for efficient logistics and implemented policies to support the mutual growth of steel and steel-consuming industries. Moreover, the government practiced protectionist trade policies long enough to get Korea’s steel business on its feet, then supported a market-driven business model.

The government also kept a close watch on supply and demand forecasts and updated its supply policies timely and accordingly. Factors such as demographic changes, industrialization patterns, urbanization and labor costs should be examined holistically to prevent the gap between supply and demand from increasing too much. For example, in 2010, the Korean government implemented capacity expansion policies that resulted in oversupply and a prolonged recession. This was because policymakers failed to diagnose the symptoms of the mid to long-term steel demand forecasts that showed sluggish demand. Since then, Korean policymakers keep close watch on such measures to update the country’s supply policies.

Finally, the Korean steel industry invested heavily in knowledge accumulation and R&D to wean off of Japan’s technical support and become an exporter of steel technology.

POSCO is now a leader in steel production technology.

Compared to Korea, India has an advantage in almost every aspect. The country’s per capita steel consumption is still low and the booming population will drive demand in steel-related industries. With much room for growth, the Indian steel industry can expect to see accelerated growth when paired with the right policies and government support.

Imagine, people with disabilities, after being told they may never walk again, find they can not only walk, but also cover a mile in an hour.

Or, a worker with a physically demanding job who lifts and carries loads of weight every day can wear a suit that does the bulk of the lifting for them. Consider the corresponding change in productivity and morale!

With AI, these scenarios are a reality.

Human Exoskeletons and Where They are Applicable

One robotic exoskeleton, SuitX, has the technology that allows users with lower-body disabilities to cover a mile in an hour. This suit is lightweight, controlled by motors at the hips and knees that move the foot supports. The user wears a backpack battery that will last up to eight hours, and controls the suit with buttons placed on crutches.

A man walks with the help of the Phoenix exoskeleton developed by SuitX. (Source: Instagram)

Another exoskeleton, the ReWalk, is commercially available in the United States. It is strapped onto the user’s body over his or her clothing, again using electric motors for power. Sensors assist in movement, which the user controls through a wrist-worn communicator.

Claire L.uses a ReWalk exoskeleton to complete a race (Source: ReWalk)

Similar technology can be used for exoskeletons in an industrial or military application. Workers and soldiers can wear human exoskeletons to gain an instant boost in strength and stamina, lifting far more than they could heft without the robotic help.

The Application of AI

Alexa, Amazon’s artificial intelligence (AI), is practically a member of the family in many households, especially across the U.S. Alexa stocks up on pantry essentials, shares the latest news, gives weather updates and even plays games. But now, she’s stepping into an all-new role that will truly transform people’s lives, beyond household assistance.

Bionik Laboratories has integrated Alexa to its lower-body exoskeleton. This means that to move, users can simply issue a voice command like, “Alexa, take a step.”

ARKE Exoskeleton by Bionik Laboratories (Source: Bionik Laboratories)

Adding AI to exoskeleton controls can potentially help users become familiar with the device. Users may face a steep learning curve with sensors, communicators, and putting it all together to move with an exoskeleton. With the application of AI, however, voice commands get the process started more seamlessly, until users are confident to take over control without Alexa’s help.

While AI-controlled exoskeletons are still in the early stages of testing, the concept holds a lot of promise for enabling greater independence for people who need mobility assistance.

Comparing Exoskeleton Materials

While exoskeletons might seem futuristic, it does not mean that they are made from futuristic alloys and newly invented materials.

Manufacturers are looking for several things from an exoskeleton material: strength, durability and cost effectiveness. Whether AI-assisted or not, exoskeletons are made from a variety of traditionally used materials; typically, carbon, aluminum, or steel.

Some manufacturers may choose carbon for lightweight parts, as this material is not as hefty as steel or aluminum. Steel is the heaviest of all of those materials, but with a powered exoskeleton, the weight may not matter as much, as the machine will be lifting itself.

Aluminum is durable, but not as resistant to damage as steel. Being an inexpensive material, aluminum might seem attractive to manufacturers at first, but that lower price tag comes with a diminished lifetime in comparison to steel.

Carbon is about as damage-resistant as aluminum, but holds less stiffness against weight. Carbon is also generally brittle, so if it faces damage, it may crack and completely break, rather than denting (or being unaffected). High-end carbon can be expensive, potentially driving up the cost of an exoskeleton made with this material.

Different types of exoskeletons (Source: Wired)

Steel, therefore, is very popular for creating exoskeletons and their parts. It provides raw strength and durability. It stands up to many kinds of damage with ease. It bends or dents instead of breaking, and can typically be repaired, even numerous times, without reaching the full point of failure.

Steel lasts, despite wear and tear. This robust material is ideal for limb elements like arms and legs, which will be doing a lot of moving and lifting. Steel will enable extremely heavy lifting of objects many times the weight that an unpowered human could lift.

Like exoskeleton technology, steel technology is evolving. Lighter weight steel materials are coming onto the market, offering all of the benefits that steel has traditionally offered, with less heft.

Whether manufacturers choose steel for every part of an exoskeleton, or select this high-quality material for some important elements of the technology, it is clear that steel has a role in exoskeletons, now and in the future.

Cover photo courtesy of New Atlas.

The FINEX® Process

The FINEX® Process was jointly developed by POSCO in Korea and Primetals Technologies in Austria. FINEX® (along with COREX® – another smelting process developed by Primetals) is the only commercial proven alternative steelmaking process to the blast furnace (BF) route.

FINEX® is based on the direct use of iron ore fines and non-coking coal while eliminating the coke-making and sintering processes, which are most critical to the conventional blast furnace process. Combining these two decisive advantages leads to lower production costs and the reduction of environmental emissions in comparison with the conventional blast furnace route.

The FINEX® Process combines cooking plant, sinter plant, and blast furnace into a single iron making unit.

Advantages of the FINEX® Process

There are several key advantages to and differences in using the FINEX Process:

• Non-coking coal can be used directly as a reducing agent and energy source
• 100% fine ore can be directly charged to the process; no sintering or pelletising is required
• Pure oxygen can be used instead of nitrogen-rich hot blast

In addition, the FINEX® Process offers several key advantages over alternative BF methods.

• Economic benefits – low investment and operational costs due to the elimination of coking and sinter plants
• Ecological benefits – lowest process-related emission rates
• Product quality – hot metal quality suitable for ecological steel applications
• CO2 mitigation potential – pure oxygen is used
• Resource preserving – directly uses a wide range of iron ores and non-coking coals
• Beneficial by-products – generation of highly valuable export gas for various purposes (electric power generation, DRI production, or natural gas substitution)
• The FINEX® Process combines coking plant, sinter plant and blast furnace into a single iron making unit.

Creating The FINEX® Process

Starting in December 1992, POSCO and Primetals Technologies signed a cooperation agreement for the joint development of the FINEX® Process. Following initial laboratory, bench scale and pilot plant tests, the FINEX® F-0.6M Demonstration Plant, with a nominal capacity of 2,000 tons per day, was built in Pohang, Korea, and started up in May 2003. On the basis of successful results and optimization of equipment and process parameters over the past few years, POSCO developed their own independently designed program in February 2017. Designed to carry out overseas FINEX projects without relying on Primetals Technologies or other external resources, the program can be used to calculate core equipment specifications and raw material conditions. In particular, the development of the FINEX Process Design Program, one of the subprograms, has made it possible for the “heat & mass balance” to be automatically calculated when raw & fuel material conditions change.

[clickToTweet tweet=”The FINEX® Process is a cost-effective, more eco-friendly, and efficient way to make steel. ” quote=”The FINEX® Process is a cost-effective, more eco-friendly, and efficient way to make steel. ” theme=”style6″]

Efficiencies of the FINEX® Process

The FINEX® smelting reduction process is one of the most exciting iron making technologies on the market. It is distinguished by the production of high-quality liquid hot metal, on the basis of directly charged iron ore fines, and coal as the reductant and energy source. A key feature of the FINEX® Process is that iron production is carried out in two separate process steps. In a series of fluidized-bed reactors, the fine iron ore is reduced to direct reduced iron, compacted (HCI), and then transported to a melter-gasifier. Coal and coal briquettes charged to the melter-gasifier are gasified, providing the necessary energy for melting in addition to the reduction gas.

The FINEX® Process is Environmentally Friendly

The FINEX® Process and the blast furnace route are coal-based processes reducing iron ore to iron, which is subsequently melted into hot metal. In both processes, the same product is generated out of almost the same raw material. A question that arises – and not only from an economic point of view – is “how do these production routes deal with unwanted impurities?”

A certain amount of environmentally harmful substances is inevitable based on the raw material mix. Hence, the objective of a sustainable steelmaking process is to discharge these substances in an environmentally compatible condition or destroy them during the process itself. Since the FINEX® Process captures most of the pollutants in an inert state in the slag, and the released hydrocarbons are destroyed in the dome of the melter gasifier, no additional investment or operational costs are incurred for a complex gas or disproportional waste water conditioning plant.

Comparing the traditional blast furnace with the FINEX Process shows the improvements that POSCO was able to achieve to be more
environmentally friendly.

Future-Proof Emissions Figures

To bring blast furnaces in line with current and expected environmental standards, plants require significant investment. This can already be seen in the case of blast furnace dust emissions that are efficient, but costly filter systems must be installed in the sinter and coking plant. The FINEX® Process values are already far better than expected future standards. Moreover, the full development potential of the FINEX® Process has not yet been realized with respect to a further reduction of emissions.

Moving Forward with Greater Potential

Because the FINEX® Process is still being optimized, additional economic and technological benefits are anticipated. Major developments are continuously being carried out to increase efficiency. The latest achievements include breakthroughs in the field of heat recovery, dry dedusting, and outstanding performance improvements. Based on the well-proven plant concept, new process features, the highly competitive production costs, and environmental features, Primetals Technologies and POSCO are confident that the FINEX® Process will account for an increasing share of future investments in iron making facilities.

*Cover image courtesy of the World Steel Association

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The cryogenic high manganese steel is a high value-added material that POSCO proprietarily developed after more than a decade of research. It is the representative World Premium Product of POSCO. Cryogenic high manganese steel is a steel product that can withstand a very low temperature of -196℃, making it suitable for storing and transporting Liquefied Natural Gas (LNG). Also, because it is more weldable than conventional nickel alloy steel and 20-30% cheaper than nickel alloy steel, stainless steel and aluminum alloy steel, it is a solid alternative to these competing materials.

POSCO is constantly striving to develop and commercialize new steel products. Its recent registration with ASTM International strengthens its competitiveness in advanced steel technology. Teresa Cendrowska, VP of Global Cooperation at ASTM International stated, “POSCO is leading the standardization of new steel technologies at ASTM International and has become a model for other steelmakers by setting a new standard for high manganese steel.”

Last year, POSCO’s cryogenic high manganese steel was used for an LNG fuel tank for the world’s largest LNG-fueled bulk carrier (a bulk carrier using LNG as fuel) built by Hyundai Mipo Dockyard. In the future, POSCO plans to provide Solution Marketing to domestic and overseas oil majors and EPC customers. It also plans to sell World Premium Products in the energy sector and develop new markets.

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Since the inception of the auto industry, steel has been used to manufacture cars because it is strong, manufacturable, and durable. Also, because roughly 55-60% of a car’s weight comes from steel, it is an obvious place to make lightweighting a priority, which is exactly what has happened. Recent innovations in steel production technologies have created solutions that are lighter, stronger, and more environmentally friendly to produce.     

Steel Alternatives Present New Obstacles for Car Manufacturers

Advanced High Strength Steels (AHSS) provide the most eco-friendly alternative for car makers in material production. (Chart courtesy of AutoSteel)

As the auto industry adapts to new government regulations and consumer expectations, many have been looking toward alternative materials to step in as a substitute for steel. However, each material carries both benefits and drawbacks that they must constantly weigh as they seek to strike a balance that adheres to safety & emissions regulations and consumer demand.

Aluminum, magnesium, and carbon fiber composites are all being used to various degrees in recent auto designs. They have become attractive as lightweighting has become more of a priority for car manufacturers; however, there are tradeoffs.

Certain types of aluminum can be weaker, more expensive, and less formable than some steels. Magnesium, while lighter than both steel and aluminum, is also more expensive. In addition, extraction of magnesium can emit more than 20 times more carbon emissions than steel. Lastly, while carbon fiber composites offer the most in lightweighting potential, it is still prohibitively expensive for mass produced cars, and producing carbon fiber is 14 times more energy intensive than steel.

Advanced High Strength Steel Offers Lightweighting Solution

Typically, to make steel lighter, sacrifices had to be made in strength and ductility. However, recent innovations in advanced high-strength steels (AHSS) have been able to bridge that gap.  AHSS offers lightweight solutions with high ductility coupled with high tensile strengths that can go beyond 1,000 MPa – meaning it can withstand more than 100 kilograms-force per square millimeter.  

In addition, compared to alternative materials used in autos, AHSS offers the most eco-friendly option for car markers. It has the lowest production emissions and because it is infinitely recyclable and durable, it can be used in multiple applications throughout its life cycle.

AHSS grades allow car manufacturers to achieve a new level of strength, ductility, and durability in steel that is also lighter and more eco-friendly due to improved production efficiencies.

Third generation AHSS provides both high tensile strength and elongation. (Chart courtesy of World Autosteel)

The Third Generation of AHSS

Recently, engineers and researchers have been working to improve the balance between strength and elongation in AHSS. Typically, conventional mild steels offer superior elongation with less strength, whereas previous AHSS offered superior strength with more elongation and ductility.

The third generation of AHSS is bridging that gap, producing steel that is both incredibly strong and ductile at the same time. Typical mild steels have a tensile strength of around 300 MPa, which means it can withstand up to 67 pounds per force per square millimeter. On the other hand, new third-generation AHSS typically have a tensile strength of 800-1500 MPa (up to 300 pounds per force per square millimeter) with a similar amount of ductility.

In tensile strength measurements, 1,000 megapascals equals 1 gigapascal. Steel that has a tensile strength over 1,000 MPa is often referred to as GigaPascal steel. This type of AHSS is both super strong and also lightweight.

AHSS provides car makers with a lightweight, strong material solution.

GigaPascal Steel and the Future of Auto Manufacturing

GigaPascal steel represents the cutting edge of steel technology and the future of auto manufacturing. Its high strength and lightweight properties make it safe and efficient. It provides car makers the material they need to meet efficiency and safety standards, with significantly fewer production emissions.

Two weeks ago SsangYong Motor unveiled their new G4 Rexton SUV at the Seoul Motor Show. They partnered with POSCO to develop the core body frame parts using its new POSCO GIGA STEEL. The SUV was designed so that 63% of the body contains POSCO GIGA STEEL – a first for the auto industry, but not the last.

SsangYong Motor’s G4 Rexton is unveiled at the Seoul Motor Show in March 2017. It is the first vehicle to be made with up to 63% giga steel.

As the auto industry seeks to build more efficient and safe vehicles, advancements in steel technology have emerged to meet their needs. Balancing efficiency, strength, weight, and price – steel continues to be the preferred material in auto manufacturing.

Throughout April & May, The Steel Wire will explore the uses and benefits of AHSS, POSCO GIGA STEEL, and what POSCO is doing to lead the industry with new automotive steel solutions.   

POSCO CEO Ohjoon Kwon (left) shakes hands with Tom Schuessler, president of ExxonMobil Upstream Research Company, at the signing ceremony between ExxonMobil and POSCO.

ExxonMobil, the world’s largest oil company, upholds strict standards when choosing materials, and for the last five years has been working with POSCO to manufacture and test slurry pipes at worksites. Last year, a 1.2 m long slurry pipe – made with POSCO’s high manganese steel – was installed at ExxonMobil’s Kearl Oil Sands Project in Canada. It demonstrated a resistance to wear five times higher than conventional materials.

With its abrasion-resistant properties, POSCO’s high manganese steel can greatly reduce overall operating costs and increase oil production. “Seamless collaboration has led to the quick commercialization of this new high manganese steel technology, which will set a new standard for oil sands mining operations,” said Tom Schuessler, president of the ExxonMobil Upstream Research Company, who attended the ceremony.

POSCO and ExxonMobil employees pose for a commemorative photo shoot after inking a high manganese steel supply contract at the POSCO Center.

In response to president Schuessler, CEO Kwon suggested furthering their partnership by utilizing high manganese steel in various other businesses within the oil sands industry.

POSCO also plans to use its high manganese steel in the making of heavy construction and bulletproof military equipment as well as steel pipes and facilities to move various minerals including oil sand slurry.

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Automotive coated steel, one of POSCO’s World Premium Products (WPP), is a high-grade product that requires a high level of sophisticated technology. Only 20 out of 800 steel companies in the world can produce it at this time. Last year, POSCO sold approximately 9 million tons of automotive steel sheets, accounting for 10% of the global automotive steel sheet market.

The ‘Smart Solution for Coating Weight Control Based on AI‘ is a technology that drastically reduces the deviation of coating weight by using artificial intelligence to precisely control the Continuous Galvanizing Line (CGL), the primary technology used in automotive steel sheet production.

In particular, this technology uses an automated control technology that predicts the coating weight in real time and accurately meets the target coating weight by combining the coating weight production model of the artificial intelligence technique with the control model of the optimization technique.

A developer and worker are seen in the operating room monitoring the optimal coating weight predicted through artificial intelligence. POSCO succeeded in developing the ‘Smart Solution for Coating Weight Control Based on AI‘ through a joint industry-university effort, and applied it to POSCO 3CGL last January. With artificial intelligence, it is now possible to collect hundreds of different types of data in real time, as well as accurately predict and control target coating weights.

Coating weight control is a highly-sophisticated technology that keeps the thickness of the coating layer consistent even when operating conditions change at the request of automakers. When coating weight is controlled manually, quality deviates depending on the skill level of the worker, inevitably resulting in significant amounts of wasted zinc. However, the plating process is now automatically controlled by artificial intelligence, increasing the quality of POSCO’s automotive coated steel while decreasing production costs. These new automated processes have also helped to increase work efficiency and productivity with workers.

Since the inauguration of CEO Ohjoon Kwon in 2014, POSCO has been preparing to take the lead in smart solutions by integrating AI into its smart factories. Last June, POSCO Technical Research Laboratories identified the need for an automated coating weight control system and collected the relevant data after discussing with several departments. POSCO worked with Prof. Jon-seok Lee of the Department of Systems Management Engineering at Sungkyunkwan University in Seoul, Korea, to develop the artificial intelligence coating weight prediction model algorithm. Prof. Lee is an expert in statistics, data mining, machine learning and optimization methodologies. He collaborated with POSCO researchers to develop the coating weight prediction program after analysis of the plating process.

Starting in July 2016, a beta program was introduced for two months. After successful completion of the beta test, POSCO Technical Research Laboratories added an additional program to ensure quality control even under changing operating conditions.

The core AI technology that was applied to the coating weight control automation is a self-learning software that utilizes big data deep learning techniques. This method operates in real time allowing the AI program to stay up-to-date by analyzing hundreds of different types of data generated during the plating process. It can accurately predict and control coating weight through real-time, even if equipment has been replaced or operating conditions have changed.

The completed coating weight control automation solution was applied to POSCO’s 3CGL line in Gwangyang on a trial basis for approximately 2 months, enhancing accuracy and stability. Normally, when operating manually, deviations in the coating weight can extend up to 7g per m², but with POSCO’s AI-based technology, this number is reduced to 0.5g per m². After a technical verification process, the technology was incorporated into the 3CGL line on January 5.

To maintain its position as a global leader in automotive coated steel technology, POSCO is planning to apply this coating weight control automation solution to other CGLs at home and abroad, like the recently opened Thailand CGL. POSCO is also taking steps to introduce artificial intelligence technology to the manufacturing processes of other steel products while also continuing to build smart factories that can help POSCO continue to be a leader in the steel industry.

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Iron Man in Hong Kong (Photo Courtesy of roy so)

From Iron Scraps to Superhero

Since the character’s debut in 1963, the one constant in the Iron Man series is Tony Stark’s ability to innovate and adapt. The first model was “bulky, battleship gray, and most definitely, low-tech,” at least compared to the more recent suits. Trapped in a prison cell with limited resources, Tony only had heavy scrap iron at his disposal to piece together the very first Iron Man suit, giving it a very crude and unrefined appearance. Tony drastically improves upon these flaws in the Mark II by stripping down the bulky and rudimentary design to a lighter, stronger, and more flexible armor, which in turn took his flight capabilities to another level.

Over time, further adjustments and improvements were made in material, color, and function – allowing him to fly further, dive into the oceans, and enter deep space. He even began to use a technology that could store the suit in his bone marrow, making portability a much simpler affair. Through each series, each battle, and each villain, Tony customized the suit to make it stronger, more advanced, and more resilient.

Since the 1960s, Iron Man has transformed from a comic book character breaking free from prison to a Hollywood superhero grabbing missiles in mid-air. His ability to adapt and innovate his suit has made him one of the most powerful superheroes in the Marvel Universe.

The Iron Man Hall of Armor at Innoventions, Disneyland (Photo courtesy of HarshLight)

Similarities between Iron Man & POSCO

If there is one thing Tony Stark and POSCO have in common, it’s their obsession with innovation. POSCO was founded in March 1968, almost 5 years after Tony Stark emerged from a Vietnamese prison wearing his first Iron Man suit in Marvel’s Tales of Suspense (#39). Both began with some basic iron and steel, and both continued to advance with hard work, innovation, and some high-tech metal alloys. It is that continuous innovation that also drives POSCO forward.

Also, like Iron Man, POSCO’s world premium products are already used to fly the skies, cross the seas, and withstand crushing pressure. POSCO’s PosMAC is built to improve upon galvanized steel and strengthen specific areas by adding materials such as magnesium and aluminum – making the steel lighter, stronger, non-corrosive, and, like Iron Man, self-healing.

Other innovations include the award winning, and vibration resistant, PosCozy, which combines manganese Z-clips with continuous galvanized steel plates. PosCozy has higher resistance to vibrations than general steel, “making the sound of children running on a floor sound like noise heard in a library.”

With its eyes on the auto industry, POSCO has made advances in automotive steel with PosM Steel, a “dream material” five times stronger than conventional automotive steel and which has excellent impact absorption qualities – a quality that (SPOILER ALERT) Howard Stark would have appreciated.

Even though POSCO has yet to develop its own freeze-beam or arc reactor that can power an entire building and give people superpowers, here at POSCO, our researchers, engineers, and specialists continue to take steel technology to the next level. POSCO is already one of the top steel producers in the world and consistently recognized for its advanced tech steel products & sustainability programs. Used in buildings, cars, planes, and even the day-to-day objects lying around the house, POSCO’s steel might not be able to protect mere humans from supervillains but it sure makes the world a stronger place.

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“Second Avenue Subway Project Causes 50% Rise in Prices” – New York Times, September 2, 1929

The idea for a Second Avenue line was first brought up in 1920 when NYC’s public transit was at maximum capacity moving around 1.3 billion riders per year having doubled since the pre-war years. When an official plan was introduced in September 1929, home prices increased 50% almost overnight. However, because of the Great Depression, WWII, and then the Korean War; the city did not break ground until 1972. But then in 1975 the project was abruptly stopped when the city ran out of money. Revived again in the mid-nineties, construction on the current line started in 2007.

Proposed Second Avenue line in June 1950. (Courtesy of New York Transit Museum)

“But it is highly improbable that the Second Avenue subway… will ever materialize.” – New York Times, January 17, 1957

Aside from the financial and political reasons that delayed the train for a century, the fact is that it is much more difficult to construct a new subway line in today’s New York than it was in the 1920s. When New York’s first subway line opened in 1904 there were less people, less buildings, and less regulations. At that time, crews would use the “cut and cover” method where they would close the road, dig up the street, and then cover it back up when finished – a feat that would be nearly impossible in today’s bustling Manhattan.

“Ground was broken yesterday for the Second Avenue subway.” – New York Times, October 28, 1972

In today’s New York, the city must use explosions (video) to help make way for the huge boring machines, reinforced with high-strength steel, that are able to cut underneath the foundation while cars and people are left undisturbed on the surface. Running 24 hours per day, these tunnel boring machines can dig around 50-60 feet per day leaving a huge underground path for the trains.

Second Avenue subway tunnel, May 21, 2015. (Photo courtesy of MTA)

While it is obvious that steel would be used in these projects, the sheer amount is astounding. From the tunnel boring machine to the steel wheels that ride on the steel tracks to the stainless steel subway cars — steel is everywhere. In fact, it was the advances made in steel technology in the 1880s that made New York’s first subway a reality. After the great blizzard of 1888 shut down city streets and brought down the electric power grid, the city started to make efforts to put things underground. In addition, the same advances in steel provided for taller and taller buildings that brought more and more people; so, the city needed a new form of transportation that could move everyone from their homes to their jobs. The NYC subway system started in 1904 with just 28 stations – it now has 468 stations running a total distance of 1,055 km (656 mi).

From the steel beams to the steel tracks to the escalators carrying passengers – steel is everywhere. (Photo courtesy of MTA)

Subways have redefined urban life in the modern era. This feat of engineering, like so many other urban wonders, is only possible because of the steel used to dig, build, and operate the subways. Watch the short film below (11:31) to see how the Second Avenue line began – and how it ended 97 years later.

*Cover photo courtesy of MTA

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