New Technology Lowers Steel Cost 10% for Automotive Stampers

    EVANSTON, Ill.--March 7, 2003--Evanston based IRMCO www.irmco.com has developed a high performance metal coating technology that gives lower grade steel, aluminum, galvenealed, and galvanized metal the formability of higher grades. This breakthrough allows metal users to lower their metal cost without scarifying quality.

    20,000 Ton Steel Users Saves $1 Million (10%)

    IRMCO's performance film allows metal to stretch and flow consistently and evenly during server drawing or forming operations. The most difficult automotive parts: oil pans, frames and body panels can be formed with less scrap or tool wear. The economic impact is significant. A 20,000 ton steel user can save $1 million or 10% by moving just one grade lower. Example: switching from DQIFCR (Draw Quality Interstitial-Free Cold Rolled) at $500/ton to DQCR (Draw Quality Cold Rolled) at $450/ton nets a $50/ton savings.
    A recent study with a global appliance company determined that a deep drawn part could be produced with Draw Quality Hot Rolled instead of Draw Quality Cold Rolled. This change generates an annual steel savings value of over $1 million.

    Lowered Scrap Saves $100,000 (1%)

    IRMCO's coating also affects metal forming scrap rates. A one percent reduction in scrap has a significant impact. A company pays in two ways: wasted metal and wasted time. The time spent making bad parts can quickly add up, and the value of the scrapped metal can never be regained. A 1% scrap reduction saves $100,000 for a 20,000 ton steel users paying $500/ton.

    Using Applied Science To Assure Savings

    IRMCO's Greenleaf Technologies Group uses applied science to perform "In-Press Strain Deformation Mapping". Critical areas of production metal are electrochemically gridded, formed, and then analyzed. The resultant strain data is then mapped to record the metal thinning at critical areas. This serves as a baseline of current process's capability. Alternative metal and/or coating combinations can then be studied accurately.

    IRMCO is a privately held Chicago based advanced lubricant and coating technology firm that specializes in the invention of high performance metal forming coatings, environmental improvement technologies and Material & Process Optimization Services.

    Metal cost data was provided by Larry Dalsin of Ferro Business Solutions Inc.