Operation-Process

OPERATION & PROCESS TRAINING

You have introduced a new technology in your company and need qualified employees? The EBNER Academy contributes to the qualification of your executives, engineers, technicians and operators with seminars, workshops and training courses. We backup you on current topics and technology in the fields of processes, automation systems and heating know-how. With international conferences and congresses, we support the exchange of expertise at expert level.

As a company, you secure your economic success by investing in training and further education. You promote the knowledge as well as the motivation and commitment of your employees which in turn strengthens your efficiency and global competitiveness. As an education service provider, the EBNER Academy is your long-term partner and companion, the common goal is your enduring and solid development.

LEVEL 1 - BASIC TRAINING ALUMINUM

Description                                       

This basic seminar is intended to provide you with the fundamentals of the physical and material engineering of heat treatment.

Questions will be answered on how the strength and ductility of metallic materials can be specifically adjusted by heat treatment or how to

State diagram reads and interprets. It also explains what happens inside the metal during heat treatment and why such different heat treatment processes are necessary.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic technical understanding of heat treatment processes and/or materials science

Benefits                                             

Understanding the metallurgical processes in the course of a heat treatment process

Content – Theory & Practice

  • Structure of metallic materials
  • Introduction of near-equilibrium heat treatment of steel (iron-carbon diagram, normalizing and annealing)
  • Introduction of heat treatment of steel (martensite, bainite, retained austenite, hardening and tempering)
  • RTD diagrams
  • Location of different heat treatments in Fe/C and ZTU diagrams
  • Influence of alloying elements
  • Basic information on heat treatment of aluminium (Al-Cu phase diagram, solution heat treatment, precipitation hardening)

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course

Duration                                            

2 days

REGISTRATION

Description                                       

By means of easily understandable examples, knowledge is obtained about further program technical possibilities in order to consolidate and furthermore extend the physical and material fundamentals of heat treatment.

Various annealing cycles, optimization possibilities and software tools are explained and deepened in hands-on training.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic knowledge of heat treatment processes and optimization of EBNER furnaces

Benefits                                             

Understanding and optimization of the heat treatment process; optimized output at the plant

Content – Theory & Practice

  • Temperature and inert gas cycles of different heat treatments or alloys
  • Optimization possibilities in the temperature and inert gas cycles to increase quality and the output or reduction of media consumption
  • Optimization possibilities in the process parameters
  • Explanation of supporting software tools

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course at customer’s facility (if available)

Duration                                            

1 day

REGISTRATION

LEVEL 2 - ADVANCED TRAINING ALUMINUM

Description

Aluminum is a preferred choice material for reduction of weight of automotive vehicle to satisfy the stringent CO2-emission standard. Because of this up to 15 % growth is predicted till 2025 in usage of aluminum sheet. A strong competition in the Aluminum industry has now started to capture the aluminum sheet market growth by targeting production of high-quality aluminum sheet.

Light weighting by aluminum in manufacturing of non-structural parts like inner and outer panels by cold forming are already practiced by OEM’s. However, for structural parts like B-Pillar, A-pillar, C-pillar, cross beam and impact beam requires high strength aluminum alloys. But the high strength aluminum alloys are not formable at room temperature. Therefore, requires another forming approach.

Audience

Engineers and technicians in the fields of production, process, tooling, material testing and QM & QS.

Prerequisites

Understanding in heat treatment and hot forming and quenching.

Benefits

The overall performance and the variety of methods of the seminar are designed most helpful for efficient studying. You will have the opportunity to experiment with various parameters and experience hot forming and quenching in the field of aluminum and acquire a deep insight into the most efficient skills in technology.

Methods

EBNER Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players.

Content

Hot forming and quenching of aluminum similar to press hardening of steel is a newly developed forming technology that is able to form complex shape structural parts made from high strength aluminum alloys (Fig. 1). In this processing technology, aluminum sheet is solution heat treated between 450-580°C for 0-10 min in a furnace. Thereafter it is transferred into the press. During transfer, the aluminum blanks cools. During pressing, it acquires the shape and necessary quenching. The formed and quenched parts artificially aged to T6 condition. Improvement in formability due to elevated temperature of high strength aluminum facilitates forming of complex shape parts which are not possible by cold forming. The major advantages of the hot forming and quenching process are follows:

  • The reduction of the number of individual steps means there are fewer opportunities for contamination of the metal within each process, and uncontrolled air-cooling.
  • Less energy is needed due to the reduction in the number of times the material is reheated.
  • The formability of the material is higher, due to the hardening stages being performed during or after the forming stage.
  • Spring back can also be reduced by the combination of quenching and forming stages. This, in turn, increases the geometrical tolerances of the component, allowing components to be assembled easily.
  • Distortion of the component is also limited due to the quenching stage being contained in the cold die.
  • The time of production for each component is reduced, because the component no longer has to be transferred between as many different items of process equipment. This consequently leads to financial savings.

T1: Introduction and fundamentals in HFQ

  • Recapitulation Process fundamentals
  • Which quality characteristics have to be fulfilled? – Critical quenching rate, Interface between tool/press/cooling, Thermal expansion, Form- ability, etc…
  • Product design, most important process parameters, tool concepts, thermal treatment

T2: Process Parameters for Tools

  • Cooling approaches, handling of problem areas
  • Segmented construction
  • Tool design
  • Failure possibilities (drawing clearance, wear, blank holder, positioning ejector, etc.)
  • Failure criteria by replica or drawing clearance measuring
  • Process control

T3: Virtual Engineering

  • From the component geometry to the tool
  • Interface definition and using software
  • How the product geometry has to be? Are there possibilities for optimization? What is not?
  • Active surface construction
  • Blank shape
  • Simulation
  • CAD (Catia)
  • Trimming

T4: Tool Materials and Coatings

  • Hot forming tool steel (mechanical and thermal properties)
  • Tool coating
  • Recent developments

T5: Practical Examples

  • Case Studies

P1: Practical Examples

  • Case Studies in the laboratory at the furnace

Summarization

  • Summary of the training
  • FAQ
  • Feedback

Duration                                            

2 days

REGISTRATION

LEVEL 1 - BASIC TRAINING COPPER BASE METALS

Description                                       

This basic seminar is intended to provide you with the fundamentals of the physical and material engineering of heat treatment.

Questions will be answered on how the strength and ductility of metallic materials can be specifically adjusted by heat treatment or how to

State diagram reads and interprets. It also explains what happens inside the metal during heat treatment and why such different heat treatment processes are necessary.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic technical understanding of heat treatment processes and/or materials science

Benefits                                             

Understanding the metallurgical processes in the course of a heat treatment process

Content – Theory & Practice

  • Structure of metallic materials
  • Introduction of near-equilibrium heat treatment of steel (iron-carbon diagram, normalizing and annealing)
  • Introduction of heat treatment of steel (martensite, bainite, retained austenite, hardening and tempering)
  • RTD diagrams
  • Location of different heat treatments in Fe/C and ZTU diagrams
  • Influence of alloying elements
  • Basic information on heat treatment of aluminium (Al-Cu phase diagram, solution heat treatment, precipitation hardening)

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course

Duration                                            

2 days

REGISTRATION

Description                                       

By means of easily understandable examples, knowledge is obtained about further program technical possibilities in order to consolidate and furthermore extend the physical and material fundamentals of heat treatment.

Various annealing cycles, optimization possibilities and software tools are explained and deepened in hands-on training.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic knowledge of heat treatment processes and optimization of EBNER furnaces

Benefits                                             

Understanding and optimization of the heat treatment process; optimized output at the plant

Content – Theory & Practice

  • Temperature and inert gas cycles of different heat treatments or alloys
  • Optimization possibilities in the temperature and inert gas cycles to increase quality and the output or reduction of media consumption
  • Optimization possibilities in the process parameters
  • Explanation of supporting software tools

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course at customer’s facility (if available)

Duration                                            

1 day

REGISTRATION

LEVEL 1 - BASIC TRAINING STEEL

Description                                       

This basic seminar is intended to provide you with the fundamentals of the physical and material engineering of heat treatment.

Questions will be answered on how the strength and ductility of metallic materials can be specifically adjusted by heat treatment or how to

State diagram reads and interprets. It also explains what happens inside the metal during heat treatment and why such different heat treatment processes are necessary.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic technical understanding of heat treatment processes and/or materials science

Benefits                                             

Understanding the metallurgical processes in the course of a heat treatment process

Content – Theory & Practice

  • Structure of metallic materials
  • Introduction of near-equilibrium heat treatment of steel (iron-carbon diagram, normalizing and annealing)
  • Introduction of heat treatment of steel (martensite, bainite, retained austenite, hardening and tempering)
  • RTD diagrams
  • Location of different heat treatments in Fe/C and ZTU diagrams
  • Influence of alloying elements
  • Basic information on heat treatment of aluminium (Al-Cu phase diagram, solution heat treatment, precipitation hardening)

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course

Duration                                            

2 days

REGISTRATION

Description                                       

By means of easily understandable examples, knowledge is obtained about further program technical possibilities in order to consolidate and furthermore extend the physical and material fundamentals of heat treatment.

Various annealing cycles, optimization possibilities and software tools are explained and deepened in hands-on training.

Audience                                           

Personnel from production, R&D, quality management, purchasing

Prerequisites

Basic knowledge of heat treatment processes and optimization of EBNER furnaces

Benefits                                             

Understanding and optimization of the heat treatment process; optimized output at the plant

Content – Theory & Practice

  • Temperature and inert gas cycles of different heat treatments or alloys
  • Optimization possibilities in the temperature and inert gas cycles to increase quality and the output or reduction of media consumption
  • Optimization possibilities in the process parameters
  • Explanation of supporting software tools

Methods

EBNER Academy offers a targeted, practice- and economically oriented transfer of knowledge in the form of seminar presentations and field tests on samples. The trainers involved are highly qualified and experienced key persons.

Training Type                                   

Open theory course or individual course at customer’s facility (if available)

Duration                                            

1 day

REGISTRATION

LEVEL 2 - ADVANCED TRAINING STEEL

Description

Nowadays energy efficiency and crash performance bring a lot of requirements within the material or the material selection. Anyone who wants to successfully manage automotive lightweight construction today must understand the principles of tailored part properties. Therefore, essential knowledge is crucial. The TPP training will give the participants the opportunity to take over a leading role in utilizing this technology on a practical level according to OEMs standards.

Audience                                           

Engineers and technicians in the fields of production, material testing and QM & QS.

Benefits                                             

Leading engineers in the field of press hardening with the key aspect on TTP will introduce new engineers and technicians into the comprehensive field of TTP. The participants will experience the different challenges in this field as well different design concepts by detecting the problems outlined in previous tests.

Methods                                            

EBNER Academy provides a focused, practically and economically oriented knowledge transfer in the form of seminar lectures and field tests on samples. The involved trainers are highly qualified and experienced key players in the PHS-market.

Content

Theoretical units aim at creating a deep understanding of TWB- and TRB- material transformations during heating, cooling and forming.

T1: The following questions will be answered

  • How can tailored part properties be achieved?
  • What are the advantages for locally different material properties regarding safety, weight and costs?
  • What needs to be considered for the PH process when working with TWB/TRB?
  • What are the possibilities to produce partial heat treated or tempered stamping parts?
  • How does tailored parts influence the tool design?
  • How and where can it be used in serial production?

T2: Summarization

  • Summary of the training
  • FAQ
  • Feedback

Duration                                            

2 days

REGISTRATION