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It’s been five years since we collaborated with specialist software producer GWJ Technology to add our clean steel into their GearEngineer software. Since then, powertrain designers have been able to use the software to see how our 159X and 159Q clean and ultra-clean steels can increase the power density of transmission systems.

One group to benefit in the last year was BRS Motorsport, a Formula Student (FS) motorsports team representing Germany’s Hochschule Bonn-Rhein-Sieg school. BRS wanted to make a significant upgrade to their gearbox but found it was pushed too close to its safety margin with the existing engineering steel.

After seeing 159Q was the top-performing steel in the GearEngineer software, the team approached us for help, advice and samples. As a result, BRS modified its design to score well at the FS championship in the Czech Republic and Italy in August and September 2023.

For us at Ovako, the project has wider significance as it represents a similar powertrain design challenge to the one faced by the wider automotive industry on a larger scale.

Increased powertrain performance in the same weight package

The BRS team’s redesign positioned the electric motor further into the wheels and replaced a 1.5-stage planetary gearbox with a single-stage design. This simplified manufacturing and maintenance by eliminating the need for a special tool. However, it also increased power density.

The challenge for the existing case-hardening steel (18CrNiMo7-6) was that the new design reduced the safety factor on the gear tooth flank to 1.037. By switching to 159Q, BRS was able to widen this safety factor to 1.373.

This was possible due to Ovako’s strict control during steel production. The steel is an Isotropic Quality (IQ) steel that provides consistent performance under complex loading from multiple directions.

The resulting design has increased performance within the same weight package as the previous design. 

Close-up of the brake system

Meeting automotive’s e-fuel challenge

Like the BRS racing team, automotive OEMs (original equipment manufacturers) need to make more effective use of energy in vehicles. This is particularly true when vehicles need high power and energy density to carry heavy loads over a long range.

It’s unlikely that pure electrification can fully support these vehicles due to current limitations in battery capacity, cycling and availability.

Instead, it is likely that combustion engines will continue to be used, and will draw on alternative fuels such as hydrogen, methanol or ammonia. The key to these e-fuels is that they should be produced from decarbonized and renewable electricity, rather than from electricity produced by burning coal.

These e-fuels will deliver the required performance and meet Net Zero targets. However, they will require a radical redesign of combustion engines as components will need to provide high strength. This is where IQ Steel will play an important role, while we foresee significant potential for our Hybrid Steel in offering a unique combination of high strength and corrosion resistance.

Driving to victory: Karlsson's Triumph with Ovako IQ-Steel

Karlsson's transition to Ovako IQ-Steel revolutionized his design process. Previously hindered by the limitations of standard steel, he now crafts drive shafts that are lighter and stronger, propelling his drivers to podium finishes in world rally cross championships.

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Stay tuned for more exciting updates as we continue to shape the future of steel and redefine what's possible.

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