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Visit report of Madras Radiators for line trials of Alcosta

(16.03.21 / POSCO India TSC- Chennai)

1. Background
Royal Enfield(RE) is currently using GA material of P-MH for fuel tank application for
various models of two wheelers. They received 4 vehicles from on field after one
year with rust inside the fuel tank. Hence they are analysing this issue in both ways
such as
1) Internal analysis within Royal Enfield wrt what has gone wrong in these 4
cases.
2) Material wise problem if any. During trial tests of P-MH GA, they found all the
tests & trials ok. Still they received complaint from the field.
So, material wise they are taking trials with different mill materials like GA material
from TATA & JSW. And also Al Si coated material (Alcosta) from Posco & Arcelor
Mittal.
Once they complete line trials, they will do welding tests, SST, paintability test, peel
off test etc with all these materials, then they will conclude upon which mill material
to use for further production. The average quantity consumed by RE for this fuel
tank application is 456T/month.
Hence line trials were taken by RE with Posco Material- Alcosta for fuel tank
application at Madras Radiators & Pressings Ltd(MRP) on 21st March 2016. (Fuel
tanks for RE are manufactured at MRP)
2. Mahindra
Line trials
@ MRP
& Force
motors uses Alcosta for Fuel tank application. Hence P-IPPC
Line
trials500kg
were done
at MRP
presence
of following
persons.
supplied
samples
frominthat
lot to Madras
Radiators
for line trials.
Royal Enfield: Mr. Gokul(Purchase) & Mr. Vishal(Supplier Quality)
Madras Radiators: Mr. Kaaleyan & team
P-India: Mr. Kim & Mr. Chandra
P-IPPC: Mr. Ashish
Line trials were done for fuel tank of one of the model of RE. Both RH & LH sides
trials were done.
Cut to length sheets--- Profile Blanking---Single step Forming in 800T press
The forming process is as per below:
Cut to
Length

After Profile
Blanking

sheets

After
trimming

After Single
step forming
(800T press)

Visit report of Madras Radiators for line trials of Alcosta


(16.03.21 / POSCO India TSC- Chennai)

During forming, they observe for 4 major defects like thinning, wrinkling, crack and
coating thickness change before & after press.
In the trials for Alcosta material,
there was no thinning & crack. But in
around 65% of parts produced, we
observed wrinkling. Wrinkling here
means surface not perfectly flat, but
there is minute surface protruding
Wrinkling
out. This can only
be felt by hand but not seen.
RE quality team took various trials for removal of wrinkles by adjusting blank
location, adding & removing shims etc.
After various trials, In LH side part of fuel tank, only 14 parts were perfectly ok out
of ~30 blanks. Similarly on RH side part also only 14 parts were ok out of 40 blanks.
With these 14 parts each of LHS & RHS, they will make 14 fuel tanks and analyze
the
other parameters like welding, SST, paintability.
LH side part
RH side part

Ok parts

Not ok parts

Ok parts

Not ok parts

RE doesnt want to disturb the die guides adjustment for correct position of blank to
get wrinkle free parts. They have taken various trials with manual adjustment only.
But they opined that the rejection ratio can be brought down by taking trial with
large quantity sheets ~ 500 sheets.
Before Posco, RE tried Arcelor Mittal material in which 40parts out of 50 are found
ok.
Theirs opinion is that they are not getting stability using Posco material. That is with
minor change in die, there is huge variation in the formed part.
There might be some reasons for this. Like Ra difference, lubricant being used etc.
For our Alcosta they used palmolein oil as lubrication during pressing operation.
We cant conclude our material performance based only on this trial.
We need to check the Ra difference between regular P-MH GA & Alcosta samples
which we supplied.

Visit report of Madras Radiators for line trials of Alcosta


(16.03.21 / POSCO India TSC- Chennai)

3. Our request to RE
1. We requested RE to share the details of Rusting issue which they faced in P-MH,
GA.
2. We also requested RE to share MTC of Arcelor Mittal, Al Si coated steel material in
which they have conducted trials.

4. REs request to Posco

1. RE requested us to provide them with comparison report between GA & Alcosta


with
respect to all chemical & mechanical properties.
2. RE wants the comparison report of Ericsson cupping test.
3. As of now for these trials they used Palmolein oil as lubricant during pressing. But
they want to know which lubricant suits better for Alcosta forming operations.
4. RE used different types of welding like Spot welding, Seam welding, Mig welding.
Hence they are requesting us to provide us with preferred weld parameters for
Alcosta material.
5. They also want to know the effect of Brazzing on Alcosta material. Whether
brazzing
will have any impact or not.