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AK Steel Corporation/Gestamp/Gonvauto Confidential

The concepts described and/or content of this document are not to be revealed to persons outside of AK Steel Corporation,
its divisions or subsidiaries and/or Gestamp/Gonvauto without the express written consent of the management.

December 8, 2014

Gestamp South Carolina, LLC

BMW Body Side Outer - EG EDDS Plus
Surface Issues after Forming
AK Steel Coil Numbers 159051-4A & 160766-2A
George Paraskos & Jim Unglesby

INTRODUCTION & ANALYSIS

Sections of formed BMW Body Side Outer panels with identified surface features
were forwarded to AK Steel Research for analysis.
A panel section from AK Steel Coil Number 159051-4A displayed multiple
longitudinal features on the top side after stoning. A photograph of the part is shown
in Figure 1. Examination of the bottom side of the panel revealed numerous linear
features as shown in Figure 2. Removing the EG coating using 50% HCl revealed
light surface disruptions as shown in the stereoscope image in Figure 3. These linear
bottom side disruptions were highlighted on the top surface of the panel during press
forming.
The linear features were analyzed by standard metallographic techniques using a
Scanning Electron Microscope (SEM) equipped with Energy Dispersive Spectroscopy
(EDS). The feature is characterized as a linear mechanical gouge that likely occurred
after the acid tanks at the Pickler. The few small iron oxide particles may be rust
formed by entrapped acid as suggested by the Cl detected in spectrum 1.
Samples from two formed sections from AK Steel Coil Number 160766-2A displayed
single linear features on the top surface of the panel. The samples were analyzed in
similar fashion. A photograph of the two parts is shown in Figure 5. The SEM/EDS
analysis revealed a linear mechanical gouge that contained entrained iron oxide
particles (see Figure 6). This is consistent with a mechanical gouge during processing
at the Hot Strip Mill.

*Disclaimer
The information and data in this document are accurate to the best of our knowledge and belief, but are intended
for general information only. Applications suggested for the materials are described only to help readers make
their own evaluations and decisions, and are neither guarantees nor to be construed as express or implied
warranties of suitability for these or other applications.
Data referring to material properties are the result of tests performed on specimens obtained from specific locations
of the products in accordance with prescribed sampling procedures; any warranty thereof is limited to the values
obtained at such locations and by such procedures. There is no warranty with respect to values of the materials at
other locations.
This document or any part therein may not be reproduced without the written permission of AK Steel Corporation.

AK Steel Corporation/Gestamp/Gonvauto Confidential

December 8, 2014
Page 2

SUMMARY
The sections of formed panels from the BMW Body Side displayed linear features.
The sample from AK Steel Coil Number 159051-4A had bottom side linear
mechanical gouges that likely occurred from coil processing after the acid tanks at the
Pickler. The sample from AK Steel Coil Number 160766-2A had top side linear
features consistent with mechanical gouging during processing at the Hot Strip Mill.

George Paraskos
Manager
Process Research
GP/JU/jj

Jim C. Unglesby
Laboratory Leader
Primary Process Research

AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 1 - Photograph of Formed Panel Section from Coil Number 159051-4A - Top
Side

Gestamp-Gonvauto EG SC 159051-4A - Lines (Top)

Gestamp-Gonvauto EG SC 159051-4A - Lines (Top Close-up)

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AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 2 - Photograph of Formed Panel Section from Coil Number 159051-4A - Bottom
Side - Coated & Stripped

Gestamp-Gonvauto EG SC 159051-4A - Lines (Bottom)

Gestamp-Gonvauto EG SC 159051-4A - Lines (Bottom Close-up)

Gestamp-Gonvauto EG SC 159051-4A - Lines (Bottom Close-up - Stripped)

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AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 3 - Stereoscope Image of Bottom Side Features on Panel Section from Coil
Number 159051-4A

Gestamp-Gonvauto EG - SC 159051-4A - Lines (Bottom Stereoscope - Stripped)

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AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 4 - SEM Analysis of Bottom Side Features on Panel Section from Coil Number
159051-4A

SEM Micrograph 100X

SEM Micrograph 500X

SEM Micrograph

EDS Spectra

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AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 5 - Photographs of Formed Sections from Coil Number 160766-2A and One with
No Identity

Gestamp-BMW EG EDDS Lamination SC 160766-2A - (Top) Sample 1

Gestamp-BMW EG EDDS Lamination Sample 2 - Top

Gestamp-BMW EG EDDS Lamination Sample 2 - (Top Close-up)

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AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 6 - SEM/EDS Analysis of Formed Sections from Coil Number 160766-2A

Samples 1 & 2

SEM Micrograph (100X) SC 160766-02A Sample 1

SEM Micrograph (250X) SC 160766-02A Sample 1

SEM Micrograph

EDS Spectra

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AK Steel Corporation/Gestamp/Gonvauto Confidential

Figure 6 Cont.

SEM Micrograph (250X) No Stock card ID

SEM Micrograph (1000X) - Sample 2

SEM Micrograph

EDS Spectra

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