Competitive Product Innovation

Manufacturers face mounting pressure to shorten development cycles while meeting high standards for material performance, sustainability, and cost efficiency. These challenges are compounded by fragmented data systems, which make it difficult to access and leverage critical information across the product lifecycle, from design through production to end-of-life.

Adapting to fast-changing market demands requires more than just technical expertise; it demands a unified approach to managing materials data, ensuring informed collaboration across teams and departments. By addressing these data and communication gaps, manufacturers can streamline decision-making, reduce risks, and unlock new opportunities for product innovation.

Why it matters

The materials and manufacturing sectors are at a critical crossroads, facing mounting pressures to balance environmental sustainability with economic viability. The demand for advanced materials like high-strength steels, essential for sectors such as renewable energy, e-mobility, etc.,  continues to rise. Yet, the industry struggles with a range of challenges:

• Decarbonization: Reducing CO2 emissions during steel production is vital to meet EU targets of cutting greenhouse gas emissions by 40% by 2030.
• Critical Raw Materials Dependency: The EU heavily relies on external suppliers for essential alloying materials, making it vulnerable to supply chain disruptions and price volatility.
• Cost Efficiency: Developing scalable, cost-effective manufacturing methods is key to maintaining competitiveness, especially in applications such as wind energy turbines and heavy transport.
• Innovation Bottlenecks: Traditional trial-and-error approaches in materials design and process optimization lead to inefficiencies, waste, and high R&D costs.

Industries need advanced tools and methodologies to accelerate innovation, reduce environmental impact, and ensure a secure, sustainable supply chain for critical materials.

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Project Example: AID4GREENEST

The AID4GREENEST project addresses these challenges head-on by integrating artificial intelligence (AI) with materials science to develop innovative, sustainable solutions for the steel industry. Running from September 2023 to August 2026 with a budget of €5 million, AID4GREENEST brings together 10 leading European universities, research centers, steel companies, and a small enterprise to pioneer cutting-edge tools and methodologies.
 

Objectives and Innovations

• AI-Driven Modeling Tools: AID4GREENEST is developing three AI-based chemistry-process-structure modeling tools that enable the design of robust materials and eco-friendly production routes. These tools optimize material properties and processing parameters, reducing CO2 emissions and waste generation.
• Creep Performance Prediction: The project introduces machine learning-based tools for predicting creep performance in heat-resistant steels. By leveraging accelerated creep testing, the methodology drastically improves R&D efficiency and reduces reliance on resource-intensive testing methods.
• Microstructure Evolution Modeling: A sequential model is being developed to predict microstructure changes during forging and quenching of large-scale steel products. This eliminates wasteful re-processing and replaces conventional trial-and-error testing with data-driven precision.
• Lifecycle Assessment and Innovation Roadmap: AID4GREENEST performs lifecycle assessments to support model-based innovation processes. A roadmap will guide the adoption of AI-enhanced tools across the entire value chain, from materials design to product development.
• Online Platform for Knowledge Sharing: The project includes the development of an AI-based online platform to centralize knowledge transfer. This resource will feature workflows, open-access publications, and standardized data for the industry.
   

Impact and Applications

• Hot Rolling of Steels: AID4GREENEST accelerates the decarbonization of hot-rolled steels, particularly martensitic grades. These high-strength steels, while currently a niche market, hold immense potential for applications in renewable energy and heavy transport. The project’s innovations in redesigning existing grades offer billions of euros in value while reducing environmental footprints.
• Forging and Quenching: The optimization of forging and quenching processes, particularly for turbine and generator components, is another focus. The project addresses energy-intensive heat treatment challenges, ensuring long-lasting and cost-effective components for wind turbines. By improving material efficiency and durability, AID4GREENEST enhances competitiveness in the renewable energy sector, helping reduce the levelized cost of energy for offshore wind systems.
• Critical Materials Supply: By developing tools to optimize the use of secondary and recycled materials, AID4GREENEST mitigates Europe’s dependency on critical raw materials. Its innovative methods improve alloying processes and reduce the need for primary resources, creating a more resilient supply chain for high-tech steel sectors.

Through its AI-powered tools, lifecycle assessment methodologies, and focus on sustainability, AID4GREENEST exemplifies how technology can transform the steel industry into a cleaner, more resilient, and more innovative sector.

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Related services

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