THE STRONGER.

THE BETTER.

TRANSMISSION

VALVES INJECTION PUMPS

PISTON RINGS
 Stronger springs, better cars 4

Content Developing your business

Committed to service
Engineered to last
6
8
10
The surface is everything 12
Spring wire for applications with high Tested, tested and tested again 14
performance demands.

VALVES
Since 1926, our driving force has been to develop
an even stronger wire, as this can deliver the Intro 16-18
performance you need to create an even better Tech Talk 19
spring - the stronger, the better.
In focus 20
Product information 21

TRANSMISSION

Intro 22-24
Tech Talk 25
In focus 26
Product information 27

DIESEL INJECTION PUMPS

Intro 28-30
Tech Talk 31
In focus 32
Product information 33
In focus GARBA 177 family 34
Tech Talk GARBA 177 family 35

PISTON RINGS

Intro 36-38
Tech Talk 39
In focus 40
Product information 41

Edition 2
Produced 2016
4 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 5

Stronger springs, better cars.

When your spring works perfectly year after year, despite great strain, extreme conditions and
constant use, the odds are that you are benefiting from one of the spring wires from Suzuki
Garphyttan. We develop and produce high-performance wire from low-alloy and stainless steel
for automotive applications where reliability means everything. Therefore, we accept only
perfection and constantly drive development forwards so that you can create even better
springs and forge an even stronger bond with your customers - the stronger, the better.

A WIDE AUTOMOTIVE RANGE

Suzuki Garphyttan develops and manufactures round, flat and shaped oil tempered
or stainless spring wire from various alloyed steels. The main applications
are valve springs, transmission springs, piston rings, wave springs,
die springs, linear guides and springs for injection systems.

David Thureborn
Vice President, Research & Development.
6 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 7

Developing your business

We see our customer relations as a partnership facing a common and stimulating

challenge: to support the automotive industry in meeting and exceeding the
increasingly stringent demands for higher power output and lower fuel consumption.
You know the market, the trends and design development. We know the material
and processes from the steel works to the spring factory. Together we can create
the conditions you need to give your customers the springs they want today
and tomorrow.
WHAT WE BRING TO THE PARTNERSHIP

Time to market Business excellence

Quality focus

Research & Development Spring production

know-how
High supply reliability
High yield

Global presence
JIT delivery

Technical support Environmental

awareness

Your role in the partnership is to listen to the market and
analyse the existing requirements and put forward the
design concepts needed to drive development forward.
The design of new components or parts often means
the spring wire has to be produced in new materials and
shapes to achieve new and improved properties.
What we bring to the partnership is our expertise in
processing and treatment of steel and material surfaces,
which enables us to produce the new properties and
abilities required of the wire. We have cultivated extensive
knowledge of steel grades, efficient manufacturing and
quality assurance, all of which are crucial for the finished
product. We invest a high amount of resources in
research and development to improve the properties of
our products and end of the line manufacturing process-
es.
COST-EFFECTIVE PRODUCTION
Our production process supports the partnership by
providing spring wire of a consistent and reliable quality,
resulting in less waste and reduced down-times in your
production. We also supply wire that is either ready for
final production or requires minimal after-treatment.
This ensures you have the right conditions to increase
productivity, cut manufacturing costs and strengthen
your competitiveness on the market.
TECHNICAL SUPPORT
An important part of our R&D and sales support work is to
discuss and support the customer in material engineer-
ing matters. We focus our work on developing materi-
als, products and production processes to satisfy the
emerging needs and requirements from you and your
customers.
GLOBAL PRESENCE
We have manufacturing plants in Europe, North America
and Asia, which together account for over 80% of the
global car production. This means that we can offer you
redundant manufacturing capacity. This also means that
if you move production or expand into a new market, we
are already there and can support you with a reliable and
well-tested supply chain.
8 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 9

Committed to service
Together with product development and product quality, service is one of our three
areas of commitment. We support your business and profitability with a wide range of
services that match your specific ambitions and challenges.

We are driven by perfection and development, for our- TRUST IS A MUST

selves and for our partners. Together with our customers
we create the conditions for developing world-class prod-
ucts for cutting edge technology companies around the
world. The basis for this work is a commitment to service
that strengthens our cooperation and makes it easier for
you to focus on market demands.
Everything we do in our service is based on the need for
trust between the customer and ourselves. We should be
able to share information, plans and ambitions freely and
quickly, so that we can work effectively together to secure
our customers success and profitability. Within this
framework of trust, we provide the partnership with a wide

TIME TO MARKET range of services, from prototypes to system integration.

Everything we do in our service is all about giving the Depending on what best serves the customers needs,
customer a shorter time to market. each partnership will have its own tailor-made combina-
tion of services.
To make this happen, it is important that we can coop-
erate with the customers from an early stage in their
REGULAR SERVICE CHAIN development processes and provide the specific quality OUR RANGE OF SERVICES
A regular service chain is set up to organize and facilitate the producers internal efforts to deliver. - Prototypes
products that they need to succeed. - In-house tool development and production
TIME - Flexible planning
By being integrated into the customers development - Delivery tracking
Sourcing Research Development Risk Communication Engineering Process Supply Chain Financing
management & integration Management chain, we can be a better partner. In practice this means - Logistical services
- Lab reports analysis
that our service chain is set up to match the customers
- Capacity reservation
development cycle and provide everyone with fast infor- - Call-off service
COMMITTED SERVICE CHAIN mation, availability and flexibility. - Simple contact and short answer time
A committed service chain is set up to accelerate and facilitate the customers development activities. - Real-time data
- Tech support
TIME LOCAL TO LOCAL
- Warehousing and transport services
We believe our service should have a global footprint, with - Tailor-made flexible packaging
Risk Communication Supply Chain
Sourcing Research Development management & integration Engineering Process Management Financing local production and development. One advantage is that - Early warnings
we can deliver quickly and with great flexibility. Another - Quality control
is that we understand the local culture, language and - Traceability
ITS ABOUT TIME - Financing
When we merge the position in the market, providing a more effective cooper-
- System integration
steps in our service ation with customers. In addition, our customers can sign - APQP Services
chain, we shorten your contracts in the local currency with less financial risks.
time to market.
10 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 11

Engineered to last

Suzuki Garphyttan works with top steel producers to match the industrys techni-
cal development. Together we develop new material compositions and treatment
methods to improve existing products or develop new ones. The aim is always
to produce increasingly better properties from steel, most importantly even
higher strength. In short, we can provide steel as you want it.

The valve spring is a critical component in todays modern engines

and has been ever since the beginning of the automotive era.

Suzuki Garphyttan is always creating new opportunities
for improvement in collaboration with the steel producers.
We carefully select the producers we work with, who act
as partners in our work. Together we test materials and
methods effectively in our search for the properties the
automotive industry needs to meet its challenges.
an alternative. The result is OTEVA 101 - an oil tempered,
SiCrVMoW-alloyed, ultra-high tensile spring steel designed
for surface nitriding. The material has now set a new stan-
dard in the automotive industry and has enabled further
new designs in clutch and transmission applications.

The most important property of all is even higher strength Final stress (MPa)
1500
- combined with high ductility. This paves the way for
lighter and smaller components and, ultimately, more ef- d
1 SC nitrite
OTEVA 10
ficient and smoother drivelines and transmissions. 1325
OTEVA 96 SC
nitrited
d
91 SC nitrite
OTEVA 90/
t nitrided
/101 SC no
OTEVA 101 SETS A NEW STANDARD 1150 OTEVA 96
75/76 SC
OTEVA 74/
Development work often starts as a response to a cus- OTEVA 70 SC

tomer requirement. One example is the design concept 975

for the clutch in a new advanced gearbox. The design

required spring components with extreme performance in 800
50 100 150 200 250 300
a demanding environment. Initial stress (MPa)

Goodman diagram for fatigue limit of our OTEVA steel grades

Thanks to our valuable experience in valve spring quality
are all available in a span with very high fatigue strength to cope
and cooperation with our parent company Nippon Steel with the most demanding applications. All customers can find an
& Sumitomo Metal Corporation, we were able to produce OTEVA that is right for them.
12 THE STRONGER. THE BETTER.
The surface is everything
The surface is one of the most critical properties of a spring wire. One of the
secrets in the surface of Suzuki Garphyttans wire is that we can control the
production processes and wire properties with immense precision from wire
rod to finished product.
Besides the material, the wire surface is our big op-
portunity to develop new properties and functions that
can satisfy the new requirements from the automotive
industry. It is the surface that has to withstand wear,
corrosion and heat. It is the surface that must deliver high
fatigue strength, precise dynamics and minimum friction.
Consequently, we have amassed expertise in all wire and
spring surface treatment techniques.
SURFACE QUALITY
At the start of the process, the wire rod is shaved to
remove surface defects. The shaving process comprises
two stages; the wire first passes through a calibration die
where it is made perfectly round and centred, thus ensuring
that the surface is evenly shaved in the second stage.
After shaving, the wire is heat-treated to reset the micro-
structure in the surface, and therefore its ductility, before
the drawing process, which gives the wire its dimension
within very narrow tolerances.
The wire is now ready for a series of tempering stages,
which vary depending on its final destination. The temper-
ing stages ensure an even microstructure and the
THE STRONGER. THE BETTER. 13
mechanical properties needed in the end product.
The heat treatment is carried out in continuous lines
developed to ensure a high surface quality of the wire.
Each stage is verified during the process, and in the
final check all of the wire is inspected using Eddy Current
testing to ensure maximum possible surface quality.
INCREASED HARDNESS WITH NITRIDING
We are constantly working on increasing the fatigue
strength in the spring. The area of the spring under
the most stress is in the surface, where the strength of
the spring can be increased with a nitriding process.
Our UHT steel grades have a specially adapted
composition suitable for nitriding.
LOW FRICTION TO INCREASE COILABILITY
We work constantly on improving the wires coilability by
reducing surface friction. This enables you to maintain a
high production rate and reduce the wear on your tools.
Final stress (MPa)
1100
d
Shave
1000
aved
Unsh
900
800
50 100 150 200 250 300
Initial stress (MPa)
Goodman fatigue diagram. Shaving the wire rod improves the
fatigue life of springs by removing surface imperfections.
14 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 15

Tested, tested and tested again.

Our ultimate aim is to deliver a product in which every millimetre has the same
high, faultless quality and where the whole delivery is precisely as you want it.
We therefore invest a lot of energy and resources into maintaining total control
of the entire production process, in which we continuously test the wire from
steel production to the moment it is coiled and ready for delivery to you.

Defect free surfaces and narrow tolerances in terms of
dimensions and strength are very important for your
production output. The more precise and faultless we can
make the wire, the more efficient your production will be.
QUALITY WIRE STARTS WITH QUALITY MANUFACTURERS
Our suppliers are approved by means of an evaluation
process in which the steels inclusion cleanliness and
fatigue strength are assured by Nakamura testing and
spring fatigue testing. Deliveries are then systematically
inspected on receipt to ensure that the material quality
has been maintained.
Cleanliness in steel Eddy Current continuous
surface testing
INCOMING INSPECTION OF THE STEELS CLEANLINESS
We carry out systematic checks for non-metallic
inclusions in the wire rod using the Suzuki Garphyttan
method. Our criterion is that there must be no inclusions
larger than 15 m in an inspection area of 1000 mm2. We
inspect the wire rod samples from the surface to 1 mm
depth, the area where the stress on the valve springs is
the highest.
END SAMPLE TESTING
The start and end of every coil of OTEVA wire is evaluated
in terms of strength, ductility, microstructure, surface
decarburization and surfaces. Our OTEVA products have
set the industry standard for the quality of advanced
spring wire and we are always trying to make improvements.

Spring fatigue
testing
CONTINUOUS SURFACE TESTING FOR LONGER LIFE
The final stage in the manufacturing process involves
Nakamura testing
continuous Eddy Current testing along the length of the
SEM-EDS scanning
wire using rotating and stationary test probes.
End sample testing
Eddy Current testing uses magnetic induction principles,
which can detect very small cracks and irregularities in
the surface layer of the spring wire. We use the most
NAKAMURA TESTING advanced equipment on the market for surface defect
The rotating bending test for wire is a fatigue testing testing. With our many years of experience we have
method used for evaluating steel inclusion cleanliness. developed a method to detect and colour-mark defects
Wire samples are surface treated with shot peening to deeper than 40 m. The better the surface, the longer the
promote fatigue breakages initiated from inclusions. During life of the springs.
testing the wire samples rotate with a constant bending
stress, resulting in alternating compression and tension
stresses. The bending stress and number of cycles until
inclusion breakages occur provides information about the
steel suppliers production process. The size and composi-
tion of inclusions are evaluated using statistical methods in
order to follow and compare steel suppliers.

Cross-section of OTEVA wire in 200 x magnification.

16 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 17

Intro >

Valves Tech Talk >

In focus >

Product information >

OTEVA 96 SC PLUS >
OTEVA 91 SC PLUS >
OTEVA 90 SC PLUS >
OTEVA 76 SC PLUS >
OTEVA 75 SC PLUS >
OTEVA 74 SC PLUS >
OTEVA 70 SC PLUS >
18 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 19

Tech Talk VALVES

WIDE SUPPLIER BASE
We have worked with the worlds leading steel mills
for many years. We regularly test and evaluate the valve
spring wire rod from all existing and potential suppliers.
Our aim is to offer customers a product that is the
optimum choice based on performance, quality and
value for money. Only the steel mills which process is based
on continuous cast blooms can qualify for OTEVA SC PLUS.
INCLUSION INSPECTION
Inclusion inspection represents a very important part of
the quality control of a valve spring material. For every
heat of OTEVA material our steel supplier carries through
inclusion inspection. Although SG performs another
inclusion inspection on every heat before the release of
OTEVA SC PLUS.
HIGHEST FATIGUE STRENGTH
The material must have high strength, defect free surfac-
es and excellent dynamic properties in the engine envi-
ronment. A basic requirement is the use of super clean
IN THE WORLD OF VALVES steel, a steel with a specific composition and size dis-
tribution of non-metallic inclusions. Through our fatigue
testing we select the steel mills that meet the highest
one. With profiled cross sections the distribution of the
stresses in the wire can be optimised, which increases
the finished springs performance, reliability and space
efficiency. All tool kits for manufacturing customers
specific profiles are produced by Suzuki Garphyttans tool
workshop.
HIGH RELAXATION RESISTANCE
We select the valve spring wires composition to enable
the spring to work under a high load and operating tem-
perature for the entire life of the engine without losing
strength. Suzuki Garphyttan systematically tests the wire
under special conditions to meet these strict require-
ments.
EXCELLENT COILING PROPERTIES
An oxide layer with an homogeneous composition,
thickness and adhesion is applied to the wire surface,
ensuring good friction properties when coiling the spring.
The ductility of the material is adapted to cope with
difficult spring geometries. The oxide layer and ductility are
determined in our drawing and heat treatment process.
Supplier A Supplier B

Adding new performance Supplier Arequirements

Supplier B of our wire and spring fatigue testing.

CONSISTENT STRENGTH AND HIGH DUCTILITY

The ductility and strength of the material must be opti-
Suzuki Garphyttan has been a leading supplier of valve spring wire on
Heat Size (MT)

an industrial scale since car production began. Now we are adding
new performance by introducing OTEVA SC PLUS.
Our strategy to meet the customers requirements is
always to deliver better quality and customer value. This
is why we now highlight our oil tempered wire for valve
applications further by introducing OTEVA SC PLUS. Only a
few steel works can satisfy the requirements we place on
our specialized wire manufacturing process, we are now
launching OTEVA SC PLUS. If you start with a high quality
valve spring wire, you can work with a lighter, thinner and
narrower design.
Stress (MPa)
mized so that it can be substantially formed during pro-
duction of the spring with no resulting cracks or fractures.
We achieve this using an ultramodern drawing and heat
treatment process in which we control and inspect the
materials properties.
Number of cycles (N)
Inclusion Size (m)
MAXIMUM SURFACE QUALITY
The original wire rod always has surface imperfections. Supplier A Supplier B
To achieve maximum surface quality in the end product
we use a combination of shaving and an ultramodern

Heat Size (MT)

the raw material. Among these, the most specialized steel
mills will be qualified for OTEVA SC PLUS.
Our organisation has been fine-tuned over a hundred
years to ensure the highest possible quality and cus-
Our competitive advantage is that we can offer valve spring
wire with top quality and service. Since 1926, valve spring
wire from Suzuki Garphyttan has been the obvious choice
and you will find it in the most demanding premium brands
on the car market.
drawing technique. To check that the surfaces are free
of harmful defects on delivery we conduct Eddy Current
testing, in which defects 40 m and deeper are colour-
marked.
Inclusion Size (m)

tomer value for our valve spring wire. By our reviews and PROFILED CROSS SECTION High capacity for Nakamura testing makes it possible to check
evaluations of the steel mills to the utmost, through our Oil tempered wire is also manufactured with an egg- and the quality of steel from new and existing suppliers to ensure that
R&D activities, we can select the best steel mills for the elliptical shaped cross section in addition to a round customers are offered the best option for the end application.
most demanding valve spring applications. Together with
20 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 21

PRODUCT INFORMATION

OTEVA 96 SC PLUS
Bloom Billet Wire rod
Valves OTEVA 91 SC PLUS
OTEVA 90 SC PLUS
OTEVA 76 SC PLUS
OTEVA 75 SC PLUS
OTEVA 74 SC PLUS
Steel OTEVA 70 SC PLUS
cross-section

CHEMICAL COMPOSITION, APPROXIMATE VALUES IN %

Our grades C Si Mn P max. S max. Cr V Ni Mo

OTEVA 96 SC PLUS 0.64 2.15 0.45 0.020 0.025 0.97 0.13 0.13
OTEVA 91 SC PLUS 0.63 2.00 0.45 0.020 0.025 0.90 0.10 0.10
Inclusion OTEVA 90 SC PLUS 0.60 2.00 0.85 0.020 0.020 0.95 0.10 0.30
Cross-section
OTEVA 76 SC PLUS 0.60 1.47 0.70 0.020 0.020 0.75 0.15 0.30

200x 200x 400x OTEVA 75 SC PLUS 0.60 1.47 0.70 0.020 0.020 0.75 0.15
OTEVA 74 SC PLUS 0.65 1.47 0.70 0.025 0.025 0.70
OTEVA 70 SC PLUS 0.53 1.47 0.70 0.025 0.020 0.67

VALVES > IN FOCUS

NEAREST EQUIVALENT STANDARDS

Super Clean concept Our grades EN 10270-2 SIS ASTM B.S. JIS
OTEVA 96 SC PLUS - - - - -
OTEVA 91 SC PLUS - - - - -
The Super Slean concept was developed at the end of the 1980s. The idea
OTEVA 90 SC PLUS - - - - -
behind Super Clean is to improve the fatigue life in high-dynamic stressed
OTEVA 76 SC PLUS - - - - -
spring applications, by reducing the harmful effect of non-metallic inclusions. OTEVA 75 SC PLUS VDSiCrV - - - -
OTEVA 74 SC PLUS - - - - -
The key to this concept is controlling inclusion composition. ternary phase diagrams and statistical methods to OTEVA 70 SC PLUS VDSiCr 142090-05 A 877 2803 685A55HD JIS G 3561 SWOSC-V
By changing composition a detrimental, non-deformable estimate maximum inclusion size.
inclusion can be transformed into a deformable inclusion.
As stated by IVSWMA (International Valve Spring Wire Visit www.suzuki-garphyttan.com for complete product information
During steelmakers hot rolling processes, the soft Manufacturers Association), it is likely to find occasional
inclusions are reduced in size and dispersed. As a result, inclusions in valve spring quality steel of a size larger
fatigue life increases. In addition, most engine valve than 15m.
A12O3-CaO-SiO2
spring material suppliers use large format casting. This SiO2

maximises the size reduction of inclusions during the

rolling stages from cast material to final wire rod size. Figure 1:
Super Clean inclusions mainly consist of CaO, Al2O3 and 1368
Ternary phase diagram.
SiO2. The ratio between the oxides is critical for reaching 1400
O

Ma
Ca

1170 1300
ss

the high deformability target (see figure 1). Too much

%

%
140
ss

SiO 2
Ma

of one component and the inclusion becomes hard and

1307

1318 1265

undeformable.
1310
1315 1400

Suzuki Garphyttan uses several criteria to follow up

suppliers Super Clean manufacturing processes.
These include Nakamura rotating bending testing, CaO AI2O3
Mass % AI2O3
22 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 23

Intro >

Transmissions Tech Talk >

In focus >

Product information >

OTEVA 101 SC >
OTEVA 96 SC >
OTEVA 91 SC >
OTEVA 90 SC >
OTEVA 76 SC >
OTEVA 75 SC >
OTEVA 74 SC >
OTEVA 70 SC >
75 KD >
70 KD >
24 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 25

Tech Talk TRANSMISSIONS

MAXIMUM SURFACE QUALITY shaped or elliptical cross section in addition to a round

The original wire rod always has surface imperfections. one. With profiled cross sections the distribution of the
To achieve maximum surface quality in the end product stresses in the wire can be optimised, which increases
we use a combination of shaving and an ultramodern the finished springs performance reliability and space
drawing technique. To check that the surfaces are free efficiency. All tool kits for manufacturing customers
of harmful defects on delivery we conduct Eddy Current specific profiles are produced by Suzuki Garphyttans
testing, in which defects 40 m and deeper are tool workshop.
colour-marked.
Equivalent stress
CONSISTENT STRENGTH AND HIGH DUCTILITY 494,55 Max
441,74
The ductility of the material must be so high that it can 388,93
336,13
be substantially deformed during production of the spring 283,32
230,51
177,71
with no resulting cracks or fractures. We achieve this 124,9
72,095
using an ultramodern drawing and heat treatment 0,0022883 Min

process in which we control and inspect the materials Equivalent stress

properties. 427,22 Max
382,83
338,44
294,05
249,66
HIGH FATIGUE STRENGTH 205,27
160,88
116,49
The material must have high strength, defect free 72,095
0,00060837 Min
surfaces and excellent dynamic properties even in high
operating temperatures. A basic requirement is the use FEM simulations give us possibility to study stress distributions in
IN THE WORLD OF TRANSMISSIONS different cross section geometries.
of super clean steel, a steel with a specific composition
and size distribution of non-metallic inclusions.

Smaller, lighter, stronger. NITRIDED FOR HIGH SURFACE HARDNESS

H2
Our steel grades are especially adapted for nitriding. We
NH3
select the materials composition to ensure maximum N2
European car makers target to reach 95 grams of CO2 emission per kilometre surface hardness and maintenance of core strength.
by 2020, while car customers are demanding power, speed and comfort. Fe N
EXCELLENT COILING PROPERTIES
An oxide layer with a homogeneous composition, thick-
The car industrys challenge is to increase energy efficiency with few impurities, high strength, a defect free wire
ness and adhesion is applied to the wire surface, ensuring
and lower fuel consumption. In terms of transmission, surface and the ability to strengthen the wire surface During nitriding, nitrogen atoms are allowed to diffuse into the
good friction properties when coiling the spring. The steel in order to increase the hardness in the surface.
development is aimed at increasing gears so that the with nitriding.
ductility of the material is adapted to cope with challenging
engine can be run at lower rpms across the speed range.
spring geometries. The oxide layer and ductility are deter-
The result is OTEVA 101, our most recently developed Evolution of Suzuki Garphyttan Spring weight (%)
mined in our drawing and heat treatment process. valve spring quality material
The trend goes towards smaller drivelines with more steel grade for nitrided ultra-strong springs, enabling us Fatique strength (%)
200
springs in a limited space. Springs are becoming smaller to supply spring material with an entirely customer-
HIGH RELAXATION RESISTANCE
and are therefore exposed to higher stress. The solution specific geometry, consistent material properties and 100
We select the spring wires composition to enable the
is to make a spring with an even stronger surface, which an extremely high surface quality.
spring to work under a high load and operating tem- 0
means dimensions can be made smaller without losing OTEVA 20 OTEVA 60 OTEVA 70 OTEVA 75 OTEVA 101/101
perature for the entire life of the engine without losing Unshaved Unshaved Shaved Nitrited Nitrited
strength. Four things are needed: a super clean steel OTEVA 31 OTEVA 70 OTEVA 75 OTEVA 90/91
strength. Suzuki Garphyttan systematically tests the wire Unshaved Unshaved Shaved Nitrited
under special conditions to meet these strict requirements.
Increased fatigue strength has made it possible to reduce the
PROFILED CROSS SECTION spring weight while maintaining the same spring compression
Oil tempered wire is also manufactured with an egg and force.
26 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 27

PRODUCT INFORMATION

OTEVA 101 SC

Transmissions
6-cylinder 4-cylinder OTEVA 96 SC
Speed in 1/min Speed in 1/min
Tolerable performance Tolerable performance OTEVA 91 SC
1500 1500
OTEVA 90 SC
OTEVA 76 SC
OTEVA 75 SC
1200 1200
OTEVA 74 SC
OTEVA 70 SC
900 900
75 KD, 75 KD S
70 KD, 70 KD S

600 600 CHEMICAL COMPOSITION, APPROXIMATE VALUES IN %

0 0,05 0,10 0 0,05 0,10
Time in s Time in s Our grades C Si Mn P max. S max. Cr V Ni Mo W
Vibrations from engine
Reduced vibrations after transmission damping OTEVA 101 SC 0.60 2.25 0.50 0.020 0.025 1.25 0.15 0.15 0.15
OTEVA 96 SC 0.64 2.15 0.45 0.020 0.025 0.97 0.13 0.13
The 4-cylinder engine creates much greater vibrations,
placing greater demand on damping springs in the transmission. OTEVA 91 SC 0.63 2.00 0.45 0.020 0.025 0.90 0.10 0.10
TRANSMISSIONS > IN FOCUS OTEVA 90 SC 0.60 2.00 0.85 0.020 0.020 0.95 0.10 0.30
OTEVA 76 SC 0.60 1.47 0.70 0.020 0.020 0.75 0.15 0.30

Bad vibrations. Good solutions. OTEVA 75 SC

OTEVA 74 SC
0.60
0.65
1.47
1.47
0.70
0.70
0.020
0.025
0.020
0.025
0.75
0.70
0.15







OTEVA 70 SC 0.53 1.47 0.70 0.025 0.020 0.67
Smaller-sized engines have to deliver more power than their larger predecessors, 75 KD, 75 KD S 0.60 1.47 0.70 0.025 0.020 0.67 0.15

hence the growing need to fine-tune the vibration damping in the transmission. 70 KD, 70 KD S 0.53 1.47 0.70 0.025 0.020 0.67

The trend is for cars to have smaller and lighter engines The critical factor is the rpm. To keep fuel consumption NEAREST EQUIVALENT STANDARDS
with fewer cylinders. There is a big move towards down, the engine needs to work at low rpm, yet it is the
lighter cars, more efficient use of energy and lower fuel low rpms that create the strongest vibrations. Our grades EN 10270-2 SIS ASTM B.S. JIS
consumption. This trend also creates a new problem for OTEVA 101 SC - - - - -
everyone working in the area of vehicle comfort. If we cannot resolve the high vibrations at low rpm, the
OTEVA 96 SC - - - - -
loss in comfort will result in us continuing to run our en-
OTEVA 91 SC - - - - -
A small 4-cylinder engine designed to deliver the same gines at high rpm, which will wipe out the environmental
power as a large 6-cylinder engine generates very strong gains in engine development. OTEVA 90 SC - - - - -
vibrations. The challenge for the designers is to maintain OTEVA 76 SC - - - - -
the same or preferably higher level of comfort as There are currently some good solutions, such as the dual OTEVA 75 SC VDSiCrV - - - -
with the larger engine. The clearest example is premium mass flywheel. The problem for manufacturers arises
OTEVA 74 SC - - - - -
brands, where slightly less comfort is quite simply not an when downsizing. Even stronger springs must fit into an
OTEVA 70 SC VDSiCr 142090-05 A 877 2803 685A55HD JIS G 3561 SWOSC-V
option. On the contrary, customers always expect an even ever smaller space. Only the strongest spring steels will
smoother, softer and more comfortable driving experi- do in this respect. These materials can give us smaller 75 KD, 75 KD S TDSiCrV - - - -
ence. Anything else feels like yesterdays technology. and thinner springs that can withstand higher stresses. 70 KD, 70 KD S TDSiCr 142090-05 A 401 2803 685A55ND -

Visit www.suzuki-garphyttan.com for complete product information

RPM
Low rpms are essential for keeping fuel consumption down. However, they generate higher
vibrations and therefore have an adverse effect on driving comfort. To maintain the same level
of comfort, increasingly sophisticated damping systems are used, which place ever greater
demands on the springs and spring wire.
28 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 29

Intro >

Diesel Injection Tech Talk >

In focus >

Pumps Product information >

GARBA 177 Supreme >
Diesel injection pumps
GARBA 177 Premium >
Stainless steel spring wire
GARBA 177 PH >
Stainless steel spring wire
GARBA 178Mo >
Stainless steel spring wire
GARBA 1812Mo >
Stainless steel spring wire
GARBA 188 >
Stainless steel spring wire
30 THE STRONGER. THE BETTER.
IN THE WORLD OF DIESEL INJECTION PUMPS
For a greener diesel engine
Diesel engines are steadily gaining momentum throughout the world. More
than 50% of the newly registered cars in Western Europe are equipped with
diesel engines.
Since the introduction of the common rail system for
diesel in 1997, the popularity of diesel systems in passenger
vehicles has increased significantly. 1997 was also the
year when GARBA 177 Supreme was patented by Suzuki
Garphyttan. One of the most important innovations of
GARBA 177 Supreme is the plunger spring in high pres-
sure pumps. The pressure is generated and transferred
via the common rail system to the injector. GARBA 177
Supreme is one of the materials which have made it
possible to increase pump pressure by almost 100%
since 1997.
THE STRONGER. THE BETTER. 31
Tech Talk DIESEL INJECTION PUMPS
HIGH FATIGUE STRENGTH IN CORROSIVE ENVIRONMENTS
GARBA 177 Supreme has good ductility and is easily
formed into complex springs. It also maintains good form
stability during the precipitation hardening heat treat- Electrode
ment, which increases the tensile strength and fatigue
life of the spring. Due to its chemical composition, GARBA
177 Supreme has a high level of corrosion resistance
and is well-suited to corrosive diesel environments. Cooling water in
HIGH CLEANLINESS
Electro Slag Refining (ESR) is used to significantly improve Slag pool
the inclusion cleanliness of GARBA 177 Supreme. During Molten metal pool
this process, steel electrodes are melted and the liquid
Cooling water out
drops are passed through a molten oxide slag. Oxide
inclusions are dissolved in the liquid slag and the final
Ingot
material is cleaned. The removal of oxide inclusions
significantly improves the fatigue life of the springs.
Starting plate
Water cooling
Material properties achieved by Electro Slag Refining (ESR)
in combination with shaved wire surfaces and precipitation
hardening result in superior fatigue resultsOur GARBA 177
Supreme.
HOMOGENEOUS MATERIAL
Hydrocarbon + NOx Emmission
100
100 %
Homogeneous material is an advantage for improved
material properties. Electro Slag Refining makes it possible 75 -20 %
to control the microstructure of the material and minimize
50
segregations. Good control of the microstructure ensures -57 %
high quality and constant material properties throughout 25 -67%
the length of the wire. -76 %
0
Euro II - 1996 Euro III - 2000 Euro IV - 2005 Euro V - 2009 Euro VI - 2014
CONTINUOUS IMPROVEMENTS IN THE SUPPLY CHAIN
The production route is optimized to obtain high product- Since the launch of GARBA 177 Supreme in 1997, more
ivity and to ensure uniform material properties in the final stringent environmental requirements for diesel cars have
spring wire. led to a significant reduction in emissions.
We are continuously working on improvements through-
out the supply chain for GARBA 177 Supreme, all the way
from steelmaking to wire production.
32 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 33

PRODUCT INFORMATION

GARBA 177 Supreme

Diesel Injection Diesel injection pumps

GARBA 177 PH

Pumps
Stainless steel spring wire
GARBA 178Mo
Stainless steel spring wire
GARBA 1812Mo
Stainless steel spring wire
GARBA 188
Stainless steel spring wire

DIESEL INJECTION PUMPS

CHEMICAL COMPOSITION, APPROXIMATE VALUES %

Our steel grades Dimensional C Si Mn P S Cr Ni Mo Al Cu

ranges mm max. max.
DIESEL INJECTION PUMPS > IN FOCUS GARBA 177 Supreme 0.30 5.60 0.09 0.50 0.50 0.025 0.015 17.00 7.00 1.00

The development of GARBA 177 Supreme NEAREST EQUIVALENT STEEL GRADES NEAREST EQUIVALENT STANDARDS

Our steel grades EN AISI/SAE JIS EN ASTM AMS BS JIS

GARBA 177 Supreme is designed for extreme performance in harsh environments. GARBA 177 Supreme 1.4568 631 SUS 631 10270-3 A313 5678 G4314

In diesel injection pumps it is a key component for increasing fuel pressure,

resulting in reduced fuel consumption.
STAINLESS STEEL SPRING WIRE FOR OTHER APPLICATIONS

The key elements of the success of GARBA 177 Supreme the electro slag refining process. In this process the steel
CHEMICAL COMPOSITION, APPROXIMATE VALUES %
in this application are its great strength, high corrosion is remelted in a highly controlled environment. This makes
resistance, surface properties, microstructure and good it possible to precisely control the microstructure of the
Our steel grades Dimensional C Si Mn P S Cr Ni Mo Al Cu
inclusion cleanliness. steel, reduce segregation to a minimum and substantially ranges mm max. max.
decrease the amount of detrimental oxide inclusions.
GARBA 177 Premium 0.30 8.00 0.09 0.50 0.50 0.025 0.015 17.00 7.00 1.00
Suzuki Garphyttan patented GARBA 177 Supreme in
1997. It is produced in cooperation with the worlds GARBA 177 Supreme is developed in close collaboration GARBA 177 PH 0.30 8.00 0.09 0.50 0.50 0.025 0.015 17.00 7.00 1.00
leading steel suppliers: Sandvik, Uddeholm and Fagersta with spring and pump producers. Suzuki Garphyttan has GARBA 178Mo 0.30 8.00 0.10 1.10 1.30 0.040 0.015 17.00 8.00 0.70
Stainless. Over the years it has been fine-tuned to further an established partnership with Robert Bosch GmbH for GARBA 1812Mo 0.25 8.00 0.04 0.50 1.00 0.040 0.015 17.50 12.00 2.50
improve performance and guarantee high quality repeat- the development of GARBA 177 Supreme Plus wire for
GARBA 188 0.25 8.00 0.08 0.50 1.00 0.045 0.015 18.00 9.00
ability. the next generation of diesel injection pumps.

A key manufacturing process that ensures the excellent NEAREST EQUIVALENT STEEL GRADES NEAREST EQUIVALENT STANDARDS
properties and high quality of GARBA 177 Supreme is
Our steel grades EN AISI/SAE JIS EN ASTM AMS BS JIS
GARBA 177 PH 1.4568 631 SUS 631 10270-3 A313 2056 301 S81 G4314

A SUPREME MATERIAL GARBA 178Mo 1.4310 302 10270-3 A313 2056 302 S26
Today, GARBA 177 Supreme is a tried-and-tested material for diesel injection technology GARBA 1812Mo 1.4401 316 SUS 316 10270-3 A313 2056 316 S42 G4314
and plunger springs made from this material are used by many European carmakers.
GARBA 188 1.4310 302 SUS 302 10270-3 A313 5688 2056 302 S26 G4314

Visit www.suzuki-garphyttan.com for complete product information

34 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 35

Tech Talk GARBA 177 FAMILY

EXCELLENT SURFACES
Direction
Surface imperfections are harmful to the fatigue life of
the spring. Therefore, GARBA 177 Supreme and GARBA
177 Premium, which are intended for highly stressed
springs, are made from shaved wire rod. Shaving is a
procedure that removes harmful defects from the surface.

During the shaving operation the surface layer of the wire

rod is mechanically removed, leaving a polished, smooth In the shaving process, the surface from the hot rolling process
surface for further processing in wire production. is removed from the wire rod. Shaving is essential for obtaining
excellent fatigue properties.

In the final inspection, the wire undergoes Eddy Current

MPa Tensile cold drawn Tensile after PH-treatment
testing in our continuous testing lines. Stationary and
2500
rotating probes induce Eddy Currents in the wire surface.
Surface defects are registered as disturbances in the
GARBA 177 FAMILY
magnetic field and colour-marked. 2000

A new premium quality Suzuki Garphyttan uses the most advanced Eddy Current
testing equipment available on the market. Our expertise, 1500

gained over many years of surface testing in continuous

testing lines, is a guarantee of high quality spring wire. 1000
When commercial grade GARBA 177 PH fails to meet your demands and GARBA 1,00 2,00 3,00 4,00 5,00 6,00 mm
177 Supreme aims too high Suzuki Garphyttan presents the GARBA 177 family, ADVANTAGE PH MATERIALS
giving a wider variety of choices for all your needs. Not only does the GARBA 177 Family provide the option The GARBA 177 family consists of semi-austenitic precipitation
of having the same shaved and EC-tested surface as the hardening materials so that you can increase hardness and
GARBA 177 Supreme The whole GARBA 177 family strength in a finishing treatment.
The newest member of the GARBA 177 Family is GARBA This provides an intermediate grade with a better surface consists of semi-austenitic precipitation hardening
177 Premium. This grade offers the same high strength, and higher fatigue life than the standard commercial materials. One of the advantages of this is that the material Final stress (MPa)
high corrosion resistance and surface properties as grades, making it an excellent material in dynamic is delivered in a drawn condition with a lower tensile 1100
GARBA 177 Supreme but without the microstructure and applications. strength, ideally suited for spring coiling. After the springs
cleanliness achieved by Electro Slag Refining (ESR). are coiled, they are heat-treated at 480C for one hour
1000 me
before being air-cooled. The material is thereby stress Supre
A 177
GARB
PH
relieved and at the same time precipitation hardening GARB
A 177
Microstructure Surface Intended for springs with 900
occurs. This increases the hardness and strength of the
Size material by approximately 250-300 MPa giving a stress
GARBA 177 PH FAMILY range EC-tested relieved spring with a higher tensile strength and longer 800
Inclusion ESR Dynamic
in mm Shaved RD 40 Load 50 100 150 200 250 300
inspection processed stress fatigue life.
Final size Initial stress (MPa)

2,00-5,6 x x x x High High

AC-COATING Thanks to a combination of Electro slag refining, shaving
GARBA 177 Supreme The GARBA 177 Family is delivered with an AC-coated and Eddy Current testing, GARBA 177 Supreme has a high,
<2,00 x x x - High High consistent fatigue strength. The fatigue strength of GARBA 177
surface. The coating consists of the drawing lubricant
Premium is expected to be found between these lines.
carrier and the drawing media combined in a thin,
2,00-5,6 x - x x Medium High
Garba 177 Premium soap-like layer. This works as protection in the delivery
0,30-8,00 x - x - Medium Normal condition and provides a good surface for spring coiling.

Garba 177 PH 0,30-8,00 - - - - Low Normal

36 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 37

Intro >

Piston Rings Tech Talk >

In focus >

Product information >

GARBAFLEX 75 >
GARBAFLEX CrSi91 >
GARBAFLEX CrSi70 >
GARBAFLEX 174Mn >
GARBAFLEX 188L >
38 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 39

IN THE WORLD OF PISTON RINGS

Tech Talk PISTON RINGS

Do more with less

MORE ADVANCED PROFILES NAPIER PROFILES AT THE DRAWING STAGE
The trend is heading towards more efficient engines that deliver more power The trend is heading towards an even more advanced The Napier profile is our most advanced design for piston
with every drop of fuel. Car manufacturers are always challenging todays design of the piston rings geometry aimed at optimising rings. It has sharp corners, a score line for optimised oil
their functionality in terms of friction reduction, seals, scraping, minimum surface contact with the cylinder
engine technology. Focus is on developing engines with a completely new
heat transfer and oil scraping. We have therefore built walls and thus creates less friction. The design was
level of performance and fuel efficiency. our own in-house expertise to manufacture the most created in collaboration with our customers and the
advanced drawing tools on the market, which can drawing dies were produced in our own toolshop.
One key to improve the efficiency of the engine is to This also sums up what Suzuki Garphyttan can offer guarantee an exact reproduction of the required design. The result is that the tighter radii and corners are now
increase the pressure in the engines cylinders while you as a manufacturer. With us as a partner, you can formed near net shape at the wire drawing stage, which
reducing the weight of the pistons and the friction against achieve a cost-effective production process. We can SMALLER TOLERANCES saves the customer time and effort.
the cylinder surface. supply the right material with the correct properties you Increased pressure in the cylinder requires smaller
need and deliver the products optimised and ready for tolerances of the finished product. With a tighter fit,
Piston rings today need to be thinner, stronger and more your production. energy efficiency is increased and fuel consumption
flexible. Its also necessary to have an optimised design lowered. The trend is also heading towards delivering a
with narrow tolerances and a material that is possible to product as close to its final form as possible to reduce
be applied with an advanced coating. the final treatment needed in the customers production.
Suzuki Garphyttans products are supplied with a dimen-
sion tolerance that at least meets the current require-
ments of designers and component manufacturers on
the market.

SMALLER DIMENSIONS
The weight of each ring is very important since it Our materials have properties that make them suitable for
affects the friction, total piston weight and ultimately applications involving the most advanced coatings used in
manufacturing of engine products.
fuel consumption. Material development has therefore
focused on producing harder material with higher
strength. This means that the ring dimensions and
total mass can be smaller, while maintaining the same
or greater durability than before.

ADVANCED COATINGS
The development of surface coating technology has
always aimed at reducing friction and increasing hard-
ness, which in turn increases resistance to wear and
service life. Our materials are designed for nitriding,
chrome plating or PVD coatings. The coatings enable
the rings to close very tightly against the cylinder walls.
The operating pressure can then increase, thus increasing
the efficiency of the engine.

The wires transformation from a round shape to a profile.

40 THE STRONGER. THE BETTER. THE STRONGER. THE BETTER. 41

PRODUCT INFORMATION

GARBAFLEX 75

Piston Rings GARBAFLEX CrSi91

GARBAFLEX CrSi70
GARBAFLEX 174Mn
GARBAFLEX 188L

CHEMICAL COMPOSITION, APPROXIMATE VALUES IN %

Alloying element % C Si Mn P max. S max. Cr V Ni Mo

PISTON RINGS > IN FOCUS GARBAFLEX 75 0,70 0,20 0,70 0,030 0.025 - - - -
GARBAFLEX CrSi91 0,60 2.00 0.45 0,020 0.020 0,90 0,10 - 0.10

Near net shape concept GARBAFLEX CrSi70

GARBAFLEX 174Mn
0,53
0,07
1,47
0,50
0,70
5,90
0,025
0,045
0.020
0.020
0,67
17,00
-
-
-
5,00
-
-
GARBAFLEX 188L 0,04 0,40 1,50 0,045 0.015 18,50 - 8,25 -
One of the biggest engineering trends in the manufacture of parts for the car industry
involves increasing the degree of refinement of the material purchased from subcon- NEAREST EQUIVALENT STANDARDS
tractors. In our area it is the shape of the final product, the piston ring, that primarily
dictates the shape of the wire bought. Ideally, all parties want the wires dimensions Alloying element % SIS AISI/SAE AFNOR DIN ASTM AMS BS JIS

and geometry on delivery to be extremely close to the piston rings final shape. GARBAFLEX 75 1070 1070 - 1.1231, CK67 - - - G3502SWRS72B
GARBAFLEX CrSi91 2090 9254 - 67SiCr5 - - -
GARBAFLEX CrSi70 2090 9254 - 67SiCr5 - - - G4801 SUP12
After delivery most piston rings have to be ground into CUSTOMISED MEASURING SYSTEMS
GARBAFLEX 174Mn - 201 - 1.4371 - - - G4308 SUS 201
their final shape, a process that requires high preci- Our measuring systems are the most advanced on the
sion and professional skill. Purchasing near net shape market. A further advantage is that the systems and GARBAFLEX 188L - 304 - 1.4301 - - - G4308 SUS 304
wire significantly optimises the cost of final treatment measuring methods are produced in collaboration with
for our customers. Examples of designs that are near our customers and are consistent with the measuring
Visit www.suzuki-garphyttan.com for complete product information
net shape today are different types of keystones, barrel technology they use in their own production. It is there-
shapes and Napier profiles. fore easy to verify specifications all the way back to the
designers plans.
FINELY CALIBRATED GEOMETRIES
Productivity increase
Whatever the shape, tolerance requirements are very grinding operation
strict and geometries are becoming ever more advanced, 600 %
as designers finely calibrate the rings functions on the
450 %
cylinder in their quest for less weight, higher compression
and more efficient combustion. Manufacturing drawn 300 %
profiled wire with extremely high tolerance requirements
is one of Suzuki Garphyttans areas of special expertise. 150 %

We have our own tool production facility for profile draw-

0%
ing where the same competent workforce who manu- 80 % 85 % 90 % 95 %
facture the tools are also responsible for measuring, Net vs. Gross Shape ratio

verifying and certifying the wire shapes. Productivity increase in grinding operations due to near net
shape products.

EVERY 0.001 MM COUNTS

We work with tolerances and measurements in single micrometres on critical surfaces and
meet the industrys most stringent requirements for radius measurements. Many measure-
ments are defined by our customers as critical and must therefore be handled according to
the requirements for special properties set out in ISO/TS 16949.
42 NOTES NOTES 43

Notes
44 NOTES NOTES 45
 SUZUKI GARPHYTTAN GROUP
The Suzuki Garphyttan Group is a world-leading supplier of
advanced spring wire products and is part of the Nippon Steel &
Sumkin SG Wire Co., Ltd. (NSSG)

Our vision is to strengthen our unique world-leading position as

suppliers of oil tempered valve and transmission spring wire as
well as other high-quality wire products and to
attain the position as the customers preferred choice
and long-term partner.

www.suzuki-garphyttan.com