Rolling Process Researcher

Context 

Isbergues Research Center is the laboratory dedicated to the study of stainless steels for the European manufacturing plants of the APERAM group. There are around eighty people whose activity consists of defining, developing and assisting the commercial development of new stainless steels. As such, it is the APERAM reference Research Center in terms of stainless steel metallurgy, their in-use properties and their manufacturing processes as flat products.

The Process R&D team is responsible for providing technical support to production plants in order to optimize process routes to meet productivity, quality, capability, energy and environmental needs. It also feeds the Innovation Process processus in order to offer disruptive solutions to prepare the manufacturing processes of tomorrow. As part of this activity, a regular presence on the production sites is to be ensured in order to collaborate with the local teams and to deepen the understanding of the manufacturing processes.

APERAM is highly committed to the transformation of stainless steel production in relation to environmental and economical / competition challenges. APERAM is the first stainless steel producer to obtain the Responsible Steel label. Very ambitious targets have been defined to reduce CO2 emissions, water consumption and waste landfilling in the coming years via, for a part, a strategic optimization of the industrial facilities. The proposed position will be part of the team dedicated to downstream process.This will go through the development of a very close network with industrial teams and CTO organization to develop key competencies in link with following thematics: Surface quality of cold rolled stainless steel, mechanics of cold rolling: flatness management, thickness capability and regulation, cold rolling strategy. Parallel thematics related to tribology / lubrication could also be included. 

Missions 

Within the Process team, you will be required to:

• Be regularly present in APERAM plants (located in Gueugnon, Isbergues, Genk and Châtelet)
  • Presence on site (estimated ~20%)
  • Development of network & strengthening of relationships with internal customers
  • Feedback of information and needs from the production site
• Develop and secure the “Cold Rolling” competency 
  • Building a technical community with APERAM specialists / experts in this domain
  • Development of a network of academic partners, participate to conferences, spread Aperam culture for R&D and technology
• Development of Isbergues Research Center experimental methods (such as tribological tests)
• Development of process modeling by in-house developed models and/or using classical tools for simulation (Abaqus)
• Active participation to the identification of strategic knowledge to be developed in HR & CR Process area 
• Manage and ensure the good progress of R&D projects in your perimeter
  • Definition of working programs & deliverables, coordination of internal / external studies with other researchers / partners
  • Regular reporting (hierarchy, program owners, internal customers)
  • Proposal for industrial trials / optimization and support for local teams
  • Capitalization, publication of technical reports and scientific writings. Publish papers and articles
• Propose disruptive ideas / solutions (Innovation)
  • Participation in scientific congresses / conferences
  • Technical watch, bibliographic reviews, ...
• Actively participate in the Safety pillar
  • Active participation in "lab life" and in the Safety action plan
  • Exemplarity and shared vigilance

The technical missions will include, among others, the study of:

• Flatness management of rolled stainless steel
  • Strip profile, flatness of Hot Rolled strip (influence of Roughing & Finishing Mill, cambering, …)
  • Strip profile, flatness of Cold Rolled strip - Fine identification of actuators, good practices in terms of rolling strategy, etc… to avoid flatness defect generation
  • Leveling Operations - How to correct flatness defect generated during Cold Rolling
  • Strip centering and scrolling on industrial annealing lines - Influence of strip profile given by Rolling operations
• Rolling Mill capabilities
  • Reduction of minimal thickness that can be achieved
  • Development of new models, improvement of existing ones
• Surface Quality - Hot & Cold rolling related defectology
  • Participation in the resolution of defects finding their origin in the hot and cold rolling process (identification of mechanism, proposition of improvements & industrial trials, …)
• Cold rolling strategy
  • How rolling strategies are defined (number of passes, reduction rate, roll change practices, speed, …)
  • Impact of rolling parameters on final products (surface quality, metallurgical state, flatness…)
  • Is there a way of progression ?
• APERAM Footprint - Optimisation of process route and existing tools
  • Support in the transfer of products from the industrialization of new process route
  • Support for new Cold Rolling process design 

Profile

BAC + 5 level with first experience or BAC + 8 (PhD), graduated from an Engineering school in Materials Science, Industrial Engineering or Mechanics, the candidate must have the following skills:

• Natural ease and taste for the presence on the shopfloor,
• Strong knowledge in Materials Science, Mechanics or Process Engineering,
• Knowledge and technical background in tribology is a plus,
• Ability in coding (Python or C, SQL); knowledge of commercial simulation tool as “abaqus” is a plus
• Good presentation & communication skills,
• English proficiency,
• Ability to write technical reports and minutes,
• Initiative and autonomy,
• Ability to work in a team and with a certain versatility
• Safety mindset
• Driving license mandatory

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