Research on the Mechanism of Oxygen-Induced Embrittlement Fracturing in Industrial Electrolytic Nickel.

In this study, severe cracking occurred during an investigation of the direct hot rolling of industrial electrolytic nickel plates. To determine the cause of hot-rolling cracking, the microstructure phase composition was analyzed through the utilization of various techniques, including optical microscopy, scanning electron microscopy, electron backscattering diffraction, transmission electron microscopy (TEM), energy-dispersive X-ray spectroscopy (EDS) and electron probe micro-analysis. The comparative microstructural analysis took place between specimens heat treated in atmospheric and vacuum environments. The characterization and analysis of the hot-rolled plates considered the crack microstructure and fracture morphology. It was shown that holes appeared along the large angular grain boundaries after annealing at 1100 °C for 8 h. Possible reason: In a high-temperature environment, the decomposition of residual additives in the electrolytic nickel releases oxidizing gases, which oxidizes the grain boundaries. The reaction with carbon diffused into the grain boundaries and produced carbon monoxide gas, which induced holes and severely reduced the grain boundary plasticity. The heat treatment time did not need to be very long for severe grain boundary degradation to occur. After severe cavitation, the electrolytic nickel was severely cracked at grain boundaries cracks due to a shear force, and brittle fractures occurred along grains with very low plasticity.

Experimental selection of rolling contact length to the average thickness (L\have) ratio for producing fine-grain Incoloy 907 superalloy sheet by hot-rolling.

The current study investigates the effects of L\have values on the microstructure and tensile properties of the superalloy Incoloy 907. These effects are studied using hot-rolling at 84 % and 96 % thickness reductions. Microstructural examination of the received sample revealed a non-uniform coarse grain structure with precipitates of oxide phases rich in niobium and Laves. These precipitates are shredded and randomly distributed in the microstructure with elongated grains after hot-rolling under 84 % reduction. Following the solution-treatment, this sample's simultaneous static recrystallization and precipitation of secondary-phase particles has formed a banded structure of grain-size and secondary-phase particle bands. The particles of the secondary-phases are locally accumulated on the material's surface in the 96 % hot-rolled sample, creating a duplex grain and non-random microstructures with different cross-sectional conditions. The secondary-phase particle bands caused by the previous solution-treatment are retained in the pre-hot-rolled sample under 84 % reduction after aging. Furthermore, XRD analysis results show that the precipitation peak of γ'/γ phase was more visible and intense in this sample. Tensile tests conducted at room temperature and 649 °C indicate that the pre-hot-rolled sample with an 84 % reduction exhibited a 1 % improvement in cold ductility and an 8 % enhancement in hot ductility compared to the sample with a 96 % reduction.

Research on Microstructure, Mechanical Properties, and High-Temperature Stability of Hot-Rolled Tungsten Hafnium Alloy.

W-(0, 0.1, 0.3, 0.5) wt.% Hf (mass fraction, wt.%) materials were fabricated by the powder metallurgy method and hot rolling. The microstructure, mechanical properties, and high-temperature stability of alloys with varying compositions were systematically studied. The active element Hf can react with the impurity O segregated at the grain boundary to form fine dispersed HfO2 particles, refining the grains and purifies and strengthening the grain boundary. The average size of the sub-grains in the W-0.3 wt.% Hf alloy is 4.32 µm, and the number density of the in situ-formed second phase is 6.4 × 1017 m-3. The W-0.3 wt.% Hf alloy has excellent mechanical properties in all compositions of alloys. The ultimate tensile strength (UTS) is 1048 ± 17.02 MPa at 100 °C, the ductile fracture occurs at 150 °C, and the total elongation (TE) is 5.91 ± 0.41%. The UTS of the tensile test at 500 °C is 614 ± 7.55 MPa, and the elongation is as high as 43.77 ± 1.54%. However, more Hf addition will increase the size of the second-phase particles and reduce the number density of the second-phase particles, resulting in a decrease in the mechanical properties of the tungsten alloy. The isochronal annealing test shows that the recrystallization temperature of W-Hf alloy is 1400 °C, which is 200 °C higher than rolling pure tungsten.

Inline Hot Rolling of Al-5%Mg Strip Cast Using an Unequal Diameter Twin-Roll Caster.

One advantage of twin-roll casting for aluminum alloys is that hot rolling can be omitted, thus shortening the process. The effect of inline hot rolling on the anisotropy of the mechanical properties, especially the elongation, of the roll-cast strip has not been investigated. In a high-speed twin-roll caster, inline hot rolling forms the metal shape before the temperature of the cast strip decreases below the temperature needed for hot rolling. In this study, inline hot rolling of Al-5%Mg strips cast using an unequal diameter twin-roll caster was performed to validate the technique and evaluate its ability to reduce surface cracking and improve the elongation anisotropy. A rolling speed of 30 m/min was used, and the effects of temperature and thickness reduction during inline hot rolling on the surface and mechanical properties were investigated. Inline hot rolling was found to effectively reduce the formation of surface cracks and the anisotropy of the mechanical properties.

Overview of Multi-Scale Simulation Techniques for Three Typical Steel Manufacturing Processes.

Steel products typically undergo intricate manufacturing processes, commencing from the liquid phase, with casting, hot rolling, and laminar cooling being among the most crucial processes. In the background of carbon neutrality, thin-slab casting and direct rolling (TSCR) technology has attracted significant attention, which integrates the above three processes into a simpler and more energy-efficient sequence compared to conventional methods. Multi-scale computational modeling and simulation play a crucial role in steel design and optimization, enabling the prediction of properties and microstructure in final steel products. This approach significantly reduces the time and cost of production compared to traditional trial-and-error methodologies. This study provides a review of cross-scale simulations focusing on the casting, hot-rolling, and laminar cooling processes, aiming at presenting the key techniques for realizing cross-scale simulation of the TSCR process.

Enhancing the Tensile Properties and Ductile-Brittle Transition Behavior of the EN S355 Grade Rolled Steel via Cost-Saving Processing Routes.

Structural rolled steels are the primary products of modern ferrous metallurgy. Consequently, enhancing the mechanical properties of rolled steel using energy-saving processing routes without furnace heating for additional heat treatment is advisable. This study compared the effect on the mechanical properties of structural steel for different processing routes, like conventional hot rolling, normalizing rolling, thermo-mechanically controlled processing (TMCP), and TMCP with accelerating cooling (AC) to 550 °C or 460 °C. The material studied was a 20 mm-thick sheet of S355N grade (EN 10025) made of low-carbon (V+Nb+Al)-micro-alloyed steel. The research methodology included standard mechanical testing and microstructure characterization using optical microscopy, scanning and transmission electronic microscopies, energy dispersive X-ray spectrometry, and X-ray diffraction. It was found that using different processing routes could increase the mechanical properties of the steel sheets from S355N to S550QL1 grade without additional heat treatment costs. TMCP followed by AC to 550 °C ensured the best combination of strength and cold-temperature resistance due to formation of a quasi-polygonal/acicular ferrite structure with minor fractions of dispersed pearlite and martensite/austenite islands. The contribution of different structural factors to the yield tensile strength and ductile-brittle transition temperature of steel was analyzed using theoretical calculations. The calculated results complied well with the experimental data. The effectiveness of the cost-saving processing routes which may bring definite economic benefits is concluded.

Pore Structure and Deformation Correlation of an Aluminum Foam Sandwich Subject to Three-Point Bending.

An Al-Si matrix foam sandwich (AFS) with 6063 Al alloy cover sheets was fabricated by hot rolling combined with melt foaming. A foamable AlSiMg1/SiCp matrix precursor was prepared by the melting route. Hot rolling at 480 °C was carried out to obtain a mechanical bonding interface between the cover sheet and the foamable precursor. Meanwhile, the pore structure of the AFS was deeply affected by the foaming temperature and foaming time during the foaming process. Different pore growth mechanics of the crack-like pore disappearance mechanism (CDM) and pore active expansion mechanism (AEM) were concluded based on the pressure difference in pores inside and outside. Three bending tests were applied to three types of AFSs with different pore structures to evaluate the relation between pore structures and AFS mechanical properties. The bending property of the AFS with fewer layers of pores is like that of a dense material. The bending property of the AFS with a pore size in the range of 0~1 mm presents a typical sandwich shear failure mode. The AFS with a uniform pore structure, in which the shapes of the pores are predominately polygons and the pore diameter is concentrated in the range of 0.5~3 mm, processes a good energy absorption capacity, and the bending stress-strain curve fluctuates greatly after the first stress drop.

The Effect of Niobium Addition and Pre-Annealing on the Tensile Properties of 52CrMoV4 Spring Steel.

In this study, the effect of niobium addition and a specific preheating process on the microstructure and tensile properties of 52CrMoV4 steel used in leaf springs was investigated. Flat and leaf spring materials were used to accomplish this aim. The flat materials under investigation were kept in a furnace for 90 min at 900 °C. A homogeneous microstructure was aimed for with the use of this pre-annealing heat treatment in addition to the standard process before rolling used to create NbC. Leaf spring production was carried out with flat materials that possessed various Nb contents, with or without pre-heating. Grain size measurement and tensile tests were performed on the flat and leaf springs. Additionally, scanning electron microscopy images were captured from the fractured surfaces after the tensile tests were carried out. The current study highlights the importance of Nb addition as an alloying element and the effect of the selected pre-annealing process in optimizing the grain structure and enhancing the tensile properties of leaf springs. The leaf spring with a Nb ratio of 0.0376 that was pre-annealed exhibited a finer grain structure (G = 11.3), greater tensile properties (YS = 1550 N/mm2 and UTS = 1688.6 N/mm2), and deeper tear valleys and larger dimples, indicating higher energy consumption during fracturing, according to the SEM images produced, in contrast with the other materials studied.

The Performance of Niobium-Microalloying Ultra-High-Strength Bridge Cable Steel during Hot Rolling.

This study focuses on exploring the effects of niobium (Nb)-microalloying on the properties of steel for ultra-high-strength bridge cables during hot-rolling processes. We employed a combination of dual-pass compression tests, stress-strain curve analysis, and Electron Backscatter Diffraction (EBSD) techniques to investigate the influence of Nb-microalloying on the static recrystallization behavior and grain size of the steel. The key findings reveal that Nb-microalloying effectively inhibits static recrystallization, particularly at higher temperatures, significantly reducing the volume fraction of recrystallized grains, resulting in a finer grain size and enhanced deformation resistance. Secondly, at a deformation temperature of 975 °C, Nb-containing steel exhibited finer grain sizes compared to Nb-free steel when held for 10 to 50 s; however, the grain size growth accelerated when the hold time exceeded 50 s, likely linked to the increased deformation resistance induced by Nb. Lastly, this research proposes optimal hot-rolling process parameters for new bridge cable steel, recommending specific finishing rolling temperatures and inter-pass times for both Nb-containing and Nb-free steels during the roughing and finishing stages. This study suggests optimal hot-rolling parameters for both Nb-containing and Nb-free steels, providing essential insights for improving hot-rolling and microalloying processes in high-carbon steels for bridge cables.

Microstructure Evolution of the Near-Surface Deformed Layer and Corrosion Behavior of Hot Rolled AA7050 Aluminum Alloy.

The current study investigates the influence of hot rolling on the microstructure evolution of the near-surface region on AA7050 aluminum alloy and the corrosion performance of the alloy. It is revealed that hot rolling resulted in grain refinement in the near-surface region, caused by dynamic recrystallization, and equiaxed grains less than 500 nm can be clearly observed. Fibrous grains were evident in the hot rolled AA7050 aluminum alloy with relatively lower rolling temperature or larger rolling reduction, caused by the more severe elemental segregation at grain boundaries, which inhibited the progression of dynamic recrystallization. The density of the precipitates in the fibrous grain layer was higher, compared with those in the equiaxed grain layer, due to the increased dislocation density, combined with more severe elemental segregation, which significantly promoted the nucleation of precipitates. With the co-influence exerted by low density of precipitates and dislocations on the improvement of the corrosion performance of the alloy, the rolled AA7050 alloy with decreased density of precipitates and dislocations exhibited better corrosion resistance.

The Effect of Ti Particles Addition on the Microstructure and Mechanical Behavior of Mg AZ31/Al 6082 Composite Sheets.

In this study, Ti particles reinforced Mg AZ31/Al 6082 composite sheets were successfully prepared by hot rolling, with the aim of revealing the effect of Ti particles addition on the mechanical behavior and microstructure of Mg AZ31/Al 6082 composite sheets. The results showed that Ti particles were uniformly distributed at the interface of the Mg/Al-Ti composite sheets, which could greatly reduce the amount of Mg-Al intermetallic compounds during annealing treatment. Compared to the Mg/Al sheet, the tensile strength and elongation of the Mg/Al-Ti sheet could be improved simultaneously after the annealing treatment. Ti particles addition hardly affected the grain size, texture type, and tensile fracture morphology of the Mg layer and Al layer in the composite sheets before and after annealing. This present study provides a new perspective on the mechanical behavior and microstructure of Mg/Al composites through the addition of metal particles.

Effect of Recrystallization Behavior of AZ31 Magnesium Alloy on Damping Capacity.

For a wide industrial application of magnesium alloys, a method for imparting high damping properties while maintaining mechanical properties is required. Controlling the crystallographic texture seems to be useful, because dislocations are known to have a significant influence on the damping characteristics of magnesium alloys. In addition, textures are affected by the microstructure and texture variation when the deformation or annealing is applied. However, there were less reports about their effect on damping capacity. Therefore, the effect of twinning and annealing, which can affect the recrystallization, were investigated in this study. An AZ31 alloy was hot rolled at 673 K with a reduction ratio of 10% and 50%, and then annealed at 673 K and 723 K for 0.5, 1, 2, and 3 h, respectively. SEM-EBSD was used to examine the microstructure and texture. In addition, each specimen's hardness and internal friction were contemporarily measured. As a result, hot rolling produced tensile twins and their fraction increased with internal friction when the reduction ratio increased. Due to annealing, a discontinuous type of static recrystallization occurred within the twinning grains, and was highly activated along with the increasing annealing temperature and the fraction of twinning. In the samples annealed at 723 K, the internal friction continuously increased over the annealing time, whereas in the samples annealed at 673 K, the decrease in dislocation density was delayed while the internal friction showed a relatively low value.

Static Globularization Behavior and Artificial Neural Network Modeling during Post-Annealing of Wedge-Shaped Hot-Rolled Ti-55511 Alloy.

The globularization of the lamellar α phase by thermomechanical processing and subsequent annealing contributes to achieving the well-balanced strength and plasticity of titanium alloys. A high-throughput experimental method, wedge-shaped hot-rolling, was designed to obtain samples with gradient true strain distribution of 0~1.10. The samples with gradient strain distribution were annealed to obtain the gradient distribution of globularized α phase, which could rapidly assess the globularization fraction of α phase under different conditions. The static globularization behavior under various parameters was systematically studied. The applied prestrain provided the necessary driving force for static globularization during annealing. The substructure evolution and the boundary splitting occurred mainly at the early stage of annealing. The termination migration and the Ostwald ripening were dominant in the prolonged annealing. A backpropagation artificial neural network (BP-ANN) model for static globularization was developed, which coupled the factors of prestrain, annealing temperature, and annealing time. The average absolute relative errors (AARE) for the training and validation set are 3.17% and 3.22%, respectively. Further sensitivity analysis of the factors shows that the order of relative importance for static globularization is annealing temperature, prestrain and annealing time. The developed BP-ANN can precisely predict the static globularization kinetic curves without overfitting.

Plastic Deformation Mechanism of High Strength and Toughness ZK61 Magnesium Alloy Plate by Multipass Horizontal Continuous Rolling.

ZK61 magnesium-alloy plate with high tensile strength and elongation is obtained by combined multipass symmetric hot rolling and asymmetric warm rolling. Deformation history considering varying strain rate obtained from the macro-finite element analysis of the selected passes are introduced into the viscoplastic self-consistent model (VPSC) as initial boundary conditions for macro- multiscale and micro-multiscale coupling analysis. VPSC simulation results show that in the initial stage of rolling deformation, the basal slip is the dominated deformation mode, supplemented by prismatic slip and pyramidal slip. With increased rolling strain, the pyramidal slip presents competitive relationship with basal slip, and the activation amount of {101-1} compression twins is limited. During asymmetric rolling, the basal slip is dominant, followed by the pyramidal slip. Experimental results show that the basal texture is gradually strengthened after symmetric rolling, and grain size is refined due to the activation and recrystallization of twins. Asymmetric rolling makes the basal texture deflect 10° to the rolling direction and further refine the grain size. With the ongoing of symmetric rolling, the mechanical anisotropy of the plate weakens, and the yield strength, tensile strength, and plasticity of the material improves. In particular, after asymmetric rolling, the tensile strength in the RD and TD directions of the plate reaches 391.2 MPa and 398.9 MPa, whereas the elongation reaches 19.8% and 25.5%.

Studies on Hot-Rolling Bonding of the Al-Cu Bimetallic Composite.

Through the approaches in this article, an attempt was made to analyze the bonding of Al-Cu bimetallic composite layers and the highlight of the diffusion at the boundary between the layers, by hot rolling. An aluminum alloy 6060 plate (EN-AW AlMgSi) and a Cu-ETP ½ hard (CW004A) plate were used. All of these layers of materials were TIG-welded, at both ends, into a heat-treated layered composite and subsequently subjected to the hot-rolling process. The Al-Cu composite material obtained was analyzed by scanning electronic microscopy (SEM) analysis, after being subjected to the tensile test, as well as energy-dispersive X-ray (EDX) analysis. The obtained results highlighted the diffusion at the boundary between the layers of the Al-Cu composite as well as its ductile breakage and the distribution of the amount of Al and Cu at the interface of the layers.

Hot Deformation Behavior and Simulation of Hot-Rolled Damage Process for Fine-Grained Pure Tungsten at Elevated Temperatures.

Fine-grained pure tungsten fabricated by a sol drying reduction low-temperature sintering method and hot isothermal compression tests were performed by using the Gleeble 3800 thermo mechanical simulator at deformation temperatures from 1273 K to 1473 K and strain rates from 0.001 s-1 to 1 s-1. In addition, the constitutive equation was established by least square method combined with the Zerilli-Armstrong model, and the hot deformation behavior was discussed. Moreover, based on constitutive equation, the influence of the rolling process and its parameters on temperature, strain, density and rolling force in the hot rolling process was investigated at elevated temperature by the finite element model (FEM). Furthermore, the form of rolling damage and its formation mechanism were analyzed. Results showed the grains of pure tungsten are dense, irregular polyhedral spherical and very fine, and the average grain size is about 5.22 µm. At a high strain rate, the flow stress increases rapidly with the increase in strain, while the stress-strain curve shows a flattening trend in the tested strain rate range with increasing temperature, and no flow stress peak exists, showing obvious dynamic recovery characteristics. Furthermore, the FEM simulation showed that compared with the rolling temperature, the reduction has a greater influence on the temperature, stress-strain field and its distribution. There are three kinds of damage in the hot rolling process: transverse cracks, longitudinal cracks and side cracks, which are attributed to the competition between additional stress caused by uneven deformation and material strength. Moreover, the control method of hot rolling defects had been preliminarily proposed. These results should be of relevance for the optimum design of the hot rolling process of pure tungsten.

Dynamic recrystallization and deformation constitutive analysis of Mg-Zn-Nd-Zr alloys during hot rolling.

Due to limited basal slips, the recrystallization of Mg-Zn-Nd-Zr alloys originated at grain boundaries with large orientation gradient based on strain-induced-boundary-migration nucleation mechanism. The primary driving force of the recrystallization was the distortion energy difference around grain boundaries. However, more non-basal slips occurred near the grain boundary at larger strain deformation, so that some dislocations of adjacent subgrain boundaries with less orientation difference transferred to other subgrain boundaries by means of dissociation and disassembly, which is called the subgrain boundary merging. Meanwhile, some ductile shear zones appeared surrounding the primary grain, which held multiple slip systems moving around the grain boundary, gave rise to larger orientation gradients and facilitated recrystallization grains growing.

Effect of Al Layer Thickness on the Bonding and Mechanical Behavior of a Mg-(Al-)Ti Laminated Sheet Prepared by Hot-Rolling after Differential Preheating Treatment.

Mg-(Al-)Ti laminated sheets with large bonding interfaces were prepared by a differential temperature hot-rolling process, in which the preheating treatment of Ti was 25-100 °C higher than that of Mg. The rolled sheets contained different Al layer thicknesses (≤0.05 mm), and the thickness of the diffused region at the interface of 3-7 µm was formed by rolling at 175 °C. The interfaces were the solid-solution regions of Mg(Al) and Ti(Al), and no intermetallic compounds were generated during both the rolling process and annealing treatment. The hardness of the interfaces was 16-30% greater than that of the Mg matrix and Ti matrix. The results of mechanical tests displayed that the Mg-(Al-)Ti sheets exhibited higher strength and elastic modulus compared to those of the rolled AZ31B sheet. Their UTS and YTS were about 223-460 MPa and 303-442 MPa, respectively, with an elongation of 0.04-0.17 and high elastic modulus of 52-68 GPa. The Mg-Ti (containing about 62 at.% Mg) rolled sheet exhibited the most excellent strength. The UTS and YTS were about 460 MPa and 442 MPa, with an elongation of 0.04 and elastic modulus of 61.5 GPa. Additionally, Mg-Ti sheets with thin Ti thickness possessed a higher work-hardening rate (n), as well as hardening rate, than the rolled Mg-Al-Ti sheets. This is because fractured Ti pieces around the interfaces have a significant strengthening effect. This study provides a simple method for fabricating Mg-(Al-)Ti sheets with high elastic modulus.

Assessment of the Impact of Wear of the Working Surface of Rolls on the Reduction of Energy and Environmental Demand for the Production of Flat Products: Methodological Approach.

An important element in the correct operation of the rolling mill is appropriate planning of the condition of the rolls because this factor constitutes a limiting element in the production process. In this work, with the aim of indicating the method of proper use of production tools-metallurgical rollers during their operation in a Polish rolling mill, the wear and tear of particular kinds of rollers built in the whole rolling set was determined. For this purpose, data were collected at the strip mill from grinding processes, production reports and roll files, while our statistical analysis, laboratory calculations and measurements were used. These data were used to perform computer calculations on the service life of metallurgical rollers installed in the rolling line. Wear mechanisms were identified in industrial practice. The characteristic features of roller wear were investigated using non-destructive tests, including eddy currents. The laboratory tests reproduced the wear mechanisms in very hot rolling rolls. The statistical method for determining the service life of working rolls indicated that their reconstruction is determined both by natural physical phenomena and inappropriate use in about 30% of cases, mainly in the F5 and F6 cages of the finishing unit. Calculations indicated the possibility of replacing the working rolls made of high chromium cast iron Hi-Cr with those made of HSS in the F5 and F6 cages, which will contribute to an increase in the durability of the rolls, a reduction in production costs and a decrease in the number of roll rebuildings. The service life of HSS rolls is 14,000-20,000 Mg of rolled material per 1 mm of wear on its surface in the radial direction, compared to 2000 Mg for rolls made of high chromium cast iron Hi-Cr. The constructed model may be a source of information for further analyses and decision-making processes supporting the management of metallurgical enterprises. On the basis of the constructed model, it was shown that the analyzed projects, depending on their type and technical specification, will bring measurable economic benefits in the form of reduced annual energy consumption and environmental benefits in the form of reduced carbon dioxide emissions into the atmosphere. The constructed model of the roll consumption, verified in the real conditions of the rolling mills, will contribute to the fulfillment of energy and emission obligations with the EU.

Finite Element Modeling of Hot Rolling of 1075 Carbon Steel Process with Variable Cross Section.

Currently, it is common to use steel poles for applications in livestock and agriculture. In this work, finite element analysis of five hot rolling passes for the manufacture of farm poles using 1075 carbon steels from recycled railway material was developed. The steel industry in Mexico imports products from other countries or from companies specialized in metallurgy at an excessive cost. To be more competitive and save costs, companies seek the reutilization of existing resources such as the railway 1075 steel, which has good mechanical properties. SFTC DEFORM-3D software was used to model five hot rolling passes considering a variable cross section railway profile. The effect of rolling speed and temperature were considered to analyze flow behavior. Rolling loads were also determined.