Hot Rolling Conditions Research Articles

Role of scandium addition to microstructure, corrosion resistance, and mechanical properties of AA7085/ZrB2+Al2O3 composites

The effect of varying amounts of scandium (Sc) on the mechanical performance and corrosion resistance of aluminum alloy (AA7085) composites reinforced with Zirconium diboride (ZrB2) and Aluminum oxide (Al2O3) nanoparticles was investigated. The specimens were made using an in-situ process with varying amounts of Sc up to 0.5 wt%, and their microstructural behavior, corrosion, and mechanical properties were explored in detail. Phase structural analysis revealed the successful incorporation of ZrB2 and Al2O3 into the matrix through in-situ synthesis, ranging from 30 to 61.7 nm. In addition, HRTEM and XRD analysis displays the Al3Zr prominence observed with 0.1 wt% Sc content, transforming to Al3(Sc, Zr) in the 0.3 wt% Sc composite, and finally becoming Al3Sc with 0.5 wt% Sc. Corrosion analysis revealed that the 0.3 wt% Sc composite exhibited fine Al3(Sc, Zr) precipitate phases that enhanced corrosion properties. The Sc addition leads to a significant improvement in the mechanical properties of AA7085/ZrB2+Al2O3 composites. The ultimate tensile strength of 678 ± 5 MPa for 0.5 wt% Sc under the hot rolled and T6 aged condition was achieved. The optimum content of Sc in AA7085/ZrB2+Al2O3 composites has identified both corrosion and mechanical properties enhancement at 0.3 wt% and 0.5 wt%, respectively.

Development of a High Ductility DP Steel Using a Segregation Neutralization Approach: Benchmarked Against a Commercial Dual Phase Steel

Commercial dual-phase steels are typically synonymous with a banded distribution of martensite in their microstructures, which can degrade ductility and increase the anisotropy of mechanical properties. The concept of neutralizing the effect of Mn segregation is employed to change the distribution of martensite to a non-banded distribution. To this end, the ratio of austenite and ferrite stabilizer elements has been changed in the composition of dual-phase steel. Microstructural analysis has been carried out on both hot-rolled (ferrite + pearlite) and heat-treated (ferrite + martensite) microstructures by optical microscope and EBSD, respectively. The microstructural examinations have confirmed the non-banded distribution of second phase and more equiaxed ferrite grains in the segregated neutralized grade microstructures compared to a commercially benchmarked dual-phase steel. Tensile properties of two grades have also been assessed in hot-rolled and heat-treated conditions in RD, TD, and 45 deg tensile directions. In the case of heat-treated condition, total elongation in RD direction has been improved from 20.9 pct in benchmark dual-phase steel to 25.4 pct in segregated neutralized dual-phase steel. Tensile anisotropy results showed a significant difference in tensile strength by tensile direction in benchmark dual-phase steel in both hot-rolled (~ 85 MPa) and heat-treated conditions (~ 48 MPa), while the corresponding differences for the segregated neutralized grades were 14 and 15 MPa, respectively.

Influence of annealing temperature on the mechanical properties and corrosion behavior of Ti-5.5Al-2.0Zr-1.5Sn-0.5Mo-1.5Nb alloy

In this work, the effect of annealing temperature of Ti552 titanium alloy is systematically investigated based on mechanical property tests, electrochemical tests and static immersion tests. The results show that after the annealing treatment, the microstructure morphology of the α-phase transforms from striated to equiaxed, and the intergranular β-phase gradually increases. As the annealing temperature increases, the grain size gradually increases and the volume fraction of α-phase gradually decreases. The tensile strength and Vickers hardness are the maximum and the elongation is the minimum in the hot-rolled condition. With increasing annealing temperature, the strength and Vickers hardness of Ti552 alloy gradually decrease, while the elongation gradually increases. In 3.5 wt% NaCl solution, Ti552 alloy has similar corrosion behavior at different annealing temperatures, although its corrosion resistance varies. In potentiodynamic polarization and EIS testing, the annealed Ti552 alloy shows a low corrosion current density (10-6 A/cm2) and a high polarization impedance (106 Ω·cm2), indicating the formation of a dense and stable oxide film. Under annealing at 800 °C, the corrosion resistance is at its highest and the corrosion rate is the lowest, according to electrochemical and static immersion studies. The comprehensive analysis suggests that the corrosion behavior of Ti552 alloy in NaCl solution may be a result of the combined effect of the volume fraction of the β-phase and the grain size of the α-phase.

Synergistic effect of B2 phase and O phase in hot-rolled Ti2AlNb alloy and its influences on mechanical properties

The Ti2AlNb alloy, solution-treated at 1070 °C, underwent hot rolling at 960 °C with different thickness reductions to investigate the synergistic effects of the O phase and B2 phase and their impact on its properties. The results reveal that after solution treatment, the Ti2AlNb alloy consists of nearly spherical O, lath O, and B2 matrix at 30% and 50% thickness reductions during hot rolling. However, at a 70% thickness reduction, the alloy exhibits spherical O, worm-like O, and a continuously distributed B2 phase. The α2 phase formed during solution treatment decomposes during hot rolling. As the thickness reduction increases from 30% to 70%, the O phase content initially rises and then declines, accompanied by an increase in the average dimension of the O phase from 0.25 ± 0.16 μm to 0.36 ± 0.18 μm. Additionally, the B2 phase in the alloy undergoes dynamic recrystallization (DRX) during hot rolling, coinciding with the growth and spheroidization of the O phase. With an increase in the thickness reduction during hot rolling, the elongation of the alloy increases from 5.9% at 30% reduction to 12.47% at 70% reduction. Meanwhile, the ultimate tensile strength reaches its peak value of 1092.2 MPa at 30% reduction, decreases to 936 MPa at 50%, and then increases to 970 MPa at 70%. The tensile strength of the alloy improves due to the interaction and accumulation of dislocations at the phase interface. The continuous distribution of the B2 matrix, dislocation movement, rotation of the O phase, DRX of the B2 phase, and interface slip all contribute to enhanced ductility. Furthermore, the fracture behavior of the Ti2AlNb alloys under various hot rolling conditions was elucidated.

Optimization of Water Based Drilling Fluid Properties with the SiO2/g-C3N4 Hybrid.

Drilling fluids are an essential component of drilling operations in the oil and gas industry. Nanotechnology is being used to develop advanced drilling fluid additives. This study looked at the viability of synthesizing SiO2/g-C3N4 hybrid extending the Stober process followed by its addition in different concentrations to water-based drilling fluids and studying impact on the rheological and fluid loss properties of the fluids. The synthesized hybrid was analyzed using XRD, SEM, TGA, and FTIR. Subsequently, it was used to develop the water-based drilling mud formulations and subjected to measurements in accordance with API standard practices. The studies were carried out at various SiO2/g-C3N4 nanoparticle concentrations under before hot rolling (BHR) and after hot rolling (AHR) conditions. The outcomes demonstrated that the rheological and fluid loss properties were enhanced by the addition of SiO2/g-C3N4 nanoparticles, as it worked in synergy with other additives. Additionally, it was discovered that the nanoparticles improved the drilling fluid thermal stability. The experimental findings indicate a significant influence of SiO2/g-C3N4 nanoparticles on base fluid properties including rheology and fluid loss as the most remarkable, especially at higher temperatures. The significant improvements in yield point and 10 s gel strength were 55 and 42.8% under BHR and 216 and 140% under AHR conditions, respectively. Permeability plugging test (PPT) fluid loss was reduced by 69.6 and 87.2% under BHR and AHR conditions, respectively, when 0.5 lb/bbl nanoparticles were used in formulations. As a result, SiO2/g-C3N4 nanomaterial has the potential to be used as drilling fluid additive in water-based drilling fluids.

Design and Properties of Hot Rolled Tough Carbide Free Bainitic Steels

Carbide free bainitic microstructures of steels in hot rolled condition have high potential for automotive and structural applications, where both high elongation and toughness at a high strength level are needed. However, achieving a combination of these properties remains a challenge due to difficulties in ensuring a high stability of retained austenite while maintaining industrial processability. Therefore, an attempt has been made in this work to achieve combined high toughness and high elongation in hot rolled carbide free bainitic steels.

Corrosion characteristics of AA 7075 and AA 7075/SiC/Gr hybrid composite processed through multistep hot cross rolling

The present work focuses on the study of corrosion characteristics of AA 7075 and AA 7075 based hybrid composite fabricated through the stir casting and hot rolling routes. The AA 7075 based hybrid composite has been prepared with 2 wt% of Silicon carbide (SiC) and 0.5 wt % of graphite (Gr) as the reinforcements. Corrosion characteristics have been studied through static immersion, potentiodynamic polarization (PDP) and electrochemical impendence spectroscopy (EIS) carried out in 3.5 wt % NaCl. Results of PDP showed that the composite as well as the base metal, cross rolled at 450 °C, possesses better corrosion resistance among all the samples (3040 Ω cm2 and 2340 Ω cm2, respectively). The compressive residual stresses on the outer surface of the samples after hot cross rolling at 450 °C led to the increased corrosion resistance. The corrosion resistance of hybrid composite is always greater than the base metal for all the processing conditions, as the addition of a small amount of graphite along with SiC improves the bonding between the matrix and the reinforcements. Further, hot cross rolling of the hybrid composite enhances this bonding. This along with the possibilities of dispersion of reinforcements, after hot cross rolling, favours the formation of a strong passivation oxide layer and increased charge transfer resistance, thereby improving corrosion resistance (from 2129 Ω in as-cast condition to 7200 Ω in hot cross rolled condition at 450 °C). The results of EIS analysis confirm the formation of a double-layer that has a compact inner layer and a porous outer layer. The field emission scanning electron microscope (FESEM) images of the corroded surfaces indicated the occurrence of pitting corrosion.

Metallographic, structural and mechanical characterization of a low-density austenitic Fe–Mn–Al–C steel microalloyed with Nb in hot-rolling condition

Metallographic, structural and mechanical characterization of a low-density austenitic Fe–Mn–Al–C steel microalloyed with Nb in hot-rolling condition

Grain Size Distribution of DP 600 Steel Using Single-Pass Asymmetrical Wedge Test

Grain size distribution after the completion of a phase transformation was studied through the laboratory-controlled hot-plastic deformation of dual phase 600 (DP 600) steel using a specially prepared asymmetric single-pass hot-rolling wedge test with a refined reheating grain size instead of the usual coarse-grained starting microstructure observed in practice. The experiment was performed to reduce generally needed experimental trials to observe the microstructure development at elevated temperatures, where stable and unstable conditions could be observed as in the industrial hot-rolling practice. For this purpose, experimental stress–strain curves and softening behaviors were used concerning FEM simulations to reproduce in situ hot-rolling conditions to interpret the grain size distribution. The presented study revealed that the usual approach found in the literature for microstructure investigation and evolution with a hot-rolling wedge test was deficient concerning the observed field of interest. The degree of potential error concerning the implemented deformation per notch position, as well as the stress–strain rate and related mean flow stresses, were highly related to the geometry of the specimen and the material behavior itself, which could be defined by the actual hardening and softening kinetics (recrystallization and grain growth at elevated temperatures and longer interpass times). The grain size distribution at 1100–1070 °C was observed up to a 3.45 s−1 strain rate and, based on its stable forming behavior according to the FEM simulations and the optimal refined grain size, the optimal deformation was positioned between e = 0.2 and e = 0.5.

Forging of PM Ti–6Al–4V alloy at the temperature above β-transus and high strain rate: modeling and trials in industrial conditions

The results of the forging process in open dies of the powder metallurgy (PM) Ti–6Al–4V alloy, carried out at the temperature above β-transus and at a high strain rate were presented. As an initial material for the research relatively cheap elemental powders were used. This approach gives a real chance for the implementation of the developed technologies. As the range of phase transition temperature in titanium alloys is influenced also by the technology of their production, the β-transus temperature was estimated for the PM Ti–6Al–4V alloy. Finite element method (FEM) numerical analysis of the forging process at the temperature of 1000 °C and high strain rate was performed. The results obtained by the FEM modeling were verified under industrial conditions. The forging trials were made at the temperature of 1000 °C on a screw press operating at a speed of 250 mm s−1. For comparison, the alloy was also studied in as-cast and hot-rolled conditions, which is widely used as a feedstock. The influence of the method of manufacturing feedstock on the microstructure and selected properties of the forgings was determined. This approach allowed for a qualitative assessment of the PM material. The forging process in open dies of two different feedstocks led to the production of forgings with a uniform and similar lamellar microstructure. Thus, it was shown that the heating conditions, the parameters of the forging process, and the method of cooling the product after forging have a decisive influence on the microstructure condition of the forgings shaped in the temperature range of the β phase.

Effects of rare earth elements addition on mechanical properties and corrosion behavior of GCr15 bearing steel under different heat treatment conditions

In this work, effects of rare earth addition on mechanical properties and corrosion behavior of GCr15 bearing steel under hot rolled, annealed, and quenched-tempered conditions were investigated via mechanical tests, electrochemical measurements, and immersion tests. Results show that rare earth elements can refine grains, improve hardness, tensile strength, and impact absorption energy of GCr15 bearing steel under different heat treatment conditions. Besides, it has been found that rare earth elements are beneficial to corrosion resistance of GCr15 bearing steel in 0.1 mol/L NaCl solution by electrochemical and immersion measurements.

Development of a Low-Density and High-Strength Titanium Alloy

Weight reduction is often considered the primary goal in the development of structure materials. A new Ti-8Al-1Cr-1V-0.5Fe-0.1Si (wt.%) alloy with a low-density and a high-strength was developed in this work. The microstructures and mechanical properties of the alloy were investigated in hot-rolled and solution-aging (STA) treatment conditions. The microstructures of the alloy in both states consist of the spherical αp phase, acicular αs phase, and a small amount of β phase. Attributed to such heterogeneous microstructures, the hot-rolled alloy exhibits an outstanding tensile strength of 1046.1 MPa, a total elongation of ~8.3%, and an impressive low density of 4.23 g/cm3. After heat treatment, the alloy also exhibits a similar strength and ductility. A detailed analysis of the deformation modes shows that the numerous dislocations slippages and deformation twinning in the αp phase are the main reasons for the high ductility, and the acicular αs phase provides the alloy with high strength after heat treatment. This newly developed alloy is a potential material for various structural applications.

Revealing Precipitate Development During Hot Rolling and Cooling of a Ti–Nb Micro‐Alloyed High Strength Low‐Alloy Steel through X‐Ray Scattering

High‐energy synchrotron X‐ray small‐angle scattering (SAXS) is used to study the precipitate development during hot rolling and cooling of a commercial Ti–Nb micro‐alloyed, high‐strength, low‐alloy (HSLA) steel. To study precipitation during hot rolling conditions, Gleeble and dilatometer trials are made. Samples are then studied at room temperature using SAXS in conjunction with transmission electron microscopy (TEM). TEM is used to determine the morphology and composition of the precipitates, whilst both TEM and SAXS are used to study the particle sizes. One major advantage with high‐energy SAXS is the ability to make measurements after a minimum of sample preparation and in transmission geometry, as opposed to just at prepared surfaces, plus the possibility to determine volume fractions of the precipitates. The measurements show that after deformation at high temperature, particle coarsening occurs and the volume fraction of precipitates increases after holding for 20 s at 900 °C which confirms strain‐induced precipitation at finishing rolling conditions. The measurements show that holding at 600 or 650 °C for one hour gives a larger volume fraction of nanosized particles. Coiling simulations with slow cooling from 600 to 470 °C show coarsening of particles and an increase in the volume fraction of the smaller particles compared to holding at a constant temperature.

Determination of the deformation parameters of the steel reinforcing phase inside the aluminum matrix during hot rolling

Purpose. Comparison of deformation parameters during rolling of reinforced composites based on aluminum alloy using braided and expanded steel meshes as a reinforcing phase. Methodology. An experimental study on the effect of pressure on the deformation of the reinforcing phase during rolling of aluminum composites is carried out. A wire mesh and expanded mesh made of stainless steel was used as a reinforcing phase. The effect of deformation on the change in the lattice angle of the reinforcing phase is investigated. Findings. In this work, experimental data on the parameters of deformation of the wire mesh and expanded mesh are obtained. A comparison is made of the shape change in such grids under hot rolling conditions between two aluminum plates, which play the role of a matrix. It is found that the elongation coefficients of the lattice for the experiment with a wire mesh c is equal to 1.682.3, which is greater than the coefficient of elongation of the lattice in the expanded mesh of 1.552.2. Therefore, expanded sheets make the best reinforcing layer for aluminum-based composites produced by the roll-bonding process. Expanded mesh also reduces the risk of rupture at the intersection of wires. Originality. In the work, for the first time, a comparison of the deformation parameters during roll bonding of composites based on an aluminum alloy, reinforced with a braided and expanded steel mesh, has been given. Obtaining composite materials by means of hot roll bonding requires an understanding of the flow of composite components during deformation and their influence on each other. These peculiarities have not been studied sufficiently. Currently, there is no reliable method for predicting the behavior of the material of a solid reinforcing phase of various shapes inside a composite. Practical value. Advantages of using an expanded steel mesh for reinforcing aluminum-based composites have been confirmed. Scientific results can be used to refine calculating methods for metal flow at high hydrostatic pressure with variable components of the stress tensor and the major stresses.

Evaluation of elastic-plastic deformation in HSS work roll under coupling of residual stress thermal stress and contact stress during hot rolling

Fatigue damage such as crack and spalling on the work roll surface in hot rolling is caused by comprehensive action of residual stress, thermal stress and contact stress. In this work, a HSS work roll was studied based on the actual hot rolling condition, and high temperature performances of the work roll materials are considered. Finite element method was used to obtain the residual stress distribution of the work roll after quenching and tempering. Then, the coupling mechanism of residual stress, thermal stress and contact stress of the work roll in the bite region are analyzed by a transient thermomechanical model. The results showed that, the maximum equivalent strain and equivalent plastic strain appear at the exit of the bite region. And residual stress and thermal stress account for about 90% of the coupling stress. The accumulation of plastic deformation only occurs in the initial rolling, and the initial temperature influences the plastic deformation accumulation. Furthermore, abnormal rolling often leads to large plastic deformation on the roll surface.

Micro-mechanisms of failure in nano-structured maraging steels characterised through in situ mechanical tests

High-pressure-torsion (HPT) processing introduces a large density of dislocations that form sub-grain boundaries within the refined nano-scale structure, leading to changes in precipitate morphology compared to hot-rolled maraging steels. The impact of such nanostructuring on the deformation and fracture micro-mechanisms is being reported for the first time using in situ characterization techniques along with transmission electron microscopy and atom probe tomography analysis, in this study. Digital image correlation has been used to quantify the full field strain maps in regions of severe strain localization as well as to determine the fracture toughness through critical crack tip opening displacements. It is seen that the phenomenon of planar slip leads to strain softening under uniaxial deformation and to crack branching under a triaxial stress state in hot rolled maraging steels. On the other hand, nano-structuring after HPT processing creates a large number of high angle grain boundaries as dislocation barriers, leading to strain hardening under uniaxial tension and nearly straight crack path with catastrophic fracture under triaxial stress state. Upon overaging, the hot-rolled sample shows signature of transformation induced plasticity under uniaxial tension, which is absent in the HPT processed overaged samples, owing to the finer reverted austenite grains containing higher Ni concentration in the latter. In the overaged fracture test samples of both the hot-rolled and HPT conditions, crack tips show a signature of strain induced transformation of the reverted austenite to martensite, due to the accompanying severe strain gradients. This leads to a higher fracture toughness even while achieving high strengths in the overaged conditions of the nanocrystalline HPT overaged samples. The results presented here will aid in design of suitable heat treatment or microstructure engineering of interface dominated nano-scale maraging steels with improved damage tolerance.

Early Spalling Analysis of Large Particles in High-Cr Steel during Thermal Fatigue: Relevant Mechanisms.

The aim of this study was to investigate the surface deterioration of high-Cr roll steel caused by the spalling of larger particles during thermal fatigue. The mechanisms of surface deterioration due to spalling of larger particles are discussed. Using a laboratory thermal fatigue test that replicates hot rolling conditions, samples were tested cyclically (up to 4500 times) at maximum cycle temperatures of 500, 600 and 700 °C, followed by water cooling. Specimens with surface deterioration were selected for analysis, revealing important influencing parameters, i.e., the combination of test temperatures, chemical composition, thermal stress and microstructural properties, leading to oxidation-assisted crack growth in different directions and consequent surface deterioration due to early spalling of larger particles. Here, we describe the mechanisms of crack propagation, especially in the lateral direction, and their relation to the subsequent spalling of larger particles, which depend on the influence of the local chemical composition on the microstructural constituents, as well as their distribution and properties. The results obtained in this study can be used in the development of roll steel microstructures with improved resistance to the identified mechanisms of surface degradation.

Effect of hot rolling process parameters on the microstructure and mechanical properties of continuously cooled low-carbon high-strength low-alloy (HSLA) steel

Abstract In this work, high-strength low-alloy (HSLA) steel with 0.22 wt% carbon was produced in laboratory scale and hot rolled with a total deformation of 42% via 4, 5, or 6 passes. After multipass hot rolling process, samples were examined either in as-rolled (AR) or as-rolled and heat-treated (ARH) conditions. The results indicated that microstructural and mechanical properties of HSLA steels are influenced by hot rolling conditions for both cases. It was observed that strength values in AR samples have a tendency to increase with increment in rolling pass number. In contrast to AR samples, it was seen that the mechanical properties were slightly decreased in ARH samples that were austenitized at 1150 °C for 45 min and then cooled in still air. Microstructural investigations showed that finer precipitates in AR samples are obviously more than that of ARH samples, as an evidence for higher strength results by precipitation hardening. In addition to precipitation strengthening, refinement of lath bainite and amount of blocky martensite/austenite in AR samples favor the increase in strength.

Optimization of Process Conditions for Ultralightweight Steel with More Than 13 wt% of Al and 5 wt% of Cr

An ultralightweight Fe–30Mn–13.2Al–1.6C–5Cr steel, which contains more than 13 wt% of Al and thereby reduces the density by 20%, is developed. The ultralightweight steel, which is very brittle due to high Al content, is fabricated by optimizing hot rolling and heat treatment conditions. Hot rolling is conducted after soaking at the temperature range of 1100–1200 °C for 2 h. The ultralightweight steel is hot‐rolled successfully after soaking at 1100 °C, whereas specimens soaked at 1150 and 1200 °C are intergranularly cracked after hot rolling, resulting from coarse grain and a large fraction and size of ferrite, which is transformed to ordered DO3 phase during cooling, at the grain boundaries. In homogenization heat treatment, water quenching and air cooling are performed, respectively, after holding at 1050 °C for 2 h. The air‐cooled steel has inferior tensile property due to the formation of brittle ordered DO3 phase at grain boundaries. Meanwhile, the water‐quenched steel shows an excellent tensile property, which is attributed to a uniform microstructure comprising austenite, fine κ‐carbide in austenite, and a very small fraction of the ordered DO3 phase.

Grain Structure Engineering of NiTi Shape Memory Alloys by Intensive Plastic Deformation.

To explore an effective route of customizing the superelasticity (SE) of NiTi shape memory alloys via modifying the grain structure, binary Ni55Ti45 (wt) alloys were fabricated in as-cast, hot swaged, and hot-rolled conditions, presenting contrasting grain sizes and grain boundary types. In situ synchrotron X-ray Laue microdiffraction and in situ synchrotron X-ray powder diffraction techniques were employed to unravel the underlying grain structure mechanisms that cause the diversity of SE performance among the three materials. The evolution of lattice rotation, strain field, and phase transformation has been revealed at the micro- and mesoscale, and the effect of grain structure on SE performance has been quantified. It was found that (i) the Ni4Ti3 and NiTi2 precipitates are similar among the three materials in terms of morphology, size, and orientation distribution; (ii) phase transformation happens preferentially near high-angle grain boundary (HAGB) yet randomly in low-angle grain boundary (LAGB) structures; (iii) the smaller the grain size, the higher the phase transformation nucleation kinetics, and the lower the propagation kinetics; (iv) stress concentration happens near HAGBs, while no obvious stress concentration can be observed in the LAGB grain structure during loading; (v) the statistical distribution of strain in the three materials becomes asymmetric during loading; (vi) three grain lattice rotation modes are identified and termed for the first time, namely, multi-extension rotation, rigid rotation, and nondispersive rotation; and (vii) the texture evolution of B2 austenite and B19′ martensite is not strongly dependent on the grain structure.