Hot Rolling Research Articles

Textural index for martensitic and bainitic steels to assess influence of hot rolling mode on parent austenite structure before quenching

To assess a state of parent austenite before the steel quenching, a scalar textural index for martensite and bainite is introduced in terms of EBSD orientation data. Deformed and recrystallized states of the parent phase are discriminated by the sign of this index, whereas its magnitude in each of the two reflects the texture sharpness depending on the hot rolling mode. Accordingly, in a virtual case of randomly distributed orientations the considered parameter vanishes. Performance of the proposed approach is demonstrated on medium carbon martensitic steel hot rolled at laboratory conditions and on industrial rolled plates of low carbon bainitic steel.

Effect of hot rolling process parameters on surface wear of descaling rolls

Purpose The purpose of this study is to explain the effect of slab and roll initial temperatures on the wear characteristics of the surface of hot roll descaling rolls. Design/methodology/approach The UMESHMOTION subroutine and the Arbitrary Lagrangian-Eulerian adaptive mesh technique are used to investigate the wear profile of the descale roll surface and to evaluate the effect of the slab and roll’s initial temperature on the wear depth. Findings Wear is more pronounced at the edges of the roll-slab contact area and less severe in the roll-body’s central region. A rise in the initial slab temperature from 1,337 K to 1,429 K results in a 67% rise in maximum wear depth and 52% in frictional stress. The peak wear region progressively shifted toward the center of the roll body. A rise in the initial roll temperature from 308.15 K to 673.15 K caused a 46% reduction in maximum wear depth and 73% in frictional stress. The location of the peak wear region remained primarily unchanged. Originality/value This study used the UMESHMOTIONI subroutine and the Arbitrary Lagrangian-Eulerian adaptive mesh technique in ABAQUS® to evaluate the quantitative correlation between the wear depth of the descaling roll surfaces and the initial temperatures of the slab and rolls. This study offers valuable insights into improving the wear of descaling roll surfaces. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0231/

Generalisation of the hydrodynamics model method for hot and cold strip rolling application

The present work constitutes a generalization of the hydrodynamic model used to predict the pressures and the rolling speeds during the hot rolling of aluminum and copper strips. The hydrodynamic model with a linear behavior (Newton viscous) of the materials shows good predictions in the literature but its applicability is questionable in non-linear cases, when the materials exhibit viscoplastic or plastic behavior. This work extends the model to accommodate non-linear cases commonly encountered in rolling models (viscoplastic and plastic behaviors). The obtained results are in good agreement with experimental data from the literature. The validated model can, therefore, be considered an enhanced hydrodynamic model for predicting pressures and velocities during both hot and cold rolling of thin strips.

Inverse flow stress characterization in hot rolling

Inverse flow stress characterization in hot rolling

Integrated AGC Approach for Balancing the Thickness Dynamic Response and Shape Condition of a Hot Strip Rolling Control System

Thickness and shape are two significant indices in the tandem hot strip rolling process. Excessive thickness correction can cause rolling force imbalance, leading to deteriorated shape conditions. Aiming at this problem, we propose a new monitor automatic gauge control (M-AGC) with consideration of the rolling force distribution to not only keep the shape condition but also improve the robustness of the rolling process. First, the M-AGC with the Smith predictor control structure was studied. Second, based on the rolling force and thickness correction redistribution algorithm, shape balance automatic gauge control (SB-AGC), the phenomenon of rolling force imbalance was improved. Third, the transient response was improved by adding a command prefilter to the upstream stands, which is asynchronous shape balance automatic gauge control (ASB-AGC). The proposed algorithms can be applied to all steel grades and are easy to implement. Finally, cross-validation was conducted through numerical simulations and application results, confirming the alignment between the theoretical derivation and practical implementation. The simulation results show improvements in both the rolling force balance and the thickness response. The practical application results also confirm that better flatness conditions and thickness response can be achieved, significantly reducing the amount of head-end cutoff losses.

Microstructural Formation Mechanism of α+β Dual Phase Ti-Fe Sintered Alloys via Hot Rolling Process

Microstructural Formation Mechanism of α+β Dual Phase Ti-Fe Sintered Alloys via Hot Rolling Process

Microstructures Formation and Strengthening Mechanism of Ultra-Rapidly Solidified Powder Metallurgy Ti-Si Alloys via Hot Rolling Process

Microstructures Formation and Strengthening Mechanism of Ultra-Rapidly Solidified Powder Metallurgy Ti-Si Alloys via Hot Rolling Process

Application of digital twin for industrial process control: A case study of gauge-looper-tension optimized control in strip hot rolling

Background During the hot rolling process, the performance of most control systems gradually degrades due to equipment aging and changing process conditions. However, existing gauge-looper-tension control method remain restricted by a lack of intelligent parameter maintenance strategies. Methods To address this challenge and enhance the smart manufacturing capabilities of strip hot rolling, based on the digital twin method, this paper proposes a data-driven optimized control method for the gauge-looper-tension system of strip hot rolling. First, a hot rolling process model is constructed based on a digital twin method to serve as an evaluation and optimization platform. Subsequently, relevant data are collected to calculate the Hurst index for identifying the performance of the controller during the rolling process. Additionally, for controllers with poor Hurst index values, the crayfish optimization algorithm is employed for adjusting controller parameters to maximum the Hurst index. Results A real case of hot rolling steel production was used to validate the proposed data-driven optimized control method. Experimental results demonstrate that the proposed evaluation method can effectively recognize the state of gauge-looper-tension controller. Moreover, after optimizing the controller parameters through crayfish optimization algorithm (COA), the value of Hurst index showed significant improvement. Conclusions The proposed digital twin -based optimized control method effectively enhance the manufacturing capability and maintain strategy of hot rolling steel production. Through the proposed method, the Hurst index of gauge-looper-tension system increasing from 0.574 to 0.862.

Effects of Process Parameters on Microstructure Evolution of Pure Aluminum Target under Clock 135° Collaborative Hot Rolling: A Simulation Study

Based on the results of current research and experiments, clock 135° hot rolling has been widely considered to be the preferred method in target rolling. However, it has been found that the process parameters are of vital importance during the rolling. Therefore, this work focuses mainly on the investigation of the effects of the roll speed ratio and offset distance on the microstructure evolution of a pure aluminum (Al) target under clock 135° collaborative hot rolling. Taking the ultra-thick pure Al metal circular billet as a research object, firstly, the evolutionary behavior of the effective strain (ES) and grain refinement for a rolled piece under the clock counterclockwise 135° synchronous and asynchronous (the speed ratios between rollers are set to be 1:1.05, 1:1.1, 1:1.2, respectively) rolling modes has been comparatively studied based on numerical simulation by DEFORM-3D software. It has been shown that a large ES value of 5.835 mm/mm is obtained in the lower surface layer by counterclockwise 135° asynchronous rolling with a roll–speed ratio of 1:1.2. Meanwhile, the average grain size below 80 µm accounts for ~61.8% of the total grains. These results demonstrate that the clock counterclockwise 135° asynchronous rolling method with a roll speed ratio of 1:1.2 should be an ideal strategy in obtaining finer grains. Unfortunately, nevertheless, the maximum degree of the bad plate shape is generated after forging by clock asynchronous rolling with a speed ratio of 1:1.2. As a consequence, clock counterclockwise 135° snake rolling with a 30 mm offset distance was proposed on the basis of a rolling speed ratio of 1:1.2, which perfectly corrected the warping plate shape caused by clock asynchronous rolling. What is more important, the minimum damage value of 1.60 was achieved accordingly. Meanwhile, the ES value increased in the core of the plate for the clock counterclockwise 135° snake rolling with all of the four offset distances compared to clock synchronous rolling. This study should be significantly conducive to guidance on setting process parameters in the industrial production of hot rolling metal or alloy targets.

In situ phosphorus-modified Mg2Ge/Zn-Cu composite with improved mechanical, degradation, biotribological properties, and in vitro and in vivo osteogenesis and osteointegration performance for biodegradable bone-implant applications

Zinc (Zn)-based composites are promising biodegradable bone-implant materials because of their good biocompatibility, processability, and biodegradability. Nevertheless, the low interfacial bonding strength, coordinated deformation capacity, and mechanical strength of current Zn-based composites hinder their clinical application. In this study, we developed a biodegradable in situ 4Mg2Ge/Zn-0.3Cu-0.05P composite (denoted ZMGCP) via phosphorus (P) modification and hot-rolling for bone-implant applications. The mechanical properties, corrosion behavior, biotribological performance, in vitro cytocompatibility and osteogenic differentiation, and in vivo osteogenesis and osteointegration of the as-cast (AC) and hot-rolled (HR) ZMGCP samples were systematically evaluated and compared to those of 4Mg2Ge/Zn-0.3Cu (denoted ZMGC). The primary and eutectic reinforcement Mg2Ge phases formed during solidification were refined after P modification and hot-rolling. The HR ZMGCP exhibited the best tensile properties among all the samples with an ultimate tensile strength of 288.9 MPa, a yield strength of 194.5 MPa, and an elongation of 17.7 %. The HR ZMGCP showed the lowest corrosion rate of 336 μm/a, 186 μm/a, and 61.7 μm/a as measured by potentiodynamic polarization, electrochemical impedance spectroscopy, and immersion testing, respectively, among all the samples in Hanks’ solution. The HR ZMGCP also showed higher biotribological resistance than its ZMGC counterpart. The HR ZMGCP exhibited the highest in vitro cytocompatibility, the best osteogenesis capability and angiogenesis property among the HR samples of pure Zn, ZMGC, and ZMGCP. Furthermore, the HR ZMGCP displayed complete in vivo biocompatibility, osteogenesis, osteointegration capability, and an appropriate degradation rate, showing significant potential for a biodegradable bone-implant material.

High-Temperature Creep Resistance of FeAlOY ODS Ferritic Alloy.

A significant effort in optimizing the chemical composition and powder metallurgical processing led to preparing new-generation ferritic coarse-grained ODS alloys with a high nano-oxide content. The optimization was aimed at high-temperature creep and oxidation resistance at temperatures in the range of 1100-1300 °C. An FeAlOY alloy, with the chemical composition Fe-10Al-4Cr-4Y2O3 (wt. %), seems as the most promising one. The consolidation of the alloy is preferably conducted by hot rolling in several steps, followed by static recrystallization for 1 h at 1200 °C, which provides a stable coarse-grain microstructure with homogeneous dispersion of nano-oxides. This represents the most cost-effective way of production. Another method of consolidation tested was hot rotary swaging, which also gave promising results. The compression creep testing of the alloy at 1100, 1200, and 1300 °C shows excellent creep performance, which is confirmed by the tensile creep tests at 1100 °C as well. The potential in such a temperature range is the target for possible applications of the FeAlOY for the pull rods of high-temperature testing machines, gas turbine blades, or furnace fan vanes. The key effort now focuses on expanding the production from laboratory samples to larger industrial pieces.

Gray relational analysis for parametric optimization of micro-EDM of thermo-mechanically processed AA7075 and AA7075/SiC/Gr composite

The AA7075 alloy and AA7075/SiC/Gr hybrid composite prepared by the stir-casting method have been further thermo-mechanically processed through unidirectional hot rolling and hot cross-rolling routes to eliminate casting defects like voids, blow holes etc. Three initial sample temperatures, that is, 350℃, 400℃, and 450℃, have been considered for the hot cross-rolling. The Al alloy and its hybrid composite prepared at different rolling temperatures are studied to investigate their micro-machining behavior through micro-electric discharge machining (µ-EDM). The micro-holes are made on the rolled samples along the rolling direction of the final rolling pass using a tool with twist drill bit geometry. Further, multi-objective optimization of the µ-EDM process parameters considering the response parameters viz. material removal rate (MRR) and tool wear rate (TWR) has been carried out using the gray relational analysis (GRA) technique. The µ-EDM parameters chosen to optimize in this study are voltage, pulse on time, and tool rotation. The obtained GRA results are further analyzed through normality and equal variance tests. The R-squared values of 95.02% and 95.53% for AA7075 alloy and hybrid composite, respectively, indicate that the data fit well with the statistical model. In material removal, the different electrical and thermal characteristics of the Al matrix and the reinforcements possibly generate sparks with a different characteristic that ultimately affects the MRR of the composite. Through scanning electron microscopy (SEM), the morphological study confirmed the presence of globules and voids on the machined surface. The formation of globules and voids is more significant in the AA7075 alloy than in the composite.

Degradation Modeling and RUL Prediction of Hot Rolling Work Rolls Based on Improved Wiener Process.

Hot rolling work rolls are essential components in the hot rolling process. However, they are subjected to high temperatures, alternating stress, and wear under prolonged and complex working conditions. Due to these factors, the surface of the work rolls gradually degrades, which significantly impacts the quality of the final product. This paper presents an improved degradation model based on the Wiener process for predicting the remaining useful life (RUL) of hot rolling work rolls, addressing the critical need for accurate and reliable RUL estimation to optimize maintenance strategies and ensure operational efficiency in industrial settings. The proposed model integrates pulsed eddy current testing with VMD-Hilbert feature extraction and incorporates a Gaussian kernel into the standard Wiener process to effectively capture complex degradation paths. A Bayesian framework is employed for parameter estimation, enhancing the model's adaptability in real-time prediction scenarios. The experimental results validate the superiority of the proposed method, demonstrating reductions in RMSE by approximately 85.47% and 41.20% compared to the exponential Wiener process and the RVM model based on a Gaussian kernel, respectively, along with improvements in the coefficient of determination (CD) by 121% and 19.76%. Additionally, the model achieves reductions in MAE by 85.66% and 42.61%, confirming its enhanced predictive accuracy and robustness. Compared to other algorithms from the related literature, the proposed model consistently delivers higher prediction accuracy, with most RUL predictions falling within the 20% confidence interval. These findings highlight the model's potential as a reliable tool for real-time RUL prediction in industrial applications.

Effect of Ca addition on structure, phase composition and hardness of Al–6 %Cu–2 %Mn sheet alloy

The Al–Cu–Mn–Ca system was proposed as a bases for the design of new group of heat-resistant alloys which can be used for high-temperature applications instead of the 2219 types industrial alloys. Unlike the latter ones, the new alloys also do not require a full cycle of strengthening heat treatment including solid solution treatment, quenching and aging. The effect of calcium addition in the 1–4 wt% range on the structure, phase composition and hardness after high temperature annealing of the Al–6 %Cu–2 %Mn base sheet alloy has been studied. It has been shown that calcium addition leads to the formation of high-temperature eutectics (614–617 °С) with the participation of the Al27Ca3Cu7 and (Al,Cu)4Ca phases that are capable of spheroidization at high temperature annealing. The ingots of Ca-containing alloys do not require homogenization but have sufficient deformation plasticity at both hot and cold rolling. The structure of the previously unstudied quaternary Al–Cu–Mn–Ca phase diagram in the region of the aluminum corner has been also proposed, according to which it can contain 5 four-phase fields in the solid state with the participation of (Al), binary (Al2Cu, Al4Ca, Al6Mn) and ternary (Al8CaCu4, Al27Ca3Cu7, Al10CaMn2 and Al20Cu2Mn3) phases. Based on the obtained data, the composition Al–6 %Cu–2 %Mn–1 %Ca has been proposed as a basis for the development of a new heat-resistant alloy. It is shown that this alloy superior to industrial 2219 alloy in terms of heat resistance, especially after annealing at 400 °C, when the difference in hardness reaches 32 HV. The high heat resistance of the new wrought alloy originates from the formation of a specific microstructure consisting of fine Ca-containing eutectic inclusions and Al20Cu2Mn3 phase dispersoids with a size of about 100 nm which prevent recrystallization and allow maintaining the fine sub-grained structure.

Towards microstructure control in forging and rolling: combining AI with process models for closed-loop property control

Abstract Metal forming processes like open-die forging or hot rolling are well-established for the production of key components in various industries. Nevertheless, the control of the final microstructure and hence mechanical properties is not yet common. To achieve this, the authors propose and discuss a control concept based on reinforcement learning, fast process models (FPM) and an “operator in the loop” approach. The concept is explained and tested using deviating initial ingot temperatures as idealized process disruptions. RL algorithms are trained for both processes and transferred into the controllers that are connected to a simulative environment based on FPM. Within this framework, the online adaption is possible in ∼2 s in rolling and 4–6 s in forging. This highlights the concepts suitability to be used for property control in hot metal forming.

Simulation of the Evolution of Phase Composition and Austenite Grain Size upon Multi-Pass Hot Deformationof Low-Alloy Steels

The paper presents a model for predicting the structural characteristics and phase composition of low-alloy steels upon hot rolling in the multi-pass deformation mode. The model considers recovery, dynamic, primary, dynamic and static recrystallization of grains, and the normal grain growth, as well as nucleation (including accelerated nucleation during deformation), growth or dissolution, and coarsening of carbonitride particles. The comparison between the calculated results and the experimental data available in the publications shows a satisfactory agreement.

Microstructural Evolution, Mechanical Property, and Strengthening in a Lightweight Mg-Y-Zn-Mn Alloy Fabricated by Multidirectional Forging and Hot Rolling

Microstructural Evolution, Mechanical Property, and Strengthening in a Lightweight Mg-Y-Zn-Mn Alloy Fabricated by Multidirectional Forging and Hot Rolling

Characterization of Cu-13Al-3.5Ni-0.7Ti-(0, 0.5, 1) Y Alloy Prepared by Mechanical Alloying, Sintering, and Hot Rolling

Characterization of Cu-13Al-3.5Ni-0.7Ti-(0, 0.5, 1) Y Alloy Prepared by Mechanical Alloying, Sintering, and Hot Rolling

Natural convection and variable fluid properties of tangent hyperbolic nanofluid flow with Cattaneo-Christov theories and heat generation

The main aim behind this work is that we have to determine the enhancement that happens in thermal conductivity by using the Buongiorno model of nanofluid when the nanofluid particles are added to the tangent hyperbolic base fluid moving above the stretched surface. The viscosity of tangent hyperbolic nanofluid is assumed to be temperature-dependent. The modified form of the Fourier law of heat conduction motivated us; therefore, the Cattaneo-Christov heat and mass flux model is considered to observe its significance for heat and mass transport. The chemical reaction and heat generation are also considered to determine their influence on temperature and concentration gradients. This study is crucial because of its application in industrial manufacturing processes such as the coating of wire, the thinning of copper, the production of paper, photographic films, hot rolling, and the purification of crude oil. In electronic cooling systems, the efficient dissipation of heat in smartphones, computers, and data centers is critical to preventing overheating. Nanofluids, with their enhanced thermal properties, can significantly improve heat transfer rates, ensuring better performance, stability, and energy savings. The partial governing equations arising from fluid flow, mass, and heat transfer are transformed into ordinary differential equations via appropriate similarity variables. The obtained ordinary differential equations are solved numerically by using the Runge-Kutta Fehlberg method in the MATLAB software. The effects of the emerging parameters are represented through graphs. According to the results, the velocity profile upsurges due to the natural convection parameters and curvature parameter, while the power law index declines the velocity profile. As the Brownian motion coefficient rises, the concentration profile diminishes while the temperature profile increases. Both the concentration and temperature profiles increase for larger values of the thermophoresis parameter. The concentration profile declines for larger values of chemical reaction parameters, and enhancement happens in the temperature region.

Analysis of fatigue damage of hot rolling work rolls coupled with wear effect

During the hot rolling process, the work roll experiences cyclic contact stress due to the deformation of the strip steel, as well as thermal stress from periodic heating and cooling. The surface failure of the work roll results from the combined effects of wear and fatigue damage. This study proposes a comprehensive approach to analyzing coupled wear and fatigue damage using a method based on the Manson-Coffin equation, modified slope formula, and the Miner criterion. Finite element models were developed to simulate simplified heat transfer and thermal coupling, taking into account the actual rolling parameters and high-temperature material properties of the work roll. The evolution of the physical field of the work roll during the rolling process was analyzed. The analysis of these models revealed that the maximum strain on the work roll occurred at the rolling exit and was predominantly influenced by temperature. The effects of rolling speed and temperature on work roll strain varied, with fatigue damage being significantly reduced when wear was considered compared to scenarios where wear was not accounted for, under the same number of cycles.