Twin-roll Casting Process Research Articles

Research on temperature field and thermal deformation characteristics of casting rollers in twin-roll casting process

The twin-roll casting (TRC) process is considered a revolutionary technology in the metallurgical field and has garnered significant attention and research in recent years. The casting rollers used in the TRC process are crucial for achieving the desired shape of the casting strip. This study investigates the temperature distribution and thermal deformation of casting rollers in the TRC process using numerical simulation. A novel model for predicting the thermal resistance distribution at the circumferential interface between the casting roller and the molten pool has been introduced. The study examined the effects of various factors including casting roller diameter, water channel position, number, and diameter on temperature, thermal deformation, and heat flux. The findings reveal that increasing the casting roller diameter from 460 mm to 500 mm or augmenting the distance from the water channel to the casting roller surface from 35 mm to 55 mm resulted in a 37 % and 30 % increase in the maximum surface temperature of the casting roller, respectively. Additionally, an increase in the number of water channels from 30 to 50 and a growth in their diameter from 20 mm to 28 mm resulted in the average heat flux of the casting roller remaining stable, with fluctuations less than 1 MW/m2. Leveraging the insights gained from the thermal deformation behavior of the casting roller and the ideal shape of the casting strip, a comprehensive control approach for the casting roller profile was developed. The outcomes of this research provide a valuable theoretical framework for enhancing the design of casting roller structures in the TRC process.

Research on flow, heat transfer, and solidification characteristics of flow distribution process in the twin-roll casting

Twin-roll casting (TRC) has seen a significant interest in recent years due to its short process, low energy consumption, and low emission. The research included both numerical simulation and experimental validation to examine the flow and temperature field distribution of the TRC process. The “U-shaped” buffer groove is identified as beneficial for maintaining a stable liquid level distribution in the molten pool through comparison with various flow distributor structures. The solidified billet shell dispersion around the casting roller in the molten pool is observed to undergo three distinct stages: stable growth, thickness fluctuation, and rapid growth. The inclusion of two circular side outlets, each with a diameter ranging from 8 to 10 mm, proves advantageous in maintaining a stable distribution of the liquid level within the molten pool. The edge outlet size ranges from 7 to 9 mm, and ensuring a U-shaped buffer groove width/flow distribution of 1.25–1.58 aids in enhancing casting stability.

Numerical Analysis of Temperature and Stress Field of Side Dam on the Twin‐Roll Strip Casting

Side sealing technology is crucial in the twin‐roll casting process. The performance of side dam materials directly determines twin‐roll casting (TRC) process stability and safety. An orthogonal test is conducted to study the effects of thermal conductivity, linear expansion coefficient, and elastic modulus on the maximum thermal stress of side dams. The elastic modulus and linear expansion coefficient are identified as key factors affecting the maximum thermal stress of the side dam. The fluctuation of maximum thermal stress under different elastic modulus and linear expansion coefficients is 79.7 and 75.8 MPa, respectively, whereas it is only 11.2 MPa under different thermal conductivity. A side dam with heterogeneous material along height and thickness gradient is designed. The results indicate that the maximum thermal stress in the contact area between the side dam and the molten metal decreases to 31.2 MPa, representing a reduction of more than 30 MPa compared to the homogeneous side dam with optimal performance. The results provide important guidance in improving the stability of the TRC process.

Annealing temperature effects on microstructure and magnetic properties of Fe-6.5wt. %Si alloy strips prepared by TSTRC process

The Fe-6.5wt.%Si alloy exhibits remarkable soft magnetic characteristics, such as high magnetic permeability, low coercivity, high resistivity, and nearly zero magnetostriction. These attributes establish it as an ideal material for low-power, low-noise electric motors and transformers. This investigation aimed to assess the impact of annealing temperature (ranging from 800 to 1200 °C for 1 h) on the microstructure, texture, and magnetic properties of a 0.15 mm thick Fe-6.5wt.%Si alloy sheet, which was obtained by subjecting the strips produced through the top side-pouring twin-roll casting (TSTRC) process to multi-pass warm rolling in the temperature range of 600 ∼ 800 °C, avoiding hot rolling. Additionally, the recrystallization mechanism of the annealed sheet at 1100 °C for 1 h was explored. The findings indicate that enhancing the annealing temperature corresponded to a reduction in magnetic induction (B8 and B50) as well as iron losses (P10/50, P10/400, and P2/1000). The annealed sheet at 1200 °C for 1 h demonstrated the most favorable magnetic properties, displaying iron losses of 0.486 W/kg, 6.895 W/kg, and 1.232 W/kg for P10/50, P10/400, and P2/1000, respectively. These results illustrate excellent overall magnetic characteristics. The coercivity (Hc) of both B8 and B50 decreased as the annealing temperature increased in the hysteresis loop measurements. Specifically, for B8, it decreased from 62.84 A/m to 24.50 A/m, and for B50, it decreased from 78.10 A/m to 35.50 A/m. The average grain size of the samples gradually increased as the annealing temperature ranged from 800 to 1200 °C. The dominant texture observed was {111}, and the volume fraction of {111} texture increased while the volume fractions of {100} and {110} textures decreased. Upon annealing at 1100 °C for 8 s, the elongated and flattened deformed structures were mainly replaced by equiaxed grains, indicating the completion of the recrystallization process. However, there was a noticeable distinction in the coarsening degree of equiaxed grains based on their orientations. The presence of λ-oriented grains was less prominent, while α-oriented and γ-oriented grains were relatively more abundant. As the annealing time increased from 8 s to 1 h, there was a decrease in the presence of λ-oriented and α-oriented grains, while the presence of γ-oriented grains significantly increased.

Investigation of segregation behaviour in 2060 aluminium-lithium alloy during twin-roll casting

The utilization of the twin-roll casting process to fabricate aluminium (Al) - lithium (Li) alloys is regarded as an efficient and energy-saving strategy to meet the aerospace industry’s demands for reducing processing steps, cost-effectiveness, and corrosion resistance. This study successfully achieved the preparation of Al-Li alloy twin-roll cast slabs across various processing ranges to investigate the corrosion resistance differences in different processing conditions. Remarkable macro segregation phenomena were observed in the fabrication under high twin-roll casting speeds for TRC-3. By combining temperature and flow rate calculations, we comprehensively analysed the results of this segregation mechanism. The segregation is inherited into the final T6 state microstructure, exacerbating the precipitation of the T1 phases and deteriorating the ultimate corrosion resistance performance. We delved into a profound discussion regarding the mechanistic impact of segregation on corrosion behaviour. Ultimately, this study postulates a process parameter range for twin-roll casting of Al-Li alloys, aimed at attaining minimal segregation and maximal corrosion resistance.

Study on effect of melt level on heat transfer characteristics and quality of continuously cast Al-Mg2Si composite sheet

Composite sheets fabricated by the Twin roll casting (TRC) process often suffer from quality issues, primarily microporosity resulting from solidification shrinkage. The presence of fabrication defects can be controlled by varying the casting parameters such as casting speed, superheat temperature, rolling force, and the height of the liquid metal in the melt pool. The present study developed a three-dimensional model to analyze the solidification and flow behavior of the melt with increasing melt pool height (4 cm, 6 cm, 8 cm) to see the quality of the fabricated Al-Mg2Si composite sheet. The developed model was validated using the optimized inlet temperature and interlamellar spacing. This model studies the effect of melt pool height on the solidification behavior, optimized inlet temperature, temperature gradient and heat flux. Results show that the increasing melt pool height shifts a solidification temperature above the roll exit and requires a higher inlet temperature for continuous sheet fabrication. Increased melt pool height decreases the heat flux from the roller surface and shows a lesser velocity fluctuation at the top and bottom of the melt pool. Experimental investigation demonstrates that a rise in melt pool height lowers the porosity in the casted sheet from 10.9% to 2.7% due to improved temperature gradient and pressure at the roller exit, enhancing sheet quality within the TRC process.

Advanced multi-scale analysis of segregation mechanisms in twin-roll casting of Al-Cu-Li alloys

In this paper, a detailed analysis of the rheological behaviour and segregation mechanisms within twin-roll casting (TRC) processes for 2060 Al-Cu-Li alloys is presented. Building on previous research where fixed roll gaps limited the adjustability of cast-rolling speed, this study expands the scope by adjusting roll gaps from 3 mm (TRC-3), to 6 mm (TRC-6), to 10 mm (TRC-10). This approach yields three typical process ranges with gradually increasing roll gaps and a wide range of decreasing cast-rolling speeds, allowing us to investigate the inherent nature of segregation and identify conditions conducive to segregation-free processing. A significant contribution of this study is the development of a novel multi-scale simulation model that integrates the thermal, flow, mechanical, solute and phase fields. This advanced simulation framework enhances our understanding of TRC processes and aids in exploring the interplay between the various factors affecting alloy fabrication. This study identified two primary stress-induced inverse segregation mechanisms: the reflux of the semi-solid phase due to rolling stress and expansion of the solidifying shell under shearing stress. Using these insights, a low-stress, low-segregation process, termed TRC-6, was established, which showed notable improvements in the mechanical properties. Specifically, TRC-6 demonstrated a remarkable strength of 562.9 MPa post-T8-treatment, surpassing those of TRC-3 and TRC-10 by 9.0 % and 5.2 %, respectively. These findings offer valuable insights for future TRC process designs with the aim of eliminating segregation defects and enhancing the sustainable and efficient production of Al-Cu-Li alloys.

Metallurgical Method of Determining Heat Transfer Coefficient in Simulations of Twin-Roll Casting

We herein suggest a metallurgical method using pure aluminum with no freezing temperature range to derive appropriate roll/melt interfacial heat transfer coefficients in simulation of twin-roll casting process. This method is inspired by the concept that the position of the kiss points where two solidifying shells encounter and the roll nip coincides under the condition where the roll load becomes zero as the roll rotation speed decreases. The conditions where the roll load becomes zero under various melt supply temperature conditions in the actual TRC process are found experimentally. These conditions are then applied to simulation models to derive heat transfer coefficient values. When comparing these values with those derived previously from the empirical relation for roll rotation speed and heat transfer coefficient, the conclusion is drawn that the deviation was reasonably low, around 10%.

Effects of Zn Addition and Twin Roll Casting Process on the Microstructure, Texture, and Mechanical Properties of the Mg-Al-Mn-Ca Sheet

In this work, the microstructure and texture of Mg-1.0Al-xZn-0.2Mn-0.5Ca (wt.%, x = 0, 1) alloys, which were produced via conventional casting or twin roll casting (TRC), were investigated, and their relation to the mechanical properties of the sheets at the final gage was analyzed. In the Zn-containing AZMX1100 alloy sheets, the amount and size of the secondary phases were significantly reduced, in comparison to the Zn-free AMX100 alloy sheet. The TRC sheet shows a smaller grain structure and fine secondary phases in comparison to the sheets produced via the conventional casting process. The texture of the AMX100 sheet is characterized by the basal poles tilted in the sheet rolling direction (RD). In the AZMX1100 sheets, the texture with the tilted basal poles towards the RD and transverse direction (TD) was developed after recrystallization annealing, while the tilting angle of the basal pole in the TD is larger than in the RD. There is no significant difference in the texture between the sheets produced by the casting and TRC process. The highest yield strength was obtained in the AZMX1100 sheet produced by the TRC process, and all examined sheets showed the mechanical anisotropy in accordance with their textures.

Numerical Analysis and Experimental Study on Side Dam Temperature and Stress Field of Two‐Roll Casting

The side sealing technology is crucial for ensuring the quality and process stability in twin‐roll casting (TRC). Investigating the temperature and stress distribution in side dams under operational conditions is vital, especially in understanding the causes of side dam fractures. Optimal performance of side dam materials is achieved when the boron nitride (BN) matrix is fine and homogeneous, with zirconium dioxide (ZrO2) and silicon carbide (SiC) particles evenly dispersed throughout. The fracture of the side dam after casting is mainly caused by BN interlamellar tear. The coexistence of BN lamellar tearing and BN layer fracture leads to the fracture of the side dam during the casting process. Through finite element simulation, the effects of variables such as pouring temperature, preheating temperature, and side dam thickness on temperature and stress distribution were analyzed. The findings indicate that a preheating temperature range of 1200–1300 °C minimizes thermal stress in the side dam. Building on these findings, a composite structure for the side dam is developed. Both internal and external composite structures have shown significant effectiveness in reducing thermal stress. These results are pivotal in extending the service life of side dams and enhancing the stability of the TRC process.

Mechanical properties of three typical aluminum alloy strips prepared by twin-roll casting

Twin-roll casting (TRC) is a near-net shape processing technology that has found widespread application across various series of Al alloys. In this study, the process-structure-property relationships of 2099, 3003, and 6082 Al alloy strips prepared by TRC and traditional rolling (TR) methods were investigated. It shows that the tensile strength and fatigue strength of 2099-TRC are lower than 2099-TR, which is attributed to the reduced solid solubility of copper (Cu) elements resulting from the precipitation of Cu-rich micron phases and the presence of microstructure inhomogeneities. While both 3003-TRC and 3003-TR materials exhibit similar yield and tensile strength, the occurrence of casting micro-void defects in 3003-TRC leads to an accelerated accumulation of fatigue damage, consequently diminishing its fatigue strength. Conversely, 6082-TRC demonstrates an enhanced fatigue strength relative to 6082-TR. This improvement is primarily linked to the higher yield strength and comparable fatigue resistance observed in the former. In light of these findings, the TRC process holds promise for enhancing the fatigue performance of 6xxx Al alloy strips with good elongation. However, for 2xxx and 3xxx alloy strips with comparatively lower elongation, the TRC process enhancements may be necessary to realize similar benefits. The insights gleaned from this study could offer valuable reference and guidance for optimizing both the TRC process itself and the fatigue performance of Al alloy strips.

Mechanical and Microstructure Characterisation of the Hypoeutectic Cast Aluminium Alloy AlSi10Mg Manufactured by the Twin-Roll Casting Process

Multi-material designs (MMD) are more frequently used in the automotive industry. Hereby, the combination of different materials, metal sheets, or cast components, is mechanically joined, often by forming joining processes. The cast components mostly used are high-strength, age-hardenable aluminium alloys of the Al–Si system. Here, the low ductility of the AlSi alloys constitutes a challenge because their brittle nature causes cracks during the joining process. However, by using suitable solidification conditions, it is possible to achieve a microstructure with improved mechanical and joining properties. For this study, we used the twin-roll casting process (TRC) with water-cooled rollers to manufacture the hypoeutectic AlSi10Mg for the first time. Hereby, high solidification rates are realisable, which introduces a microstructure that is about four times finer than in the sand casting process. In particular, it is shown that a fine microstructure close to the modification with Na or Sr is achieved by the high solidification rate in the TRC process without using these elements. Based on this, the mechanical properties increase, and especially the ductility is enhanced. Subsequent joining investigations validate the positive influence of a high solidification rate since cracks in joints can be avoided. Finally, a microstructure-property-joint suitability correlation is presented.

Numerical Modeling and Experimental Study of Solidification Behavior of Al-Mg2Si Composite Sheet Fabricated Using Continuous Casting Route

Abstract Owing to manufacturing challenges, the fabrication of thin sheets of metal matrix composites has been an area of concern for sheet manufacturers. Converting a billet of composite into a sheet using rolling and extrusion is quite energy-intensive and prone to cracking using the conventional casting route. To address this issue, this study explores the development of particle-reinforced near eutectic Al-Mg2Si composite sheets using a vertical twin-roll continuous casting process. The numerical simulation involves fluid flow, solidification, and heat transfer analysis of the twin-roll continuous casting process for producing thin strips. Processing parameters such as the velocity of rolls and superheat temperature of the melt are optimized to successfully convert the melt into a sheet of composite material. A combined numerical and experimental study show that the continuous casting process is more sensitive to the casting speed. A small change in roller speed (2 rpm) significantly affects the solidified fraction at the roller exit. Optimizing the casting speed to 0.072 m/s and inlet temperature to 886 K, an in situ Al-Mg2Si composite sheet of 3 mm thickness is successfully cast. The particle distribution along the casting direction of the sheet is uniform, ensuring the homogeneous mechanical properties reported in terms of hardness. The entire process does not require external stirring to get uniform distribution of the reinforced particles.

Effectively mitigated macro-segregation and improved tensile properties of twin-roll cast Al–Mg–Si (6022) alloy strips via Zr addition

It is a great challenge to avoid the central macro-segregation during the solidification process of twin-roll casting (TRC), which seriously limits the mechanical properties of 6xxx series Al alloys. In this study, we find that the trace addition of 0.08 wt% Zr to Al-1.0Mg-1.2Si (6022) alloy can effectively promote the columnar-to-equiaxed transition and refine the solidification microstructure (particularly α-Al dendrites and π-AlFeMgSi phase). More importantly, the macro-segregation of the as-cast TRC strip is well mitigated with Zr addition. The refinement of α-Al dendrites and π-AlFeMgSi phase may be attributed to the formation of (Al, Si)3Zr phases when introducing Zr element, which can act as heterogeneous nucleation sites for both of them. The secondary dendrite arm spacing (SDAS) in the central region of strips is sharply decreased from ∼33 to ∼16 μm, which facilitates the incorporation of more solute elements into the Al matrix, thus increasing the partition coefficients of Mg (kMg) and Si (kSi) elements. As a result, there are fewer solute atoms in the residual liquid phase during the final stage of solidification, leading to the alleviation of central macrosegregation. The tensile properties of the as-cast, solid solution treated (T4) and paint baking treated (T6) alloys are synchronously optimized with Zr addition. In particular, the fracture elongation of the T4 alloy is increased from ∼30.9% to ∼33.4%, indicating excellent formability. The yield strength of the T6 alloys is increased from ∼227 MPa to ∼239 MPa, satisfying the more demanding service requirements. This work can provide a strategy for the effective control of macro-segregation and produce alloy strips with high performance by the TRC process.

Effect of cooling rate on the order degree, residual stress, and room temperature mechanical properties of Fe-6.5wt.%Si alloy

The top side-pouring twin-roll casting (TSTRC) process was used to prepare a 100 × 1.7 mm non-oriented Fe-6.5 wt% Si alloy as-cast strip. The as-cast strip is directly rolled at 700 °C into 0.4 mm without the intermediate hot rolling step. This paper discusses the effects of different cooling rates in furnace cooling, air cooling, oil quenching, and water quenching on the order degree, residual stress, room temperature mechanical properties, and cold-rolled processing properties of Fe-6.5wt.%Si alloy after annealing of warm-rolled sheets are systematically investigated. Meanwhile, the effects of order degree, residual stress, and grain boundary element segregation on the mechanical properties were analyzed. The results show that as the cooling rate increases, the order degree of the Fe-6.5 wt% Si alloy decreases and the maximum residual tensile stress increases. The fracture modes of the furnace cooling, air cooling, and oil quenching samples are through-crystal disintegration fracture, and the fracture mode of the water quenching samples is an along-crystal fracture. The oil-quenched samples exhibit good room temperature plasticity due to the relatively low order degree and residual tensile stresses in the Fe-6.5wt.%Si alloy. Oil quenching improves the room temperature plasticity and cold rolling properties of Fe-6.5wt.%Si alloy warm rolled sheets, reduces edge cracks, and offers greater room temperature cold rolling processibility of the Fe-6.5wt.%Si alloy warm rolled sheets.

Towards relieving center segregation in twin-roll cast Al-Mg-Si-Cu strips by controlling the thermal-mechanical process

Serious center segregation greatly limits the application of twin-roll casting (TRC) technology for producing 6xxx alloy strips. Herein, Al-0.9Mg-0.6Si-0.2Cu-0.1Fe (wt.%, 6061) strips with different thicknesses were fabricated by TRC, and we found that the center segregation was well relieved with the thickness increased from 3 mm to 4 mm. To reveal the mechanisms of mitigation of center segregation in the 4 mm strip, various techniques including solidification simulation, crystallographic calculation, electron backscatter diffraction (EBSD), and electron probe micro-analyzer (EPMA) were utilized. The results disclosed that the Fe-containing phase in the 3 mm strip was π-AlFeMgSi, while the counterpart in the 4 mm strip was α-AlFeSi. The α-AlFeSi could serve as nucleation substrates for Mg2Si and Q-AlCuMgSi phases, thus promoting the uniform distribution of elements and preventing the accumulation of phases in the center region. Three matching planes between the α-AlFeSi and Q/Mg2Si were examined as: (112¯0)α-AlFeSi // (0001)Q, (0001)α-AlFeSi // (110)Mg2Si, and (112¯0)α-AlFeSi // (11¯0)Mg2Si. Meanwhile, the smaller roll separating force during the TRC process in the 4 mm strip could weaken the force-induced liquid flow behavior in the semi-solid region, which is the other reason for the alleviation of center segregation. Owing to the elimination of the center segregation, a more excellent fracture elongation was achieved in the as-homogenized 4 mm strip (∼29%) compared with the counterpart of the 3 mm strip (∼20%). This work may provide a strategy to eliminate the center segregation, thus further promoting the application of TRC process and producing high-performance Al alloy strips efficiently.

A novel approach to improve the macro-segregation defect and mechanical properties of Al–Mg–Mn aluminum alloys during twin-roll continuous casting

In this paper, the microstructure and properties of Al–Mg–Mn alloy slabs with different thicknesses by twin-roll continuous casting were investigated. Under the twin-roll continuous casting process, the alloy melt conducts directional crystallization due to the near-horizontal heat transfer direction. In this way, the growth direction of the columnar crystal is changed to improve the shape and size of the sump and effectively eliminate the central segregation defect. Additionally, the improvement of segregation defects was more significant with the increase in thickness. As low angle grain boundary content and solution degree increased, the electrical conductivity decreased, the hardness increased, and the phenomenon of hard-soft-hard core-shell was significantly improved.

Tribological and texture analysis in Twin-roll casting 2060 Al-Li alloy

In this work, the wear behaviors of a 2060 Al-Li alloy prepared by the twin-roll casting (TRC) process was analyzed and supplemented with coupling simulation calculations. As the load increased from 2 N, 5 N, 10 N, and 20 N at room temperature, the friction coefficient decreased due to the oxidation lubrication triggered by heat accumulation, which was calculated via the simulation; the wear volume decreased; and the decrease in wear volume rise rate was a result of dynamic recrystallization and grain rotation. Observing the grain rotation and analyzing the texture evolution law during wear tests with scanning electron microscopy (SEM) and electron back-scattered diffraction (EBSD) was an innovation. To support the rotation behavior, a method for calculating the Schmid factor of rotating grains was developed. As the load rose, the R-Cube {001} 〈110〉 texture rotated to the rotating cube {001} 〈310〉 texture towards the α-fiber line. The modification decreased the maximum Schmid factor along the sliding and rolling directions, indicating an increase in initial strength and wear resistance. In addition, at a 2 N load, the TRC-3 sample with higher substructure and deformation texture exhibited less wear volume than the TRC-6 sample.

Mechanical Properties and Joinability of AlSi9 Alloy Manufactured by Twin‐Roll Casting

AlSi casting alloys combine excellent castability with high strength. Hence, this group of alloys is often used in the automotive sector. The challenge for this application is the brittle character of these alloys which leads to cracks during joint formation when mechanical joining technologies are used. A rise in ductility can be achieved by a considerable increase in the solidification rate which results in grain refinement. High solidification rates can be realized in twin–roll casting (TRC) by water‐cooled rolls. Therefore, a hypoeutectic EN AC–AlSi9 (for European Norm ‐ aluminum cast product) is manufactured by the TRC process and analyzed. Subsequently, joining investigations are performed on castings in as‐cast and heat‐treated condition using the self‐piercing riveting process considering the joint formation and the load‐bearing capacity. Due to the fine microstructure, the crack initiation can be avoided during joining, while maintaining the joining parameters, especially by specimens in heat treatment conditions. Furthermore, due to the extremely fine microstructure, the load‐bearing capacity of the joint can be significantly increased in terms of the maximum load‐bearing force and the energy absorbed.

Effect of test temperature on tensile behavior of Fe-6.5wt.%Si alloy as-cast strip

The non-oriented Fe-6.5wt.%Si alloy as-cast strip is prepared by the top side-pouring twin-roll casting (TSTRC) process and the solidification structure of the as-cast strip is a uniform fine equiaxed grain structure. This paper studied the mechanical properties, fracture morphology, ordered phase morphology, and types of Fe-6.5wt.%Si alloy as-cast strips at different temperatures. The results show that the yield and tensile strength of the as-cast strip decreased gradually with the increase of tensile temperature, and the elongation after fracture increased gradually. The temperature rise prevented the formation of cleavage cracks, and the temperature rise is an effective method to improve the plasticity of Fe-6.5wt.%Si alloys. Concurrently, the ambient temperature is the main factor determining the tensile mechanical properties of Fe-6.5wt.%Si alloy at medium temperature. When the stretching temperature exceeds 500 °C, the Fe-6.5wt.%Si alloy has apparent plastic deformation ability. The Fe-6.5wt.%Si alloy exhibits excellent elongation when the stretching temperature is 700 °C. The serration fluctuations that appear on the 400 °C stretch curve should be attributed to the Portevin-Le Chatelier (PLC) effect caused by the reordering of the antiphase domains and the deformation-induced disorder. The Fe-6.5wt.%Si alloy as-cast strip is directly subjected to warm-rolling without the hot-rolling. When the warm-rolling is performed at the temperature of 700 °C, there are almost no cracks at the edge of the plate, the edge cracks are effectively controlled, and the surface quality of the warm-rolled sheet is fine. The obtained 700 °C warm-rolled sheets were cold-rolled at room temperature, and after recrystallization annealing, the sample had good comprehensive magnetic properties. Suppose the TSTRC-warm rolling-cold rolling-annealing process prepares the Fe-6.5wt.%Si alloy cold-rolled sheet. In that case, the production efficiency will be significantly improved, the process flow will be shortened, and the goal of energy-saving and emission reduction will be achieved.