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Metals
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Numerical Simulation and Experimental Research of Metal Rolling
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Numerical Simulation and Experimental Research of Metal Rolling

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 10 August 2025 | Viewed by 4985

Special Issue Editor

Dr. Xianlei Hu

E-Mail Website
Guest Editor
State Key Laboratory of Rolling and Automation, Northeastern University, Shenyang 110004, China
Interests: ultra-thin rolling; variable thickness rolling; plate rolling; rolling process; transverse variable thickness thin plate

Special Issue Information

Dear Colleagues,

With the rapid development of energy conservation, emission reduction, lightweighting, and greening, the application of traditional equal thickness materials is facing challenges. Variable cross-section structural materials have become an important choice for structural design in many industries due to their significant weight reduction and consumption reduction effects, without compromising structural safety. Some precision mechanical components are also using variable thickness plates and strips. The development and application of variable thickness materials, including the control and characterization of materials in all processing steps and their final performance analysis, are within the scope of this special issue. At present, typical variable cross-section materials have been widely used in many industries, such as TRB for automobiles, variable thickness plate springs for trucks, and LP plates for ships. The advantages of this material will have potential applications in the fields of metals, metal alloys, and composite materials. The rolling method determines the dimensional accuracy, surface quality, coating adhesion, and equipment stability of variable thickness materials. The annealing process has an important impact on the mechanical properties of different variable thickness areas and the alloying process of coatings. Due to the above reasons, the preparation process of variable thickness materials is closely related to different material properties and surface coating types, and the material properties obtained based on different process paths vary greatly.

In this special issue, we welcome articles on different types of variable thickness preparation methods and their impact on final performance. The variable thickness preparation method is not only in the field of steel but also in the fields of stainless steel, aluminum alloy, and titanium alloy, which is the future development direction.

Dr. Xianlei Hu
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • TRB
  • variable thickness rolling
  • LP
  • transverse variable thickness sheet
  • annealing
  • hot stamping steel
  • Al-Si coating

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Published Papers (4 papers)

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Research

14 pages, 4396 KiB  
Article
Interfacial Microstructure and Cladding Corrosion Resistance of Stainless Steel/Carbon Steel Clad Plates at Different Rolling Reduction Ratios
by Jie Chen, Yixin Zhu, Xia Chen, Xiaoli Ma and Bin Chen
Metals 2025, 15(1), 16; https://doi.org/10.3390/met15010016 - 28 Dec 2024
Cited by 1 | Viewed by 816
Abstract
Optical microscope (OM), energy dispersive spectrometer (EDS), electron backscatter diffractometer (EBSD), electrochemical test, and transmission electron microscope (TEM) were employed to conduct interface microstructure observation and cladding corrosion resistance analysis on 304 SS/CS clad plates that have four different reduction ratios. The increase [...] Read more.
Optical microscope (OM), energy dispersive spectrometer (EDS), electron backscatter diffractometer (EBSD), electrochemical test, and transmission electron microscope (TEM) were employed to conduct interface microstructure observation and cladding corrosion resistance analysis on 304 SS/CS clad plates that have four different reduction ratios. The increase in rolling reduction ratio leads to larger grain size, gradually refined microstructure, and a decreased thickness of the interfacial martensite area. As the concentration disparity of the C element between carbon steel (CS) and 304 stainless steel (SS) is small, no evident carburization layer or decarburization layer can be detected. The ferrite microstructure on the CS side has greater stress distribution and greater local orientation deviation, and deformed grains are dominant. Austenite undergoes strain-induced martensitic transformation with the transformation mechanism of γ→twinning→a’-martensite. The martensite microstructure within the interface region grows in the direction of the interior of austenite grains. The reduction ratio increases sharply, leading to an increase in dislocation density, which promotes the nucleation, growth, and precipitation of carbides and seriously reduces the corrosion resistance of the cladding. Subsequently, the reduction ratio keeps on increasing. However, the degree of change in the reduction ratio diminishes. High temperature promotes the dissolution of carbides and improves the corrosion resistance. From this, it can be understood that by applying the process conditions of raising the reduction ratio and keeping a high temperature at the carbide dissolution temperature, a clad plate that has excellent interface bonding and remarkable corrosion resistance can be acquired. Full article
(This article belongs to the Special Issue Numerical Simulation and Experimental Research of Metal Rolling)
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20 pages, 17479 KiB  
Article
Computationally Effective Modeling of Cold Rolling: Application to Al Alloys
by János György Bátorfi and Jurij J. Sidor
Metals 2025, 15(1), 11; https://doi.org/10.3390/met15010011 - 27 Dec 2024
Viewed by 764
Abstract
An accurate and numerically efficient description of the rolling process is a challenging task since the degree of computational accuracy is directly related to the complexity of the algorithm employed. In the most general case, finite element models (FEM) are used for the [...] Read more.
An accurate and numerically efficient description of the rolling process is a challenging task since the degree of computational accuracy is directly related to the complexity of the algorithm employed. In the most general case, finite element models (FEM) are used for the simulation of deformation processes; however, these techniques require significant computational time. Analytical approaches, which are suited for one or another deformation process, seem to be a proper alternative to FEM. In this study, the well-established flowline modeling approach (FLM) is extended with the aim of better describing the flow of a rolled material in both surface and subsurface regions. A new flowline function is defined, while the velocity along the particular streamline and strain rate gradients are determined analytically, based on the roll gap geometry. The new model is validated by comparing the velocity components to the ones computed by the finite element model. The distortion of meshes predicted by both FEM and FLM follow the same evolutionary pattern. Full article
(This article belongs to the Special Issue Numerical Simulation and Experimental Research of Metal Rolling)
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17 pages, 7638 KiB  
Article
Finite Element Simulation of Multi-Pass Rolling of a Pure Aluminum Target under Different Rolling Routes and Methods
by Chaoxin Qiu, Rui Xu, Xin Xu and Shengcan Ma
Metals 2024, 14(8), 845; https://doi.org/10.3390/met14080845 - 24 Jul 2024
Cited by 3 | Viewed by 1594
Abstract
By coordinating the rolling direction and mode, a multi-rolling plastic deformation process for an aluminum (Al) sputter target is proposed to achieve multiple excellent properties, including a uniform and fine grain structure and low defect risk, which are significant in producing high-quality sputtered [...] Read more.
By coordinating the rolling direction and mode, a multi-rolling plastic deformation process for an aluminum (Al) sputter target is proposed to achieve multiple excellent properties, including a uniform and fine grain structure and low defect risk, which are significant in producing high-quality sputtered films. In this work, therefore, DEFORM 3D 10.2 software is adopted to establish three strategies, clock-synchronous rolling, cross-synchronous rolling, and clock–snake rolling. The effect of different rolling routes and modes on the metal flow velocity (MFV), effective strain distribution (ESD), grain size distribution (GSD), damage, and rolling force (RF) are comparatively investigated. The simulation results show that clock–snake rolling can increase the MFV and effective strain by producing a deeper deformation than the others. It provides sufficient energy for dynamic recrystallization to promote grain refinement. In combination with the microstructure homogeneity promoted by the clock rolling route, the GSD from 6.5 to 44.3 μm accounts for about 80.5% of all the grains because of the fact that a randomly oriented grain region is full of high-angle grain boundaries. Compared with the synchronous rolling mode, the decrement in RF maximum reaches up to 51% during the asynchronous rolling process because component energy is consumed to form cross-sheering stress. It remarkably reduces the risk of defects, with a damage value of less than 73%, and simultaneously improves energy efficiency owing to smaller and uniform grains caused by less RF. The results obtained in this work are of great significance as they can guide practical production in the metal target industry. Full article
(This article belongs to the Special Issue Numerical Simulation and Experimental Research of Metal Rolling)
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18 pages, 13337 KiB  
Article
Numerical Simulation and Experimental Verification of Hot Roll Bonding of 7000 Series Aluminum Alloy Laminated Materials
by Wei Xu, Chengdong Xia and Chengyuan Ni
Metals 2024, 14(5), 551; https://doi.org/10.3390/met14050551 - 7 May 2024
Cited by 1 | Viewed by 1317
Abstract
In the present study, the hot roll bonding process of 7000 series aluminum alloy laminated materials was numerically simulated and investigated using the finite element method, and the process parameters were experimentally verified by properties testing and microstructure analysis after hot roll bonding. [...] Read more.
In the present study, the hot roll bonding process of 7000 series aluminum alloy laminated materials was numerically simulated and investigated using the finite element method, and the process parameters were experimentally verified by properties testing and microstructure analysis after hot roll bonding. In the roll bonding process of aluminum alloy laminated materials, the effects of the intermediate layer, pass reduction ratio, rolling speed and thickness ratio of component layers were studied. The results of finite element simulations showed that the addition of a 701 intermediate layer in the hot roll bonding process could effectively coordinate the deformation of the 705 layer and 706 layer and prevented the warping of the laminated material during hot rolling. It is recommended to use a multi-pass rolling process with small deformation and high speed, and the recommended rolling reduction ratio is 20%~30%, the hot rolling speed is 1.5~2.5 m/s and the thickness ratio of the 705 layer and 706 layer is about 1:5. Based on the above numerical results, five-layer and seven-layer 7000 series aluminum alloy laminated materials were prepared by the hot roll bonding process. The results showed that metallurgical bonding was realized between each component layer, and no delamination was observed from the tensile fracture between the interfaces of component layers. The tensile strength of the prepared laminated materials decreased with the increase in the thickness ratio of the 705 layer, and the bonding strengths of the laminated materials were in the range of 88–99 MPa. The experimental results verified the rationality of the process parameters recommended by the numerical simulations in terms of warping and delamination prevention. Full article
(This article belongs to the Special Issue Numerical Simulation and Experimental Research of Metal Rolling)
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