Search Results (6)

To resolve the challenges of weak bonding interface and to avoid expensive and time-consuming trials, integrated computational materials engineering (ICME) was applied to study the hot roll bonding and forming of ultra-thick 45 steel stacked assemblies (>60 mm) and to optimize the rolling processes. Microstructure and properties of the continuous cast slabs of 45 steel subjected to heating and forming were acquired from JMatPro V13.2 calculations and essential experimental validations. Interfacial bonding criteria were established from hot compression tests and were applied to the finite element simulations of the multi-pass rolling processes of a two-slab stacked assembly and a three-slab stacked assembly to predict the bonding of interior interfaces and the deformation of the plates. Unlike previous studies, the aim of this research is to apply the concept of integrated computational materials engineering to shorten the development cycle and reduce re-search costs. The results revealed that the compressive strain of 0.05 is sufficient to form metallurgical bonding at the interface for machined 45 steel in a vacuum. Finite element simulation results indicate that complete bonding of the interfaces is established after two passes for the two-slab stacked plate and four passes for the three-slab stacked plate. Optimized rolling process parameters from analyzing the finite element simulation results are applied to design the hot rolling process of the stacked slab assemblies to produce ultra-thick plates. By applying the concept of integrated computational materials engineering, the development cycle of product processes can be significantly shortened, and financial investment can be reduced. Full article

This work involves studying the effects of applying various designed hot-rolling strategies, using the uniaxial hot compression regimes of the Gleeble 3500 thermo-mechanical simulator on the microstructure, flow behavior, and productivity of Ti-6Al-4V alloy. These strategies were then practically implemented using a rolling mill to produce finished sheets with a thickness of 3 mm. The tensile properties of these finished Ti-6Al-4V sheets were examined, aiming at attaining the optimum rolling strategy conditions that result in upgrading the mechanical performance of the alloy. The undertaken hot-rolling strategies can be divided into two main groups; both comprise applying a total amount of deformation of 75% at a constant strain rate of 0.1 s⁻¹. The first group, isothermal hot rolling regime (IR), includes three strategies and involves applying the total amount of deformation at constant temperatures, i.e., 900, 800, and 750 °C. The second group, non-isothermal hot rolling regime (NIR), includes three strategies and involves partitioning the total amount of deformation into multi-step deformation at variable temperatures in a range of 900–750 °C. The dynamic flow softening is dominant in all IR strategies after the flow stress attains the peak at a low strain value. Then, dynamic flow softening occurs due to the dynamic recrystallization and α phase spheroidization, while a combination of flow softening and hardening takes place on the different passes of the NIR strategies. The designed hot-rolling strategies result in finished sheets with a fine multimodal microstructure that fructifies different mechanical properties that can be employed for different industrial purposes. Full article

To further improve the comprehensive performance of Mg-based alloy, hot extrusion combined with multi-pass equal channel angular pressing (ECAP) was applied to process Mg-3 wt%Zn-0.2 wt%Ca alloy and 1 wt%β-TCP/Mg-3 wt%Zn-0.2 wt%Ca biocomposites. The microstructure evolution, mechanical properties, corrosion behavior, and cell biocompatibility of the experimental specimens were systematically investigated. The average grain size of 13.4 ± 0.6 μm in MgZnCa alloy and 9.6 ± 0.3 μm in composites materials can be achieved by six ECAP passes. The uniaxial compressive strength (UCS) of 388.4 ± 7.3 MPa and the strain at failure of 14.3 ± 1.5% were confirmed in MgZnCa alloy, while the UCS of 405.3 ± 7.4 MPa and the strain at failure of 9.8 ± 1.9% were achieved by the addition of β-TCP after six ECAP passes. In spite of different compositions, the minimum corrosion rate of 0.895 mm·Y⁻¹ and 1.117 mm·Y⁻¹ can be achieved by two ECAP passes at 593 K. The cytocompatibility evaluation revealed that the experimental materials processed by six ECAP passes had no significant cytotoxicity to L929 cells, and the addition of β-TCP improved the cytocompatibility. Full article

The two-pass thermal compression behavior of near-β Ti-55511 alloy was investigated. The first-pass restoration mechanisms changed from dynamic recrystallization (DRX) to dynamic recovery (DRV) as the first-pass deformation temperature increased from 700 °C to 850 °C. The occurrence of recrystallization reduced the dislocation density, resulting in a slower grain growth rate in the subsequent process. Because of the static recrystallization (SRX) and β grain growth, the β grain size increased and the morphology became less uniform during the subsequent β holding process, which also changed the restoration mechanism during second-pass compression. The level of continuous dynamic recrystallization (CDRX) and discontinuous dynamic recrystallization (DDRX) become weaker during second-pass deformation. The changes in the restoration mechanism and the microstructures slightly increased the peak stress during the second-pass deformation. Full article

This paper proposes the novel idea of eliminating the front-end converters used indirect current (DC) bus voltage variation, thereby allowing for control of the speed of the brushless direct current (BLDC) motors in the two-quadrant operation of a permanent magnet brushless direct current (PMBLDC) motor, which is required for multiple bi-directional hot roughing steel rolling mills. The first phase of steel rolling, the manufacture of plates, strips etc., using hot slabs from the continuous casting stage, is carried out for thickness reduction, before the same is sent to the finishing mill for further mechanical processing. The hot roughing process involves applying high, compressive pressure, using a hydraulically operated mechanism, through a pair of backup rolls and work rolls for rolling. Overall, the processes consist of multiple passes of forward and reverse rolling at increasing roll speeds. The rolling process was modeled, taking into account parameters like roller dimensions, angle and length of contact, and rolling force, at various temperatures, using actual data obtained from a steel mill. From this data, speed and torque profiles at the motor shaft, covering the entire rolling process, were created. A profile-based feedback controller is proposed for setting the six-pulse inverter frequency and parameters of the pulse width modulated (PWM) waveform for current control, based on Hall sensor position, and the same is implemented for closed loop operation of the brushless direct current motor drive system. The performance enhancement of the two different controllers was also evaluated, during the rolling of 1005 hot rolled (HR) steel, and was taken into consideration in the research analysis. The entire process was simulated in the MATLAB/Simulink platform, and the results verify the suitability of an entire-drive system for industrial steel rolling applications. Full article

Isothermal interrupted hot compression tests of 5754 aluminum were conducted on a Gleeble-3500 thermo-mechanical simulator at temperatures of 350 °C and 450 °C, and strain rates of 0.1 s⁻¹ and 1 s⁻¹. To investigate the metadynamic recrystallization behavior, a range of inter-pass delay times (5–60 s) was employed. These tests simulated flat rolling to investigate how softening behaviors respond to controlled parameters, such as deformation temperature, strain rate, and delay times. These data allowed the parameters for the hot rolling process to be optimized. The dynamic softening at each pass and the effect of metadynamic recrystallization on flow properties and microstructural evolution were analyzed in detail. An offset yield strength of 0.2% was employed to calculate the softening fraction undergoing metadynamic recrystallization. A kinetic model was developed to describe the metadynamic recrystallization behaviors of the hot-deformed 5754 aluminum alloy. Furthermore, the time constant for 50% recrystallization was expressed as functions related to the temperature and the strain rate. The experimental and calculated results were found to be in close agreement, which verified the developed model. Full article