Xianghua Liu

Under the background of dual carbon policy as well as energy conservation, blanks with variable thicknesses (BVTs) which act as structural components have drawn extensive attention due to their excellent strength and formability and reasonable load-bearing distribution characteristics, particularly in the field of automotive manufacturing. With these advantages, the manufacturing technologies of these plates using more efficient rolling methods have thus emerged. This article summarizes four methods and their characteristics for manufacturing plates with variable thicknesses based on rolling technology. In addition, a review is conducted on the latest research progress of the metal flow and rolling theories of existing plates with different thicknesses in the longitudinal and transverse direction.

In normal cold rolling, the elastic deformation of the strip is typically ignored because of the dominant plastic deformation. However, this neglect may introduce additional errors when the strip is very thin. The aim of this study is to investigate the characteristics of the deformation region and thickness reduction in the asymmetrical rolling of ultra-thin strips. Mathematical models were developed based on the slab method, with consideration of the elastic deformation of the strips, and employed in the simulation calculation. The percentage of the three zones and the thickness reduction were analyzed using the simulation results. An increase in the speed ratio results in an increase in the reduction ratio, which is influenced by parameters, such as front tension, back tension, friction coefficient, and entry thickness. The elastic deformation of the strip reduces the tension and the roll pressure and causes the reduction ratio to decrease. The findings and conclusions of this study may be helpful to the mill operating in the asymmetrical rolling process of ultra-thin strips.

The cellular automata (CA) method has played an important role in the research and development of metallic materials. CA can interpret the microstructure changes of materials and obtain more abundant, accurate and intuitive information of microstructure evolution than conventional methods. CA can visually represent the process of grain formation, growth, development and change to us in a graphical way, which can assist us in analysis, thinking and solving problems. In the last five years, the application of CA in materials research has been rapidly developed, and CA has begun to occupy an increasingly important position in the simulation research of metallic materials. After introducing the advantages and limitations of CA compared to other widely used simulation methods, the purpose of this paper is to review the recent application progress on the microstructure simulation of metallic materials using CA, such as solidification, recrystallization, phase transformation and carbide precipitation occurring during forming and heat treatment. Specifically, recent research advances on microstructure simulation by CA in the fields of additive manufacturing, welding, asymmetrical rolling, corrosion prevention, etc., are also elaborated in this paper. Furthermore, this paper points out the future work direction of CA simulation in the research of metallic materials, especially in the simulation of the crystal structure, the prediction of mechanical properties, CA simulation software and rule systems, etc. These are expected to attract wide attention of researchers in the field of metallic materials and promote the development of CA in materials research.

This paper presents an investigation on the forming characteristics of the tailor rolled blank of an aluminum alloy (Al-TRB) during three-point bending at room temperature through experiments and finite element simulations. The strain distribution, spring-back characteristics, and metal flow law of 6000 series Al-TRB during three-point bending are explored. The prepared Al-TRB has good bending properties, and no surface cracks appear in the bending region of the Al-TRB when bent to 180°. Surface roughening occurs on the outside of the bending region. Since the strain in the thick zone is greater than that in the thin zone, the surface roughening in the thick zone is more obvious than that in the thin zone. The spring-back angle in the thin zone is higher than that in the thick zone after three-point bending, and the overall spring-back angle of Al-TRB becomes larger with an increasing bending angle. When the transition zone of Al-TRB is centered and the length of the transition zone is certain, as the length of the equal-thickness zone increases, the spring-back angle of the thin zone is larger, while the spring-back angle of the thick zone is smaller. Under the premise of a certain total length of Al-TRB and the length of the transition zone, the larger the length proportion of the thin zone, the larger the overall spring-back angle of Al-TRB, and the larger the length proportion of the thick zone, the smaller the overall spring-back angle of Al-TRB. In addition, a slight metal flow phenomenon exists during three-point bending, which shows that the metal in the bending region will flow to the thick zone, and the metal at the edge will flow to the thin zone. At the same time, there are localized thickening and thinning phenomena in Al-TRB. This study is helpful because it provides theoretical guidance for designing molds for the actual production of Al-TRB parts for automotives.

A prediction model for the outlet temperature of magnesium alloy strips in the process of heated-roll rolling was established by using linear fitting and nonlinear regression methods. By inputting the rolling parameters into the model, the outlet temperature of the strip can be accurately predicted, which will then optimize and regulate the properties and microstructures of the magnesium alloys in the rolled form. To verify the reliability of the model, heat transfer experiments of the magnesium alloy rolled by heated rolls were carried out. The results show that under the same conditions, the actual outlet temperature measured experimentally matches well with the outlet temperature predicted by the model, and the relative error is kept within 10%. In the modeling process, Deform V11.0 software was used to simulate the thermal–mechanical behavior of the magnesium alloy rolled by the heated roll. In the process of analyzing the simulated heat transfer, it was found that the temperature rise of the surface and the core is divided into three identical stages: the slow rise, the fast rise, and the thermal equilibrium stages. In addition, the mechanical behavior of the rolling deformation zone was also analyzed, and the strip was subjected to direct heat transfer from the heated rolls during the hot rolling process so that the softening played a major role and the stress value gradually decreased from the middle of the deformation zone to the inlet end and the outlet end. This is so that it can be known that the process of being rolled by the heated rolls not only improves the rolling efficiency, but also ensures the deformation temperature and obtains fine grains.

Mechanical parameters, time consumption and energy consumption are important considerations in the application of a certain rolling process. This study aims to investigate characteristics of the roll force, roll torque, roll power, rolling time and total work in multi-pass asymmetrical rolling of strip. Mathematic models were built using the slab method to calculate parameters in the asymmetrical rolling process, and the characteristics of these parameters were analyzed on the basis of simulation results. Mechanical parameters are affected by the change of deformation region type. When the speed ratio is less than the critical speed ratio, the roll force, absolute values of roll torque and roll power are found to increase with the increase in the speed ratio. After the speed ratio reaches the critical speed ratio, the roll force, roll torque and lower roll power keep constant, but the upper roll power continues increasing. The upper roll torque and upper roll power required by asymmetrical rolling are much greater than that by symmetrical rolling, which indicates that stronger drive shafts and more powerful drive motors are required by asymmetrical rolling. Compared with symmetrical rolling, asymmetrical rolling requires less roll force to obtain the same thickness reduction, especially for thin and hard strips. Rolling time can be saved at the cost of more energy consumption by using asymmetrical rolling with the same roll force to attain the same final thickness. The results and conclusions of this study can provide a reference for mill design and application of asymmetrical rolling in strip manufacturing.

SiC particle-reinforced Ti/Al/Ti clad plates were successfully fabricated by the powder-in-tube method. The surface micrography, element diffusion, peeling strength and tensile property of clad plates were studied after annealing and cold rolling. The experimental results show that 6 wt.% is optimal. The presence of SiC particles has been seen to significantly enhance the diffusion of Ti and Al elements. Additionally, it has been observed that the diffusion width of the intermetallic compound (IMC) increases as the size of SiC particles grows. However, it is worth noting that the average of Ti/Al–SiC/Ti clad plates initially increases and subsequently falls. The optimized diffusion thickness of the Ti/Al–SiC/Ti clad plate’s IMC layer determined via the powder-in-tube method is approximately 4.5 μm. The 1 μm SiC-reinforced Ti/Al/Ti clad plate can obtain the best mechanical properties after annealing at 500 °C and further hot rolling, and the peeling strength, ultimate tensile strength and elongation are 31.5 N/mm, 305 MPa and 26%, respectively. The efficacy of Ti/Al–SiC/Ti clad plates in delivering exceptional performance is substantiated by the analysis of peeling surfaces, peeling tests and tensile testing, which collectively demonstrate the presence of compact and homogenous intermetallic compounds.

Al-Si coated press-hardened steel (PHS) is widely used along with the development of light-weight vehicles, and the tailor-rolled blank parts based on Al-Si coated PHS have attracted much attention. The preparation process includes cold rolling, austenitization, hot-stamping, and quenching. The most widely used AS60/60 coating will change after cold rolling and austenitization, which has been little-studied. Herein, the effects of cold rolling reduction on the microstructure, thickness, adhesive force of AS60/60 coating and on bending toughness of AS60/60 coated PHS were studied. As the cold rolling reduction ratio increased from 0% to 50%, the coatings were gradually thinned, but the overall continuity was unchanged. When the reduction ratio was 40% or above, rapid diffusion channels were formed. The adhesive force of coatings was 21.50–22.15 MPa. After austenitization, the coating thickness gradually decreased as the cold rolling reduction ratio rose from 0% to 50%, but the structure and overall continuity were both unchanged, and the adhesive force was 21.60–22.40 MPa. The rapid diffusion channels promoted the transition from brittle Fe2Al5 to tough FeAl during austenitization, leading to a rapid increment in bending toughness after Al-Si coated PHS was quenched. When the reduction ratio was 50%, the bending angle was improved by 23%.

Static recrystallization is a method of tailoring the microstructure and mechanical properties of steels, which is important for microalloyed forging steels as the hot deformation process significantly affects their mechanical properties. In this paper, the static recrystallization behavior of a low-carbon Nb-V-microalloyed forging steel was investigated by double-pass hot compression tests at deformation temperature of 800–1100 °C and interruption time of 1–1000 s. The static recrystallization fractions were determined using the 2% offset method. The static recrystallization activation energy and the static recrystallization critical temperature (SRCT) of the experimental steel were determined. When the deformation temperature was higher than the SRCT, the recrystallization fraction curve conformed to the Avrami equation. When the deformation temperature was below the SRCT, the recrystallization curve appeared to plateau, which was caused by strain-induced precipitation. Before and after the plateau, the static recrystallization kinetics still obeyed the Avrami equation.

A series of mathematical models were proposed to calculate the roll force, torque and power for cold strip asymmetrical rolling by means of the slab method, taking the percentages of the forward-slip, backward-slip and cross-shear zones into account. The friction power, plastic work and total energy consumption can be obtained by the models. The effects of variable rolling parameters—such as the speed ratio, entry thickness, friction coefficient and front and back tension—on the process of asymmetrical rolling are analyzed. In all cases, an increase in speed ratio leads to an increase in friction work and its proportions. The increase in entry thickness and deformation resistance causes both friction work and plastic deformation work to increase. The proportion of friction work decreases with increasing deformation resistance, entry thickness, front tension and back tension. In the circumstances of a thin strip being rolled with a large speed ratio, the proportion of friction work could exceed that of plastic deformation work. The concept of a threshold point of friction work was proposed to explain this phenomenon. As an example, threshold points T1, T2, T3 with the effect of the entry thickness and S1, S2, S3 with the effect of the friction coefficient have been obtained by computation. Finally, the experiment of the strip asymmetrical rolling was conducted, and a maximum error of 9.7% and an RMS error of 5.9% were found in the comparison of roll forces between experimental measurement values and calculated ones.