Lisong Zhu

With the advancement of welding technology, the demand for 70S-6 welding wire steel has steadily increased in industries such as construction, automotive, pressure vessels, and line pipe manufacturing. To optimize the production process of the target material, this study utilized the finite-element software ABAQUS to numerically simulate the multi-pass finish rolling process of 70S-6 welding wire steel. The study investigates the effects of the key rolling parameters—pass distribution (8/10/12 passes), finish rolling temperature (860/880/900 °C), and rolling speed (0.5 Vp/1.0 Vp/1.5 Vp, here Vp denotes the reference industrial rolling speed) on the rolling force, temperature field, and equivalent stress/strain during finish rolling. The results show that the increased number of passes homogenizes deformation, reduces local stress concentration and enhances mechanical properties. Specifically, 12 passes reduce the peak rolling force from 250,972 N to 208,124 N, significantly enhancing stress and temperature uniformity across the section. Increasing the finish rolling temperature lowers the pass-averaged flow stress and attenuates rolling-force fluctuations. At 880 °C, the simulated core–surface temperature gradient is minimal (50 °C), whereas at 900 °C the gradient increases (80 °C) but the rolling-force histories exhibit a lower peak level and smaller low-frequency oscillations; thus 880 °C is preferable when through-thickness thermal uniformity is targeted, while 900 °C is more suitable when a smoother load response is required. Increasing the finish rolling speed from 0.5 Vp to 1.5 Vp reduces the peak rolling force from 233,165 N to 183,665 N and significantly damps low-frequency load oscillations. However, it concurrently intensifies stress localization at the outer-surface tracking points P3/P4, which are in direct contact with the rolls, where the local equivalent stress approaches 523 MPa, even though the overall strain distribution along the bar length becomes more uniform. Overall, the optimal processing window is identified as a 12-pass schedule, a finish rolling temperature of 880–900 °C, and a rolling speed of 1.0–1.5 Vp, which can improve both rolling quality and temperature and stress and strain uniformity.

Stainless steel is essential in high-performance industries due to its strength, corrosion resistance, and biocompatibility. However, conventional manufacturing methods limit material efficiency, design complexity, and customization. Additive manufacturing (AM) has emerged as a powerful alternative, enabling the production of stainless-steel components with complex geometries, tailored microstructures, and integrated functionalities. Key AM methodologies, including laser powder bed fusion (L-PBF), binder jetting, and directed energy deposition (DED), are evaluated for their effectiveness in producing stainless-steel components with optimal performance characteristics. This review highlights innovations in stainless-steel AM, focusing on microfabrication, multi-material approaches, and post-processing strategies such as heat treatment, hot isostatic pressing (HIP), and surface finishing. It also examines the impact of process parameters on microstructure, mechanical anisotropy, and defects. Emerging trends include AM-specific alloy design, functionally graded structures, and AI-based control. Applications span biomedical implants, micro-tooling, energy systems, and automotive parts, with emphasis on microfabrication for biomedical micromachines and precision microforming.

This study investigates the forming process (stamping) of bipolar plates which have applied a novel ultra-thin (0.1 mm) super ferritic stainless steel, i.e., SUS470, whose chromium is sufficiently high for corrosion resistance. A three-dimensional finite element model of the stamping process was developed using the commercial software ABAQUS version 2022. The model incorporated optimized die parameters obtained through Central Composite Design (CCD). This model was used to analyze the effects of key forming parameters, including stamping speed and friction coefficient, on the distribution of stress, strain, and thickness reduction during the stamping process. The finite element modeling (FEM) results disclose that the inner corner of the flow channel is a critical defect-prone region, exhibiting stress concentration, uneven strain distribution, and severe thinning. The optimal forming quality can be achieved at a stamping speed of 100 mm/s and a friction coefficient of 0.185 among all varied options. Further, a comparative study of single-stage, conventional two-stage, and optimized two-stage stamping strategies based on previous investigation demonstrates that the optimized two-stage stamping process can effectively alleviate stress and strain concentrations at the corners, significantly reduce thinning problems, and enhance the uniformity and stability during stamping. In summary, this study provides theoretical support for the design of the forming process (stamping) of high-performance super ferritic stainless steel bipolar plates, which is beneficial to subsequent practical engineering application.