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Metals
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Advances in Metal Rolling Processes
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Advances in Metal Rolling Processes

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 April 2025 | Viewed by 6157

Special Issue Editor

Prof. Dr. Lipo Yang

E-Mail Website
Guest Editor
National Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao 066004, China
Interests: electro-plastic rolling; asynchronous rolling; foil rolling; difficult to deform alloy; high-performance material; flatness; size effect; cold/hot/warm rolling; shape detection and shape control

Special Issue Information

Dear Colleagues,

Rolling is considered to be one of the most efficient formation processes. It plays an important role in the automated production of many metal foils or strips. The shape and properties of material are important criteria used in the rolling process to evaluate strip quality. Therefore, many factors, such as the metal flow characteristics, the shape detection and control, the work hardening, as well as the size effect, must be researched in detail. According to these mechanisms, there may be opportunities for some better rolling methods. For example, asynchronous rolling, electro-plastic rolling, extrusion rolling, and warm rolling are often used to produce the foils of difficult-to-deform metals. All in all, newer and better processes should be continuously studied by researchers. This will contribute to the quick industrial application of key technologies and the industrialization of rolling products. All these aspects deserve special attention.

This Special Issue provides an excellent opportunity to publish theoretical and experimental studies on metal rolling, especially on alloy steel, magnesium alloys, amorphous alloys, high-entropy alloys, etc. Any new findings on this topic are welcome, such as metal flow rules in asynchronous warm/hot/cold rolling processes, microstructural evolution in special rolling processes, shape detection and shape control, etc.

Prof. Dr. Lipo Yang
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

  • cold rolling
  • hot rolling
  • warm rolling
  • electro-plastic rolling of alloy
  • asynchronous rolling
  • difficult to deform metals
  • size effect of foil
  • shape detection and shape control

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Published Papers (6 papers)

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Research

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10 pages, 2457 KiB  
Article
Research on the Prediction of Roll Wear in a Strip Mill
by Jianhua Wei and Aimin Zhao
Metals 2024, 14(10), 1180; https://doi.org/10.3390/met14101180 - 17 Oct 2024
Viewed by 545
Abstract
In the process of hot rolling silicon steel, roll wear directly affect its shape. Accurate prediction of roll wear is an important condition for rolling qualified silicon steel strips. The traditional roll wear prediction model is established by the slicing method. The wear [...] Read more.
In the process of hot rolling silicon steel, roll wear directly affect its shape. Accurate prediction of roll wear is an important condition for rolling qualified silicon steel strips. The traditional roll wear prediction model is established by the slicing method. The wear of F5–F7 work rolls used for finishing rolling silicon steel on a 2250 mm production line in a steel mill was predicted by this model. It was found that there was deviation between the predicted results and the actual wear, and the prediction accuracy of the model was insufficient. Therefore, the wear of the surfaces of the rolls used for rolling silicon steel on this production line was studied. Based on the analysis of the work roll wear’s form and the rolling parameters that affect the roll wear, the traditional roll wear prediction model was optimized by the genetic algorithm. Finally, the optimized model was verified, and the prediction accuracy of the wear prediction model improved. The accurate prediction results provide a basis for the formulation of a shape control strategy when rolling silicon steel on this production line. Full article
(This article belongs to the Special Issue Advances in Metal Rolling Processes)
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13 pages, 8166 KiB  
Article
Reduction of Elongation Anisotropy of Roll-Cast Strips by Cold Rolling and Annealing
by Toshio Haga
Metals 2024, 14(9), 965; https://doi.org/10.3390/met14090965 - 26 Aug 2024
Viewed by 520
Abstract
Roll-cast strips are usually cold-rolled and annealed before forming. The elongation of these strips is known to be different between the casting and lateral directions after thinning by cold rolling. Whether cold rolling is the main factor determining the anisotropy of the elongation [...] Read more.
Roll-cast strips are usually cold-rolled and annealed before forming. The elongation of these strips is known to be different between the casting and lateral directions after thinning by cold rolling. Whether cold rolling is the main factor determining the anisotropy of the elongation is not clear. Likewise, it is not clear whether the elongation anisotropy can be reduced by conventional cold rolling. Roll-cast strips have centerline segregation, forming a so-called band area. The relationship between the anisotropy of the elongation and these defects is not clear. A strip cast using an unequal-diameter twin-roll caster also has a band area but a strip cast using a single-roll caster equipped with a scraper has no centerline segregation or band area. Strips made this way were cold-rolled in the casting and lateral directions, and tensile testing was conducted on the cold-rolled and annealed strips. In this study, the ability of conventional cold rolling and one-time annealing to reduce the elongation anisotropy of a cast strip was clarified. Moreover, the influence of the band area and Fe impurities on the elongation anisotropy was determined. Full article
(This article belongs to the Special Issue Advances in Metal Rolling Processes)
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Graphical abstract

14 pages, 20687 KiB  
Article
Effect of Silicon on the Martensitic Nucleation and Transformation of 301 Stainless Steel under Various Cold-Rolling Deformations
by Jun Li, Yaji Li, Jian Wang and Peide Han
Metals 2024, 14(7), 827; https://doi.org/10.3390/met14070827 - 18 Jul 2024
Viewed by 983
Abstract
A systematic study was conducted on the influence of silicon on the microstructure, stress distribution, and martensitic nucleation and transformation of 301 metastable austenitic stainless steel during cold-rolling deformation. When the deformation amount of conventional 301 stainless steel is ≤20%, the amount of [...] Read more.
A systematic study was conducted on the influence of silicon on the microstructure, stress distribution, and martensitic nucleation and transformation of 301 metastable austenitic stainless steel during cold-rolling deformation. When the deformation amount of conventional 301 stainless steel is ≤20%, the amount of martensite transformation is very small. When the deformation amount is ≥30%, the amount of martensite transformation significantly increases. The introduction of Si significantly improves the amount of martensite transformation and the uniformity of deformation. 301Si-H has a significantly higher amount of martensite in the same deformation microstructure than conventional 301Si-L with a lower silicon content. Increasing the Si content decreases the stacking fault energy of 301 stainless steel. During deformation, Si tends to cluster at the grain boundaries, reducing stacking fault width and increasing dislocation density, creating sites for shear martensite nucleation at the grain boundaries. Simultaneously, significant deformation encourages the formation of deformation twins and facilitates martensite nucleation. Full article
(This article belongs to the Special Issue Advances in Metal Rolling Processes)
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16 pages, 6452 KiB  
Article
Dry, Cold Forging of Oxygen-Free Copper by Massively Nitrogen-Supersaturated CoCrMo Dies
by Tatsuhiko Aizawa, Tatsuya Funazuka and Tomomi Shiratori
Metals 2024, 14(7), 755; https://doi.org/10.3390/met14070755 - 26 Jun 2024
Viewed by 1140
Abstract
With the aim of achieving a sustainable society with green manufacturing, every metal-forming process has been changed to a dry process with the use of limited lubricants via regulation. In parallel, die materials must have sufficient wear resistance to prolong the die life [...] Read more.
With the aim of achieving a sustainable society with green manufacturing, every metal-forming process has been changed to a dry process with the use of limited lubricants via regulation. In parallel, die materials must have sufficient wear resistance to prolong the die life even when forming active metals. A massively nitrogen-supersaturated (MNSed) superalloy was selected as a galling-free die substrate to forge oxygen-free copper wires and bars in dry conditions. A plasma immersion nitriding system was utilized to induce nitrogen supersaturation in CoCrMo, forging dies at 723 K for 21.6 ks with a high nitrogen solute content. Microstructure analyses and microhardness testing proved that the MNSed CoCrMo die had a multilayered structure from the top surface to the depth and that the surface hardness increased up to 1300 HV. Dry, cold forging experiments demonstrated that the oxygen-free copper bar was upset, with a reduction in thickness of 70% in a single stroke under low friction. No fresh copper work debris adhered onto the MNSed CoCrMo die surface. The loading–stroke relationship was used to describe the forging behavior, with low friction and without galling. Full article
(This article belongs to the Special Issue Advances in Metal Rolling Processes)
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14 pages, 5024 KiB  
Article
The Coupled Temperature Field Model of Difficult-to-Deform Mg Alloy Foil High-Efficiency Electro-Rolling and Experimental Study
by Gengliang Liu, Jiaxuan Yang, Tianren Shan, Huaimei Li, Dianlong Wang and Lipo Yang
Metals 2024, 14(3), 343; https://doi.org/10.3390/met14030343 - 17 Mar 2024
Viewed by 1041
Abstract
In response to the challenging difficult-to-deform of magnesium foils, a high-efficiency and high-precision electro-rolling temperature field coupled model is established. This model is designed to simulate the non-annealing electric rolling (NAER) process of Mg foils under conditions of high current density, rapid temperature [...] Read more.
In response to the challenging difficult-to-deform of magnesium foils, a high-efficiency and high-precision electro-rolling temperature field coupled model is established. This model is designed to simulate the non-annealing electric rolling (NAER) process of Mg foils under conditions of high current density, rapid temperature rise rates, and large temperature gradients. Firstly, a coupled temperature field difference model for the guide roller, roll, and Mg foil is established, based on the equipment for NAER and the electrification conditions. The Joule heat, distortion heat, and friction heat in the electric rolling process were precisely considered. Secondly, considering the peculiarity of the heat source and the heat transfer mechanism during NAER, the influence of the dynamic boundary conditions on the instantaneous temperature of the Mg foil was analyzed, which was closer to the actual situation. The experimental results show that the original model can accurately simulate the transient temperature change in Mg foils during NAER, and the error between the predicted value and the measured value is within 7.1%. According to the calculation of the model, the microstructure of completely recrystallized magnesium foil with a grain size of 4.61 μm and a texture strength of 11.3 can be obtained at an inlet temperature of 250 °C. Full article
(This article belongs to the Special Issue Advances in Metal Rolling Processes)
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Review

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36 pages, 4623 KiB  
Review
Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels
by Dilifa Jossley Noronha, Sathyashankara Sharma, Raghavendra Prabhu Parkala, Gowri Shankar, Nitesh Kumar and Srinivas Doddapaneni
Metals 2024, 14(6), 667; https://doi.org/10.3390/met14060667 - 4 Jun 2024
Viewed by 1315
Abstract
The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI [...] Read more.
The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI 1040 steel. Key parameters such as the rolling force, feed rate, number of passes, and roller geometry are analyzed in detail, considering their influence on residual stress distribution, surface hardness, and microstructural alterations. Additionally, the impact of deep rolling on the fatigue life, wear resistance, and corrosion behavior of AISI 1040 steel is discussed. Engineering components manufactured by AISI 1040 steel can perform better and last longer when deep rolling treatments are optimized with an understanding of how process variables and material responses interact. This review provides critical insights for researchers and practitioners interested in harnessing deep rolling techniques to enhance the mechanical strength and durability of steel components across diverse industrial settings. In summary, the valuable insights provided by this review pave the way for continued advancements in deep rolling techniques, ultimately contributing to the development of more durable, reliable, and high-performance steel components in diverse industrial applications. The establishment of generalized standardizations for the deep rolling process proves unfeasible because of the multitude of controlling parameters and their intricate interactions. Thus, specific optimization studies tailored to the material of interest are imperative for process standardization. The published literature on the characterization of surface and subsurface properties of deep-rolled AISI 1040 steel, as well as process parameter optimization, remains limited. Additionally, numerical, analytical, and statistical studies and the role of ANN are limited compared with experimental work on the deep rolling process. Full article
(This article belongs to the Special Issue Advances in Metal Rolling Processes)
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