Influence of Longitudinal Scratch Defects on the Bendability of Titanium Alloy

Post-manufacturing induced defects in the form of scratches are sometimes inadvertently introduced onto sheet metal surfaces during either transportation, storage or handling. However, limited research has been previously carried out to establish the impact of such surface defects on sheet formability. Test trial results after press brake forming of Ti-3Al-2.5V showed that for longitudinal scratches oriented along the sheet rolling direction, scratch profiles with depth in the ranges of -1μm to -18μm and pile up height between 1μm to 16μm can be successfully formed; hence could be deemed acceptable during the sheet selection process. Failure of the coupons during the press brake forming trials was due to the impact of the scratch defects in their role as stress raisers and occurred primarily at the longitudinal scratch defect zones

Recognition of surface defects of rolled steel in sheets by application micro-X-ray spectral analysis

Surface defects of sheet rolled products have a significant impact on its quality, performance and further processing of products, for example, on application of a protective anticorrosive coating. Therefore, the elimination of such defects and their accurate identification is an important aspect of sheet rolling production. Reducing the rejection of metal for surface defects enables to get a significant technical and economic effect. Investigation of the causes of defectiveness of the surface of sheet rolled products will make it possible to determine the source of the appearance of the defects and methods to prevent them. Determination of the nature and morphology of surface defects, the sources of which being metallic and non-metallic inclusions, as well as remnants of slag surface layer, scales from metallurgical and rolling stages, rolled into the surface of a hot-rolled sheet, is often difficult, since the appearance of the defects is very similar. It was shown that application of a scanning electron microscope (SEM) with micro-X-ray spectral analysis (MXSA), thermodynamic analysis makes it possible to determine the chemical composition of micro-areas and associate it with the end-to-end technology of sheet production. The article presents the results of identifying surface defects of cold-rolled sheet steel.

Stochastic Method to Predict Effects of Roll Grinding Deviations on Sheet Flatness in Cold Rolling

Industrial measurements of the diameter profiles of work-rolls used in cold sheet rolling are applied with a stochastic roll-stack model to better understand how residual error from the roll grinding process affects the rolled sheet flatness quality. Roll diameter measurements taken via a non-contact, optical device on new, warm, and worn work-rolls show that the diameter deviations vary along the roll lengths, across roll samples, and at different operational states, suggesting a multi-dimensional random field problem. Studies are conducted for a 4-high rolling mill with 301 stainless steel sheet to investigate the reliability in achieving target flatness considering the work-roll diameter random field. Also investigated is the sensitivity of the flatness reliability to roll diameter deviations at different locations along the roll lengths, and for the three operational states (newly machined, warm, and worn following several passes). The results lead to several key findings. Foremost, it is shown that an assumption of statistical independence among the residual grinding errors at different roll axis locations is improper. Further, it is demonstrated that, for the measured grinding error correlation patterns, the roll diameter deviations external to the roll/sheet contact region play an important role in contributing to flatness defects within the sheet, and that these influences vary according to the roll operational state (new, warm, worn). The presented stochastic model and applied measurement data thus provide for a new understanding into how roll grinding performance influences dimensional quality in the sheet rolling process.

Modelling of Friction Phenomena Existed in Drawbead in Sheet Metal Forming

The article presents the results of friction tests of a 0.8 mm-thick DC04 deep-drawing quality steel sheet. A special friction simulator was used in the tests, reflecting friction conditions occurring while pulling a sheet strip through a drawbead in sheet metal forming. The variable parameters in the experimental tests were as follows: surface roughness of countersamples, lubrication conditions, sample orientation in relation to the sheet rolling direction as well as the sample width and height of the drawbead. Due to many factors that affect the value of the coefficient of friction coefficient, artificial neural networks (ANNs) were used to build and analyse the friction model. Four training algorithms were used to train the ANNs: back propagation, conjugate gradients, quasi-Newton and Levenberg–Marquardt. It was found that for all analysed friction conditions and sheet strip widths, increasing the drawbead height increases the COF value. The chlorine-based Heavy Draw 1150 compound provides a more effective friction reduction compared to a LAN-46 machine oil.

Dynamic Characteristics of a Multimotor Electric Motor Multichannel Control System, Taking Into Account the Elasticities of Mechanical Transmitters

The study of the dynamic characteristics of two- and three-engine thyristor electric motors with constant current, in the case of a multi-motor control system, taking into account the elasticity of mechanical shafts are reviewed in this article. Such multimotor control systems are widely used in metallurgical production. For example, in sheet rolling mills, where in the mechanical part there are moments of significant dynamic curvature. The paper also reviews the functional and structural schemes of a cohesive multi-engine system. In the case of a multi-motor touring electric motor system, the structural scheme of a two-engine drive was studied in order to determine the correct load distribution. The study was conducted using a computer program - MATALAB using 150 kW and 300 kW engines. A Kalman filter-like observation device is used to quench the binding oscillations generated in the system. The quality indicators obtained from the transient mode studies are close to the optimal parameters, so the considered system is suitable for multi-motor rolling mills.

Asymmetric (Hot, Warm, Cold, Cryo) Rolling of Light Alloys: A Review

Asymmetric sheet rolling is a process used when there are differences in any technological parameters in the horizontal plane across the width of the deformation zone or in the vertical plane between the top and bottom surfaces of the deformation zone. Asymmetry can either have random causes, or it can be created purposefully to reduce rolling force, improve sheet flatness, minimize the ski effect, obtain thinner sheets and for grain refinement and improvement of texture and mechanical properties of sheet metals and alloys. The purpose of this review is to analyze and summarize the most relevant information regarding the asymmetric (hot, warm, cold, cryo) rolling processes in terms of the effect of purposefully created asymmetry on grain size and mechanical properties of pure Mg, Al, Ti and their alloys. The classification and fundamentals of mechanics of the asymmetric rolling process are presented. Based on the analysis of publications related to asymmetric rolling, it was found that a superior balance of strength and ductility in pure Mg, Al, Ti and their alloys could be achieved due to this processing. It is shown that asymmetric rolling in comparison with conventional severe plastic deformation methods have an undeniable advantage in terms of the possibility of the production of large-scale sheets.

Coupled Thermomechanical Response Measurement of Deformation of Nickel-Based Superalloys Using Full-Field Digital Image Correlation and Infrared Thermography

The paper is devoted to highlighting the potential application of the quantitative imaging technique through results associated with work hardening, strain rate and heat generated during elastic and plastic deformation. The aim of the research presented in this article is to determine the relationship between deformation in the uniaxial tensile test of samples made of 1-mm-thick nickel-based superalloys and their change in temperature during deformation. The relationship between yield stress and the Taylor–Quinney coefficient and their change with the strain rate were determined. The research material was 1-mm-thick sheets of three grades of Inconel alloys: 625 HX and 718. The Aramis (GOM GmbH, a company of the ZEISS Group) measurement system and high-sensitivity infrared thermal imaging camera were used for the tests. The uniaxial tensile tests were carried out at three different strain rates. A clear tendency to increase the sample temperature with an increase in the strain rate was observed. This conclusion applies to all materials and directions of sample cutting investigated with respect to the sheet-rolling direction. An almost linear correlation was found between the percent strain and the value of the maximum surface temperature of the specimens. The method used is helpful in assessing the extent of homogeneity of the strain and the material effort during its deformation based on the measurement of the surface temperature.

Elemental Characteristics and Source-Apportionment of PM2.5 During the Post-monsoon Season in Delhi, India

In this study, we have coupled measurements, modeling, and remote sensing techniques to better delineate the source characteristics and variability of air pollutants in Delhi primarily during the post-monsoon season in 2019. We show a comparison of ambient PM2.5 (particulate matter having aerodynamic diameter ≤2.5 μm) levels and associated elements during the post-monsoon with those during a relatively clean season of monsoon (experiencing frequent wet precipitation). Air-mass back trajectories from Hybrid Single-Particle Lagrangian Integrated Trajectory (HYSPLIT) model have been used to infer the possible source pathways of PM2.5 impacting at the receptor site in Delhi. The average concentrations of PM2.5 during monsoon (June–July) and post-monsoon (October–November) were 42.2 ± 15.5 μg m−3 (range: 22–73 μg m−3) and 121.4 ± 53.6 μg m−3 (range: 46–298 μg m−3), respectively. The PM2.5 samples were analyzed for heavy and trace elements (Si, S, Na, Mg, Al, Cl, Ca, K, Ti, V, Cr, Mn, Fe, Ni, Cu, Br, Rb, Zr, and Pb) using an Energy Dispersive X-ray Fluorescence (ED-XRF) technique and their concentrations have been used to carry out the source-apportionment utilizing principal component analysis (PCA) tool. The PCA analysis has identified three major sources of fine aerosols including contributions from the sources viz. vehicular emission, biomass burning, coal combustion, secondary aerosols formation, soil dust, solid-waste burning and industrial emission. The source involving biomass burning contributed largely to the PM2.5 in post-monsoon season through long-range transport of large-scale agriculture-residue burning emissions (occurring in the states of Punjab, Haryana, and western part of Uttar Pradesh). The industrial emissions include primarily, medium- and small-scale metal processing industries (e.g. steel sheet rolling) in Delhi-National Capital Region. Traces of emission from coal based thermal power plants and waste incineration have also been observed in this study.

Simulation of Process Rolling Plates from Alloy of Al-Mg System Economically Doped with Scandium

The modes of hot and cold rolling of plates from an alloy of the Al-Mg system alloy, doped with scandium in the range of 0.10-0.12%, are modeled. At the first stage of work, using the DEFORM-3D software package, we simulated the process of hot sheet rolling at the Quarto 2800 mill, in order to obtain a billet for further cold rolling. Analysis of the simulation data showed that with the adopted compression mode, the metal forming and temperature conditions of rolling make it possible to obtain plates up to 45 mm thick, without defects, with rational power loading of the equipment. Further modeling of the regime of cold rolling of plates with a thickness of up to 31.5 mm showed that cold rolling can be carried out in 4 passes, provided that the stress and rolling force do not exceed the permissible values. At the second stage of work, we conducted an experimental verification of the obtained simulation results both in industrial and in laboratory conditions. It was found that the value of the total compression leading to the destruction of the samples, depending on the rolling conditions, should not exceed 21-30%. At this degree of deformation, the rolled metal from the alloy under study has high strength and plastic properties. Subsequent industrial verification of the research results confirmed that this alloy is quite advanced technologically, while it has high deformability, both during hot and cold rolling, which allows us to recommend it for sheet deformed semi-finished products in the manufacture of structural products for various purposes.