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In this paper, oil-in-water (O/W) based nanolubricants containing TiO 2 nanoparticles were developed to reduce the rolling force and improve the surface quality of rolled 304 stainless steel product. Practical hot rolling tests with and without application of lubricant were conducted to systematically investigate the effects of the developed O/W based nanolubricants on the rolling force, surface roughness, oxide scale thickness and tribological behaviour. The obtained results indicate that the nanoparticles can enter the deform zone with oil droplets to take a lubrication effect. The optimal lubrication effect can be achieved when the O/W (1% oil mass fraction) based nanolubricant with a TiO 2 mass fraction of 1.5% was applied. The microstructure of oxide scales formed on the hot rolled sample was not significantly affected by TiO 2 nanoparticles in the O/W based lubricant, but the oxide scale growth could be induced by TiO 2 nanoparticles. A discontinuous thin SiO 2 layer at the substrate-scale interface was observed. It can effectively reduce the formation of iron-rich oxides. The novel nanolubricant has a great potential to be applied in the hot steel rolling, to realise the cost-effective and environmental-friendly manufacturing process. [ABSTRACT FROM AUTHOR]

The tribological behavior of traditional oil-in-water (O/W) lubricants (1.0 wt.%) and nano-TiO2 additive lubricants (1.0–9.0 wt.%) during micro rolling of titanium foils were analyzed. In this study, the surface morphologies of titanium foils under various lubrication conditions were assessed, and the corresponding lubrication mechanisms were revealed. The tribological behavior of nano-TiO2 additive lubricants during micro rolling of titanium foils was also explored through a series of characterization methods. The utilization of nano-TiO2 additive lubricants in micro rolling reduces the surface roughness of titanium foils. Moreover, it effectively inhibits the generation of indentations and cracks during rolling processes, enhancing the surface quality of rolled specimens. Additionally, owing to the synergism of rolling, tribo-film, mending and polishing effects of the nanoparticles, both the rolling force and surface roughness were minimized by using lubricants containing 3.0 wt.% TiO2 nanoparticles. Overall, an optimal concentration (3.0 wt.%) of TiO2 nanoparticles in water-based nanolubricants was obtained with enhanced tribological properties and lubrication performance during micro rolling of titanium foils. [ABSTRACT FROM AUTHOR]

Corrugated rolling is one of the metal forming processes using corrugated rolls to machine hard-to-deform metals, which leads to problems of high friction and severe wear. Lubricants are essential to reduce rolling forces, extend the life of corrugated rolls, and improve efficiency. In this work, a comparison of the surface quality of copper plates after corrugated rolling adopting different lubrication conditions (dry condition, O/W lubricant, TiO2 water-based nanolubricants) was made to explore the tribological behavior and lubricant mechanism of water-based nanolubricant during the corrugated rolling of copper plates. The results show that the 3.0 wt.% water-based nanolubricant exhibits excellent lubrication performance, and the maximum rolling force is reduced by 21.49% compared with the dry condition. Additionally, the effect of reduction on the surface quality of corrugated rolled copper plates was explored. The surface roughness at the peak position of the copper plate increased gradually with increasing reduction, and the surface roughness at the trough position showed little change, which was mainly caused by the synergistic effect of the roughness transfer and the high-strain hardening at the trough position of the copper plate. Overall, an optimal concentration of 3.0 wt.% water-based nanolubricant exhibits the best properties in terms of reducing the rolling forces and improving the surface quality of the rolled copper plates during corrugated rolling processes. [ABSTRACT FROM AUTHOR]

• Crystal plasticity finite element model exhibits higher accuracy in evaluation of surface roughness and thickness distribution of cups fabricated by micro deep drawing. • The magnitude of surface roughness S z is almost linearly dependent on the average grain size of austenitic stainless steel foils. • The brass components are beneficial to the formation of drawn cups with uniform thickness distribution and the absence of severe defects. The present work involves the numerical simulation and experimental study on the surface roughness evolution and heterogeneous plastic deformation (strain localization and concomitant surface morphology evolution) in grain scale of micro deep drawn parts of austenitic stainless steel (ASS) 304 foils. A three-dimensional modeling framework was used to simulate the micro deep drawing (MDD) process. The simulation involved the development of a Voronoi-based polycrystalline geometry model (VPGM), a multi-stress-strain response model, and a crystal plasticity finite element methods (CPFEM) model. The results indicate that CPFEM model exhibits higher accuracy in the localized stress and strain, thickness distribution fluctuation and surface roughness evolution of the fabricated parts compared to multi-stress-strain response model. Therefore, the plastic deformation heterogeneity in MDD is in-depth discussed based on CPFEM model. The results show that the coarse-grained foils correspond to the intense strain localization, which is the main cause of surface roughening. Considering the average grain size is close to the thickness of ASS foils, mounding features on the rough surface may readily develop further into potentially fractured sites during deformation. On the other hand, crystal orientation influence plastic deformation by affecting the slip behavior of materials. The effect of crystal orientations including {011} 〈211〉 (Brass), {011} 〈100〉 (Goss), and {112} 〈110〉 components on deformation is discussed. The results indicate a strong correlation between the magnitude of the Schmid's factor and the ease of deformation. Additionally, variations in Schmid's factor across different directions result in differences in deformation accumulation, which affects the thickness distribution along the radial direction and the distribution of earrings and wrinkles along the circumferential direction of the fabricated micro parts. [ABSTRACT FROM AUTHOR]

The breakaway oxidation behaviour of ferritic stainless steels 430, 443 and 445 has been investigated at 1150 °C in humid air. The oxidation kinetics exhibited significant differences among the three ferritic stainless steels. A uniform and steady growing oxide scale was developed on the 430 steel with an even steel/oxide interface. Local breakdown of the initially protective oxide scale occurred and oxide nodules were developed on the 443 and 445 stainless steels, resulting in irregular and rough steel/oxide interfaces. The breakaway oxidation behaviour was significantly influenced by the microstructure and the composition of the oxide scale. The Mn-Cr spinel oxide formed on top of the Cr 2 O 3 scale in Mo alloying 445 steel can greatly minimise the Cr depletion. [ABSTRACT FROM AUTHOR]