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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]

Oil-in-water (O/W) emulsion is widely applied as a lubricant during hot rolling process. For reducing environmental impact caused by O/W emulsion, a novel nano-TiO 2 additive O/W lubricant with improved stability and reduced coefficient of friction (COF) is developed. Little research, however, has been focused on the growth behaviour of oxide scale formed on the workpiece surface and its effects on the tribological property of nano-TiO 2 additive O/W lubricant. In the current work, oxidation tests of high strength steel were conducted to investigate the growth behaviour of oxide scale and obtain different surface morphologies of the oxide scale. Ball-on-disk tribological tests under a temperature of 80 °C were carried out to investigate the effects of surface morphology of oxide scale on the tribological behaviour under nano-TiO 2 additive O/W lubrication. The performance of the new developed lubricant was evaluated by hot rolling process. The growth mechanism of oxide scale and the modified oxide scale growth model were proposed. Tribological results indicate that oxide scale plays an important role in the tribological behaviour of nano-TiO 2 additive O/W lubricant. A reduction in surface roughness can result in a decrease of COF, while the COF will increase if the surface roughness reduces too much because some of the nano-TiO 2 particles cannot go through the contact area to play a positive role in lubrication. [ABSTRACT FROM AUTHOR]

Electron backscatter diffraction (EBSD) of the microtexture in the tertiary oxide scale after hot rolling were investigated. The surface asperity flattening and grain refinement of Fe 3 O 4 were produced at a thickness reduction of 28% and a cooling rate of 28 °C/s. Microtexture development of Fe 3 O 4 manifests as a strong θ fibre parallel to oxide growth, including the {100}<001> and {001}<110> textured components, whereas the {0001}<10 1 ̅ 0> component dominates in α -Fe 2 O 3 as the favoured basal slip. The tribological effect of α -Fe 2 O 3 at the contact surface of steel and rolls was considered at low and high thickness reductions. The propagation of cracks along the Fe 3 O 4 grain boundaries could create a dish to collect nanoparticles during lubrication and thereby changed the wear rates. [ABSTRACT FROM AUTHOR]

This work presents a fine microstructure and local misorientation study of various oxide phases in the tertiary oxide scale formed on a hot-rolled steel strip via electron back-scattering diffraction (EBSD). Local strain in individual grains of four phases, ferrite ( α -Fe), wustite (FeO), magnetite (Fe 3 O 4 ) and hematite ( α -Fe 2 O 3 ), has been systematically analysed. The results reveal that Fe 3 O 4 has a lower local strain than α -Fe 2 O 3 , in particular, on the surface and inner layers of the oxide scale. The multiphase oxides along the cracking or α -Fe 2 O 3 penetration generally develop a high local misorientation. Localised stain along the cracks demonstrates that the misorientation tends to be strong near grain boundaries. The high fraction of small Fe 3 O 4 grains accumulate at the oxide–substrate interface, which leads to a dramatic increase in the intensity of local stain. This variation is due mainly to the phase transformation among the oxide phases, i.e., the Fe 3 O 4 particles during their nucleation and growth. The combined action of stress relief and re-oxidisation is proposed to explain the formation of Fe 3 O 4 seam at the oxide–steel interface. The present study offers an intriguing insight into the deformation behaviour of the tertiary oxide scale formed on steels, and may help with understanding the stress-aided oxidation effect of metal alloys. [ABSTRACT FROM AUTHOR]

Both orientational and geometrical characteristics of grains in tertiary oxide scales have been quantitatively investigated using the electron backscatter diffraction (EBSD) technique. Phase and orientation mappings demonstrate that the {001} planes of magnetite and the {0001} planes of hematite are parallel to the direction of oxide growth. Pole figures (PFs) as scattering plots clearly display the direct correlation between the orientations and microstructure sites of magnetite grains. Magnetite grains develop a strong rotated cube texture component that shifts to the {100}< 210 > component, whereas those with the grain size of 1–5 μm develop the {001}< 100 > cube texture component. The refined magnetite grains surrounding the abnormal ones can be a combined process, including magnetite pro-eutectoid during hot rolling and cooling and re-oxidation during air-cooling. Our findings offer insights toward further understanding of the link between the geometrical and orientation parameters of grains with respect to the deformation behaviour of oxide scales formed at elevated temperatures. [ABSTRACT FROM AUTHOR]

The characters of grain boundaries in oxide layers formed on substrates influence adhesion and friction behaviour, surface fracture and wear during high temperature steel processing. In this work, an electron backscattered diffraction (EBSD) analysis was conducted to investigate the role of surface grain boundary and orientation in magnetite (Fe 3 O 4 )/haematite (α-Fe 2 O 3 ) scale during hot rolling, and further evaluate their effects on tribological properties of water-based nanoparticles lubrication. The results demonstrate that Fe 3 O 4 (100) plane is strongly sensitive to the surface characteristics as the minimisation of surface energy. Coincident site lattice (CSL) boundaries in microstructure is in presence of Σ3 in the Fe 3 O 4 and Σ13b in the Fe 2 O 3 of the substrates subjected to a thickness reduction of 28% and cooling rate of 28 °C/s. This is due in great part to the changes in crystal slip systems. These low-Σ CSL boundaries in oxide scale offer obstacles to the propagation of cracks, where some of nanoparticles collected would be trapped at the interface and thereby may cause high wear rates. A lubrication mechanism is proposed to explain the grain boundary effect on nanoparticles lubrication, and further to determine the dependence of frictional behaviour on surface energy, crystallographic preferred orientation (microtexture) and crystal structure. These results provide an intriguing new insight into the application of water-based lubricant with graphite nanoparticles. [ABSTRACT FROM AUTHOR]

The oxidation kinetics of ferritic stainless steel 430 was studied in dry and humid air at 1090 °C by Thermo Gravimetric Analysis (TGA). Different atmospheres and heating times were adopted for reheating to obtain different compositions and thickness of the oxide scale. Hot rolling was performed on a 2-high Hille 100 experimental rolling mill at various reductions. Oxide scale thickness and composition were analysed with optical microscopy (OM), scanning electron microscope (SEM) and X-ray diffraction (XRD). The surface profiles were examined by a digital microscope, and the topographic features of the thin oxide scale surface were examined with an atomic force microscope (AFM) before and after rolling. The oxide scale surface and steel/oxide interface roughness were measured after rolling. Inverse calculation of the coefficient of friction was employed to analyse and the effect of oxide scale on friction in hot rolling. The coefficient of friction depends not only on the thickness of the oxide scale, but also on its composition and surface topography before hot rolling. [ABSTRACT FROM AUTHOR]

The aim of this study is to optimise the stainless steel oxidation behaviours during hot rolling. The high temperature oxidation behaviours of ferritic stainless steels B443NT and B445J1M were studied over the temperature range from 1000 to 1150 °C in a humid atmosphere containing 18% water vapour, as measured by a thermogravimetric analyser (TGA). The results indicate that breakaway oxidation occurs at 1090 °C for the B443NT steel, which is 60 °C lower than that for the B445J1M steel. The occurrence of iron oxide nodules on the steels marks the onset of breakaway oxidation; however, the breakaway oxidation phenomenon of B445J1M is different from that of B443NT due to a compact and continuous Mn–Cr spinel which is formed on the surface of B445J1M. The oxide nodules with regenerated Cr 2 O 3 scale underneath the Fe–Cr spinel display better adhesion without showing pores at the metal–scale interface. [ABSTRACT FROM AUTHOR]