Oxide Scale Behavior in High Temperature Metal Processing

The result of a fruitful, on-going collaboration between academia and industry, this book reviews recent advances in research on oxide scale behavior in high-temperature forming processes. Presenting novel, previously neglected approaches, the authors emphasize the pivotal role of reproducible experiments to elucidate the oxide scale properties and develop quantitative models with predictive accuracy. Each chapter consists of a detailed, systematic examination of different aspects of oxide scale formation with immediate impact for researchers and developers in industry. The clear and stringent style of presentation makes this monograph both coherent and easily readable.

Table of Contents:
Preface INTRODUCTION A PIVOTAL ROLE OF SECONDARY OXIDE SCALE DURING HOT ROLLING AND FOR SUBSEQUENT PRODUCT QUALITY Friction Heat Transfer Thermal Evolution in Hot Rolling Secondary Scale-Related Defects SCALE GROWTH AND FORMATION OF SUBSURFACE LAYERS High-Temperature Oxidation of Steel Short-Time Oxidation of Steel Scale Growth at Continuous Cooling Plastic Deformation of Oxide Scales Formation and Structure of the Subsurface Layer in Aluminum Rolling METHODOLOGY APPLIED FOR NUMERICAL CHARACTERIZATION OF OXDIE SCALE IN THERMOMECHANICAL PROCESSING Combination of Experiments and Computer Modeling: A Key for Scale Charaterization Prediction of Mild Steel Oxide Failure at Entry Into the Roll Gap as an Example of the Numerical Characterization of the Secondary Scale Behavior MAKING MEASUREMENTS OF OXIDE SCALE BEHAVIOR UNDER HOT WORKING CONDITIONS Laboratory Rolling Experiments Multipass Laboratory Rolling Testing Hot Tensile Testing Hot Plane Strain Compression Testing Hot Four-Point Bend Testing Hot Tension Compression Testing Bend Testing at the Room Temperature NUMERICAL INTERPRETATION OF TEST RESULTS: A WAY TOWARD DETERMINING THE MOST CRITICAL PARAMETERS OF OXIDE SCALE BEHAVIOR Numerical Interpretation of Modified Hot Tensile Testing Numerical Interpretation of Plain Strain Compression Testing Numerical Interpretation of Hot Four-Point Bend Testing Numerical Interpretation of Hot Tension-Compression Testing Numerical Interpretation of Bend Testing at Room Temperature PHYSICALLY BASED FINITE ELEMENT MODEL OF THE OXIDE SCALE: ASSUMPTIONS, NUMERICAL TECHNIQUES, EXAMPLES OF PREDICTION Multilevel Analysis Fracture, Ductile Behavior, and Sliding Delamination, Multilayer Scale, Scale on Roll, and Multipass Rolling Combined Discrete/Finite Element Approach UNDERSTANDING AND PREDICTING MICROEVENTS RELATED TO SCALE BEHAVIOR AND FORMATION OF SUBSURFACE LAYERS Surface Scale Evolution in the Hot Rolling of Steel Crack Development in Steel Oxide Scale Under Hot Compression Oxide Scale Behavior and Composition Effects Surface Finish in the Hot Rolling of Low-Carbon Steel Analysis of Mechanical Descaling: Low-Carbon and Stainless Steel Evaluation of Interfacial Heat Transfer During Hot Steel Rolling Assuming Scale Failure Effects Scale Surface Roughness in Hot Rolling Formation of Stock Surface and Subsurface Layers in Breakdown Rolling of Aluminum Alloys OXIDE SCALE AND THROUGH-PROCESS CHARACTERIZATION OF FRICTIONAL CONDITIONS FOR THE HOT ROLLING OF STEEL: INDUSTRIAL INPUT Background Brief Summary of the Main Friction Laws Used in Industry Industrial Conditions Including Descaling Recent Developments in Friction Models Application of Hot Lubrication Laboratory and Industrial Measurements and Validation Industrial Validation and Measurements Conclusions and Way Forward

About the Author :
Michal Krzyzanowski is currently research fellow at the University of Sheffield, UK, in the Department of Engineering Materials. Graduated as physicist he obtained his PhD and DSc degrees in materials science. He was appointed Associate Professor in 1997 at the University of Science and Technology in Krakow, Poland. In 1998, he accepted the invitation of the University of Sheffield to work in the newly founded, multidisciplinary Institute for Microstructural and Mechanical Process Engineering (IMMPETUS). At IMMPETUS, Michal Krzyzanowski conducts his research on thermomechanical metal processing with a focus on characterization and multiscale modelling, application of principles of physics into the detailed numerical analysis. John H. Beynon is Dean of the Faculty of Engineering and Industrial Sciences at Swinburne University of Technology, Melbourne, Australia. He was awarded his PhD in Metallurgy from the University of Sheffield in 1980. Professor Beynon is a fellow of the Institute of Materials, Minerals and Mining, the Institution of Engineers Australia and the Royal Academy of Engineering. His main area of research is the study of the interaction of materials science and applied mechanics to solve engineering problems, particularly in thermomechanical processing and structural integrity, by using computer-based modeling, experiment and industrial input. Didier C. J. Farrugia is currently scientific fellow at Corus Swinden Technology Centre in Rotherham, UK, and a fellow of the Institute of Materials, Minerals and Mining (IOM3). After graduating with a PhD at the CEMEF, Mines-ParisTech in 1990, he has worked for more than 19 years in the steel R&D industry where his research activities include metal forming, material science, modeling, numerical techniques and tribology. Didier Farrugia has set up and managed major collaborative programs, and has been involved in technology transfer, implementation and exploitation within both industry and academia for many years. In recognition of his achievements, he was awarded the 2008 Dowding Medal and Prize.