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RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS / TALAL ABDULLAH

Swansea University Author: TALAL ABDULLAH

  • E-Thesis under embargo until: 28th June 2025

DOI (Published version): 10.23889/SUThesis.67073

Abstract

The miniaturisation of steel production is one of the fronts of metallurgy that must be tackled to provide TATA steel with a competitive edge. This research looks to explore the capabilities of small-scale (40 – 140g) Rapid Alloy Prototyping (RAP) in producing and testing a well-understood Interstit...

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Published: Swansea University, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Lavery, N., P.
URI: https://cronfa.swan.ac.uk/Record/cronfa67073
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IF steel is unforgiving towards slight deviations along the entire processing line. To achieve the desired formable properties, the process from casting to annealing must follow a set of strict tolerances. The small-scale RAP attempts to follow most of the industrial processing line; this includes (from start to finish) Coil induction melting, drop casting, reheating, descaling, hot rolling, coiling, sandblasting, cold rolling, and annealing. Techniques such as scanning electron microscope (SEM), optical microscopy, electron backscatter diffraction (EBSD), torsion testing, tensile testing, and optical emission spectroscopy (OES) were used to analyse both the industrial and RAP IF material—the ability to match the tensile-mechanical, thermomechanical, and metallurgical properties of the product demonstrates the merit of the miniaturised processing line. When exploring the scaling effects of miniaturised tensile specimens, representative mechanical properties were achieved; a specimen with a gauge length of 10mm measures an agreeable r-value. Success was seen in the tight compositional control in the synthetic production of IF steel when melting 40g (RAP40g) and 140g (RAP140g) of material in the coil induction drop casting machine and the coil induction centrifugal casting machine, respectively. Detailed analysis of each RAP80g process line stage allowed limitations to be identified and optimised for improved capability.Representative texture and r-values were observed in the RAP80g through process sheet when a single pass 70% hot reduction, 75% cold reduction, and a 100 mpm annealing cycle with a soaking temperature of 820oC was used. A thorough process was explored using a value stream map; with implemented optimisations, 20 alloys can be produced and tested within eight days. 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spelling v2 67073 2024-07-11 RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS b579dde4dfbe138386ea70e0fcf47ca1 TALAL ABDULLAH TALAL ABDULLAH true false 2024-07-11 The miniaturisation of steel production is one of the fronts of metallurgy that must be tackled to provide TATA steel with a competitive edge. This research looks to explore the capabilities of small-scale (40 – 140g) Rapid Alloy Prototyping (RAP) in producing and testing a well-understood Interstitial Free (IF) steel grade, DX57, and comparing it to the industrial product. IF steel is unforgiving towards slight deviations along the entire processing line. To achieve the desired formable properties, the process from casting to annealing must follow a set of strict tolerances. The small-scale RAP attempts to follow most of the industrial processing line; this includes (from start to finish) Coil induction melting, drop casting, reheating, descaling, hot rolling, coiling, sandblasting, cold rolling, and annealing. Techniques such as scanning electron microscope (SEM), optical microscopy, electron backscatter diffraction (EBSD), torsion testing, tensile testing, and optical emission spectroscopy (OES) were used to analyse both the industrial and RAP IF material—the ability to match the tensile-mechanical, thermomechanical, and metallurgical properties of the product demonstrates the merit of the miniaturised processing line. When exploring the scaling effects of miniaturised tensile specimens, representative mechanical properties were achieved; a specimen with a gauge length of 10mm measures an agreeable r-value. Success was seen in the tight compositional control in the synthetic production of IF steel when melting 40g (RAP40g) and 140g (RAP140g) of material in the coil induction drop casting machine and the coil induction centrifugal casting machine, respectively. Detailed analysis of each RAP80g process line stage allowed limitations to be identified and optimised for improved capability.Representative texture and r-values were observed in the RAP80g through process sheet when a single pass 70% hot reduction, 75% cold reduction, and a 100 mpm annealing cycle with a soaking temperature of 820oC was used. A thorough process was explored using a value stream map; with implemented optimisations, 20 alloys can be produced and tested within eight days. Overall, it will assist in establishing a confident campaign towards replacing industrial-scale experimentation of novel steel grade with the RAP process, which is sufficient to explore the matrix of varied parameters to swiftly filter the optimal configuration for upscale. E-Thesis Swansea University, Wales, UK Rapid Alloy Prototyping, Metallurgy, Interstitial Free steels 28 6 2024 2024-06-28 10.23889/SUThesis.67073 A selection of content is redacted or is partially redacted from this thesis to protect sensitive and personal information. COLLEGE NANME COLLEGE CODE Swansea University Lavery, N., P. Doctoral EngD WEFO WEFO 2024-07-11T15:20:16.3175521 2024-07-11T15:09:26.0072312 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering TALAL ABDULLAH 1 Under embargo Under embargo 2024-07-11T15:14:02.7197446 Output 10272341 application/pdf E-Thesis true 2025-06-28T00:00:00.0000000 Copyright: The Author, Talal Said Abdullah, 2023 Distributed under the terms of a Creative Commons Attribution 4.0 License (CC BY 4.0) true eng https://creativecommons.org/licenses/by/4.0/
title RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
spellingShingle RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
TALAL ABDULLAH
title_short RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
title_full RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
title_fullStr RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
title_full_unstemmed RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
title_sort RAPID PROTOTYPING FOR THE PRODUCTION OF INTERSTITIAL FREE STEELS
author_id_str_mv b579dde4dfbe138386ea70e0fcf47ca1
author_id_fullname_str_mv b579dde4dfbe138386ea70e0fcf47ca1_***_TALAL ABDULLAH
author TALAL ABDULLAH
author2 TALAL ABDULLAH
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publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUThesis.67073
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
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description The miniaturisation of steel production is one of the fronts of metallurgy that must be tackled to provide TATA steel with a competitive edge. This research looks to explore the capabilities of small-scale (40 – 140g) Rapid Alloy Prototyping (RAP) in producing and testing a well-understood Interstitial Free (IF) steel grade, DX57, and comparing it to the industrial product. IF steel is unforgiving towards slight deviations along the entire processing line. To achieve the desired formable properties, the process from casting to annealing must follow a set of strict tolerances. The small-scale RAP attempts to follow most of the industrial processing line; this includes (from start to finish) Coil induction melting, drop casting, reheating, descaling, hot rolling, coiling, sandblasting, cold rolling, and annealing. Techniques such as scanning electron microscope (SEM), optical microscopy, electron backscatter diffraction (EBSD), torsion testing, tensile testing, and optical emission spectroscopy (OES) were used to analyse both the industrial and RAP IF material—the ability to match the tensile-mechanical, thermomechanical, and metallurgical properties of the product demonstrates the merit of the miniaturised processing line. When exploring the scaling effects of miniaturised tensile specimens, representative mechanical properties were achieved; a specimen with a gauge length of 10mm measures an agreeable r-value. Success was seen in the tight compositional control in the synthetic production of IF steel when melting 40g (RAP40g) and 140g (RAP140g) of material in the coil induction drop casting machine and the coil induction centrifugal casting machine, respectively. Detailed analysis of each RAP80g process line stage allowed limitations to be identified and optimised for improved capability.Representative texture and r-values were observed in the RAP80g through process sheet when a single pass 70% hot reduction, 75% cold reduction, and a 100 mpm annealing cycle with a soaking temperature of 820oC was used. A thorough process was explored using a value stream map; with implemented optimisations, 20 alloys can be produced and tested within eight days. Overall, it will assist in establishing a confident campaign towards replacing industrial-scale experimentation of novel steel grade with the RAP process, which is sufficient to explore the matrix of varied parameters to swiftly filter the optimal configuration for upscale.
published_date 2024-06-28T15:20:15Z
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score 11.036116

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