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Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel / LIAM MOODY

Swansea University Author: LIAM MOODY

DOI (Published version): 10.23889/SUThesis.71075

Abstract

Dual-phase (DP) steels are of increased interest in the automotive sector due to their attractive blend of high strength and high formability, which helps automotive designers reduce vehicle weight, thereby driving down both manufacturing costs and vehicle emissions.Optimising the manufacture of Adv...

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Published: Swansea 2025
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Sackett, E.; Underhill, R.; and Gibson, I.
URI: https://cronfa.swan.ac.uk/Record/cronfa71075
first_indexed 2025-12-04T10:51:37Z
last_indexed 2025-12-05T18:13:25Z
id cronfa71075
recordtype RisThesis
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spelling 2025-12-04T10:53:35.8378385 v2 71075 2025-12-04 Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel 9966f0d661fa5ec1a6e037a79a29aa49 LIAM MOODY LIAM MOODY true false 2025-12-04 Dual-phase (DP) steels are of increased interest in the automotive sector due to their attractive blend of high strength and high formability, which helps automotive designers reduce vehicle weight, thereby driving down both manufacturing costs and vehicle emissions.Optimising the manufacture of Advanced High Strength Steels (AHSSs) is critical to the future of steel manufacturing, and as AHSSs have complex chemistries, this makes them extremely challenging to process. This project focuses on a laboratory scale process that attempts to mimic the manufacture of DP800 hot-band material (hot rolled material, before any annealing processes) on the industrial scale. This laboratory process was investigated in depth, and it was clear that challenges with geometry and physical restrictions gave rise to inconsistencies between the industrial and laboratory process. In parallel to this, a proprietary Tata Steel simulation model of the finishing mill and run out table was also evaluated and investigated in conjunction with JMat Pro®, a commercial simulation software. It was found that changing key parameters in the Tata Steel software did not have the intended outcome as expected, and when compared to the experimental data, this also confirmed that careful consideration was required when tuning these settings. Furthermore, JMat Pro® was utilised throughout this research to compare processing routes, understand the microstructural evolution at various stages through the hot mill and understand the effect of varying product chemistries in the laboratory hot rolling setting.The findings of this research complement the work of the Prosperity Partnership in the manufacture of novel alloys through Rapid Alloy Prototyping (RAP), in the pursuit of steel manufacturing in the laboratory setting. E-Thesis Swansea Hot rolling, DP800, Steel, Hot mill, hot rolling simulation, AHSS 30 6 2025 2025-06-30 10.23889/SUThesis.71075 COLLEGE NANME COLLEGE CODE Swansea University Sackett, E.; Underhill, R.; and Gibson, I. Doctoral EngD EPSRC, Tata Steel EPSRC, Tata Steel 2025-12-04T10:53:35.8378385 2025-12-04T10:47:42.7034371 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering LIAM MOODY 1 71075__35753__1d2e2873fef34ef08bb13c3014f10846.pdf 2025_Moody_L.final.71075.pdf 2025-12-04T10:50:51.4017947 Output 14030497 application/pdf E-Thesis – open access true Copyright: the author, Liam Moody, 2025 true eng
title Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
spellingShingle Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
LIAM MOODY
title_short Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
title_full Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
title_fullStr Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
title_full_unstemmed Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
title_sort Multi-Scale Simulation and Validation of Hot Rolling Processes for DP800 Steel
author_id_str_mv 9966f0d661fa5ec1a6e037a79a29aa49
author_id_fullname_str_mv 9966f0d661fa5ec1a6e037a79a29aa49_***_LIAM MOODY
author LIAM MOODY
author2 LIAM MOODY
format E-Thesis
publishDate 2025
institution Swansea University
doi_str_mv 10.23889/SUThesis.71075
college_str Faculty of Science and Engineering
hierarchytype
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
document_store_str 1
active_str 0
description Dual-phase (DP) steels are of increased interest in the automotive sector due to their attractive blend of high strength and high formability, which helps automotive designers reduce vehicle weight, thereby driving down both manufacturing costs and vehicle emissions.Optimising the manufacture of Advanced High Strength Steels (AHSSs) is critical to the future of steel manufacturing, and as AHSSs have complex chemistries, this makes them extremely challenging to process. This project focuses on a laboratory scale process that attempts to mimic the manufacture of DP800 hot-band material (hot rolled material, before any annealing processes) on the industrial scale. This laboratory process was investigated in depth, and it was clear that challenges with geometry and physical restrictions gave rise to inconsistencies between the industrial and laboratory process. In parallel to this, a proprietary Tata Steel simulation model of the finishing mill and run out table was also evaluated and investigated in conjunction with JMat Pro®, a commercial simulation software. It was found that changing key parameters in the Tata Steel software did not have the intended outcome as expected, and when compared to the experimental data, this also confirmed that careful consideration was required when tuning these settings. Furthermore, JMat Pro® was utilised throughout this research to compare processing routes, understand the microstructural evolution at various stages through the hot mill and understand the effect of varying product chemistries in the laboratory hot rolling setting.The findings of this research complement the work of the Prosperity Partnership in the manufacture of novel alloys through Rapid Alloy Prototyping (RAP), in the pursuit of steel manufacturing in the laboratory setting.
published_date 2025-06-30T05:28:00Z
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score 11.090009

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