Rapid Alloy Prototyping for a range of strip related advanced steel grades

Farrugia, Didier; Brown, Steve; Lavery, Nicholas; Pleydell-Pearce, Cameron; Davis, Claire; Pleydell-Pearce, Cameron

doi:10.1016/j.promfg.2020.08.141

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Rapid Alloy Prototyping for a range of strip related advanced steel grades

Didier Farrugia, Steve Brown, Nicholas Lavery

, Cameron Pleydell-Pearce, Claire Davis, Cameron Pleydell-Pearce

Procedia Manufacturing, Volume: 50, Issue: Special Issue, Pages: 784 - 790

Swansea University Authors: Steve Brown, Nicholas Lavery , Cameron Pleydell-Pearce, Cameron Pleydell-Pearce

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DOI (Published version): 10.1016/j.promfg.2020.08.141

Abstract

Over many decades, the traditional route for material product developments, especially in the steel industry has been the laboratory VIM cast route at scale of 25 to 60kg, followed by through-processing of steel ingots involving hot rolling and cooling as well as further downstream processes to simu...

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Published in:	Procedia Manufacturing
ISSN:	2351-9789
Published:	Elsevier BV 2020
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URI:	https://cronfa.swan.ac.uk/Record/cronfa55156
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This traditional route has so far delivered value for optimising current grades and process routes as well as developing new products prior to production implementation. However, in order to accelerate process and grade developments even smaller scale and faster laboratory synthesis and processing is desired. The AccMet project [1] developed strategies for new alloy development [2,3] and this needs to be further developed to account for the complex processing route for strip steel production. Strategies combining small scale laboratory alloy processing routes, together with mechanical/thermal testing and modelling are being developed, ranging from 20-30g to 4.5 kg [4-8].This paper summarises current Rapid Alloy Prototyping (RAP) approaches and rationale developed under a new UK Engineering and Physical Sciences Research Council (EPSRC) Prosperity project between Tata Steel and the Universities of Swansea and Warwick (WMG). 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spelling	v2 55156 2020-09-10 Rapid Alloy Prototyping for a range of strip related advanced steel grades 07a865adc76376646bc6c03a69ce35a9 Steve Brown Steve Brown true false 9f102ff59824fd4f7ce3d40144304395 0000-0003-0953-5936 Nicholas Lavery Nicholas Lavery true false 564c480cb2abe761533a139c7dbaaca1 Cameron Pleydell-Pearce Cameron Pleydell-Pearce true false 8903282940a59caee0bd2dca890771b5 NULL Cameron Pleydell-Pearce Cameron Pleydell-Pearce true true 2020-09-10 FGSEN Over many decades, the traditional route for material product developments, especially in the steel industry has been the laboratory VIM cast route at scale of 25 to 60kg, followed by through-processing of steel ingots involving hot rolling and cooling as well as further downstream processes to simulate finished cold annealed rolled and coated products. This traditional route has so far delivered value for optimising current grades and process routes as well as developing new products prior to production implementation. However, in order to accelerate process and grade developments even smaller scale and faster laboratory synthesis and processing is desired. The AccMet project [1] developed strategies for new alloy development [2,3] and this needs to be further developed to account for the complex processing route for strip steel production. Strategies combining small scale laboratory alloy processing routes, together with mechanical/thermal testing and modelling are being developed, ranging from 20-30g to 4.5 kg [4-8].This paper summarises current Rapid Alloy Prototyping (RAP) approaches and rationale developed under a new UK Engineering and Physical Sciences Research Council (EPSRC) Prosperity project between Tata Steel and the Universities of Swansea and Warwick (WMG). Specific attention is paid to the overall experimental methodology as well as benefits (throughput) of small-scale manufacturing and testing, the generation of representative microstructures for a range of strip grades as well as ways of integrating new concepts which bridge the physical length scale. A range of experimental facilities (20-40g) based on a powder route and induction melting (IM)/heat treatments is being developed to provide material for hot/cold rolling/annealing prior to mechanical testing. Modelling and testing to account for mechanical test specimen size effects for small scale RAP samples is being carried out to ensure consistent mechanical properties are obtained. This small-scale RAP is also being complemented with an intermediate material route operating between 200g and 4.5kg using centrifugal casting and small size ingot vacuum induction melting respectively to provide additional material and throughput sitting alongside the more traditional pilot-scale 25-30kg route. Finally, the 25-30kg standard route is being reviewed to provide a bridge to the laboratory routes through various innovative concepts. This paper concludes with a review of future activities and challenges for effective development and implementation of a range of small scale experimental and pilot manufacturing lines. Journal Article Procedia Manufacturing 50 Special Issue 784 790 Elsevier BV 2351-9789 Rapid prototyping, advanced metallurgy, size effect, Alloy optimisation, development, DP steels, data modelling 1 1 2020 2020-01-01 10.1016/j.promfg.2020.08.141 http://dx.doi.org/10.1016/j.promfg.2020.08.141 18th International Conference on Metal Forming 2020, Edited by Danuta Szeliga, Krzysztof Muszka COLLEGE NANME Science and Engineering - Faculty COLLEGE CODE FGSEN Swansea University 2023-06-02T15:36:33.7621908 2020-09-10T09:24:23.4235270 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised Didier Farrugia 1 Steve Brown 2 Nicholas Lavery 0000-0003-0953-5936 3 Cameron Pleydell-Pearce 4 Claire Davis 5 Cameron Pleydell-Pearce NULL 6 55156__18136__536e1e7a1fea416583ba4a0fbe58cb18.pdf 55156.pdf 2020-09-10T09:26:32.9947121 Output 1701827 application/pdf Version of Record true © 2020 The Authors. This an open access article under the CC BY-NC-ND license false eng (http://creativecommons.org/licenses/by-nc-nd/4.0/)
title	Rapid Alloy Prototyping for a range of strip related advanced steel grades
spellingShingle	Rapid Alloy Prototyping for a range of strip related advanced steel grades Steve Brown Nicholas Lavery Cameron Pleydell-Pearce Cameron Pleydell-Pearce
title_short	Rapid Alloy Prototyping for a range of strip related advanced steel grades
title_full	Rapid Alloy Prototyping for a range of strip related advanced steel grades
title_fullStr	Rapid Alloy Prototyping for a range of strip related advanced steel grades
title_full_unstemmed	Rapid Alloy Prototyping for a range of strip related advanced steel grades
title_sort	Rapid Alloy Prototyping for a range of strip related advanced steel grades
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author	Steve Brown Nicholas Lavery Cameron Pleydell-Pearce Cameron Pleydell-Pearce
author2	Didier Farrugia Steve Brown Nicholas Lavery Cameron Pleydell-Pearce Claire Davis Cameron Pleydell-Pearce
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container_title	Procedia Manufacturing
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container_issue	Special Issue
container_start_page	784
publishDate	2020
institution	Swansea University
issn	2351-9789
doi_str_mv	10.1016/j.promfg.2020.08.141
publisher	Elsevier BV
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url	http://dx.doi.org/10.1016/j.promfg.2020.08.141
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description	Over many decades, the traditional route for material product developments, especially in the steel industry has been the laboratory VIM cast route at scale of 25 to 60kg, followed by through-processing of steel ingots involving hot rolling and cooling as well as further downstream processes to simulate finished cold annealed rolled and coated products. This traditional route has so far delivered value for optimising current grades and process routes as well as developing new products prior to production implementation. However, in order to accelerate process and grade developments even smaller scale and faster laboratory synthesis and processing is desired. The AccMet project [1] developed strategies for new alloy development [2,3] and this needs to be further developed to account for the complex processing route for strip steel production. Strategies combining small scale laboratory alloy processing routes, together with mechanical/thermal testing and modelling are being developed, ranging from 20-30g to 4.5 kg [4-8].This paper summarises current Rapid Alloy Prototyping (RAP) approaches and rationale developed under a new UK Engineering and Physical Sciences Research Council (EPSRC) Prosperity project between Tata Steel and the Universities of Swansea and Warwick (WMG). Specific attention is paid to the overall experimental methodology as well as benefits (throughput) of small-scale manufacturing and testing, the generation of representative microstructures for a range of strip grades as well as ways of integrating new concepts which bridge the physical length scale. A range of experimental facilities (20-40g) based on a powder route and induction melting (IM)/heat treatments is being developed to provide material for hot/cold rolling/annealing prior to mechanical testing. Modelling and testing to account for mechanical test specimen size effects for small scale RAP samples is being carried out to ensure consistent mechanical properties are obtained. This small-scale RAP is also being complemented with an intermediate material route operating between 200g and 4.5kg using centrifugal casting and small size ingot vacuum induction melting respectively to provide additional material and throughput sitting alongside the more traditional pilot-scale 25-30kg route. Finally, the 25-30kg standard route is being reviewed to provide a bridge to the laboratory routes through various innovative concepts. This paper concludes with a review of future activities and challenges for effective development and implementation of a range of small scale experimental and pilot manufacturing lines.
published_date	2020-01-01T15:36:32Z
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score	11.037166

Rapid Alloy Prototyping for a range of strip related advanced steel grades

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