Edge crack damage analysis of AZ31 magnesium alloy hot-rolled plate improved by vertical roll pre-rolling

In the present study,through vertical roll pre-rolling of AZ31 magnesium alloy hot-rolled plate at room temperature,the effect of different vertical roll pre-rolling reduction on edge crack of the plate during flat rolling was systematically studied.The evolution of microstructure and texture in the edge and middle of the plate after vertical roll pre-rolling,heating and rolling was analyzed by using EBSD technology.The results show that during the vertical roll pre-rolling,{10–12}primary twins and{10–12}-{10–12}secondary twins dominated the edge deformation,while{10–12}primary twins dominated the middle deformation.With the increase of vertical roll pre-rolling reduction,the twin volume fraction of the edge and the middle increased,and the difference between them decreased gradually.After heating,the twin orientation caused by vertical roll pre-rolling was still maintained,and there was a significant difference in grain size between the edge and the middle.When the reduction rate of flat rolling was 30%,cracks have already appeared in the initial plate,while the vertical roll pre-rolled samples showed extremely high rolling performance.When the reduction rate of flat rolling was 50%,the 8PR sample still had no crack initiation.In addition,after flat rolling of 50%,the initial plate showed a strong basal texture,while the maximum pole density of the 8PR plate was small,and the texture distribution was very scattered,showing the characteristics of weak orientation.

Effect of copper on edge cracking behavior and microstructure of rolled austenitic stainless steel plate

Cu is known to affect the edge cracking characteristics of austenitic stainless steel as it causes embrittlement.The hot rolling test of four kinds of austenitic stainless steel with different copper content(0,2.42,3.60 and 4.35 wt.%)was carried out to examine the effect of hot rolling cracks on steel containing different copper contents.The evolution of crack and microstructure was analyzed using the scanning electron microscope,energy-dispersive spectrometer,electron back scattered diffraction and transmission electron microscope.Experimental results showed an upward trend in edge cracking degree when Cu content was 4.35%,and the crack extended from the edge of the steel plate to the middle by about 14 mm.Besides,severe oxidation was observed inside the crack by fractography.With the increase in copper content at 1250℃,the content of{110}<112>brass and{112}<111>copper textures decreased.When the content of copper was 4.35%,the decrease was most significant,and{112}<111>copper texture content decreased to only 0.5%.Generally,the textures of 2.42%Cu and 3.60%Cu 304L steel changed little,while a large change in the texture of 4.35%Cu 304L steel was observed.To conclude,the increase in rolling temperature can prevent edge crack and its propagation effectively.

Comparison of edge cracking and tensile cracking in in-situ deformation at 150℃of Mg-2Zn-1.5Mn alloy sheet

The Mg-2Zn-1.5Mn alloy(ZM21)sheets were hot-rolled in a single pass at 150℃with different reductions through on-line heating rolling.Microstructures and edge cracking behavior of the rolled sheets were investigated.The in-situ tensile tests at 150℃were also carried out,the crack initiation and propagation were compared with the edge cracking behavior of ZM21 sheets prepared by on-line heating rolling.The results reveal that the edge cracks are most likely to originate in the rolling direction and normal direction(RD-ND)plane due to the secondary tensile stress along RD.Edge cracking becomes more severe with an increasing reduction.The edge cracks mainly initiate and propagate in the fine recrystallized grain areas and the junction of recrystallized grains and sub-grains with hard orientation.The in-situ tensile test indicates that micro-cracks mainly initiate at the triple junction of grain boundaries where grains have hard orientation with low basal Schmid factor(SF).Meanwhile,those cracks are more likely to propagate along the grain boundaries with maximum difference in basal Schmid factor.Besides,the crack initiation and propagation during the in-situ tensile deformation at 150℃are found not to be associated with the recrystallization.

Limit Load Solution for Electron Beam Welded Joints with Single Edge Weld Center Crack in Tension

Limit loads are widely studied and several limit load solutions are proposed to some typical geometry of weldments.However,there are no limit load solutions exist for the single edge crack weldments in tension（SEC（T））,which is also a typical geometry in fracture analysis.The mis-matching limit load for thick plate with SEC（T） are investigated and the special limit load solutions are proposed based on the available mis-matching limit load solutions and systematic finite element analyses.The real weld configurations are simplified as a strip,and different weld strength mis-matching ratio M,crack depth/width ratio a/W and weld width 2H are in consideration.As a result,it is found that there exists excellent agreement between the limit load solutions and the FE results for almost all the mis-matching ration M,a/W and ligament-to-weld width ratio（W-a）/H.Moreover,useful recommendations are given for evaluating the limit loads of the EBW structure with SEC（T）.For the EBW joints with SEC（T）,the mis-matching limit loads can be obtained assuming that the components are wholly made of base metal,when M changing from 1.6 to 0.6.When M decreasing to 0.4,the mis-matching limit loads can be obtained assuming that the components are wholly made of base metal only for large value of（W-a）/H.The recommendations may be useful for evaluating the limit loads of the EBW structures with SEC（T）.The engineering simplifications are given for assessing the limit loads of electron beam welded structure with SEC（T）.

Effect of variable thickness cross rolling on edge crack and microstructure gradient of AZ31 magnesium alloy

The hot rolling experiment of AZ31 magnesium alloy was carried out by laying anoverlay mold at the initial temperature of 400℃.According to the Mizushima automatic plan view pattern control system(MAS)rolling theory and the cross rolling process,different reductions in the middle and edges of the magnesium alloy were realized,and the influence of the regional controlled reduction rolling on the edge cracks and microstructure gradient of the magnesium alloy were analyzed.It is shown that this rolling approach has reduced the maximum edge crack depth of the rolled piece by 56.85%,and there is a weakening tendency in the base surface texture of the strip edge,the base surface texture density drops from 23.97 to 17.48 after ordinary flat rolling.It exhibits basal texture gradients from the edge to the middle of the sheet along the RD direction,which reflected the uneven deformation of the sheets.It is suitable for the processing of metal molds that require large edge reductions such as mobile phone shells,and provided a theoretical basis for the variable thickness rolling of the magnesium alloy strip.

AN EDGE CRACK PROBLEM IN A SEMI-INFINITE PLANE SUBJECTED TO CONCENTRATED FORCES

An oblique edge crack problem in a semi-infinite plane is discussed. Re concentrated forces are applied on the edge crack face, or on the line boundary of the cracked semi-infinite plane. The rational mapping function approach is suggested to solve the boundary value problem and a solution in a closed form is obtained. Finally, several numerical examples with the calculated results are given.

Analysis of strip edge cracks during cold rolling of thin strip

In this paper,the mechanics of strip edge cracks and its propagation has been studied,and the effects of strip edge drop and stress intensity factor(SIF) on edge crack defections during cold rolling of thin strip have been discussed.An experimental investigation was presented into the effect of strip edge drop on edge cracks during cold rolling of thin strip.The edge crack increases significantly due to more inhomogeneous deformation and work hardening at the strip edge.The effective stress intensity factor range is important as it represents the major physical cause of the crack propagation.The efficiency and reliability of the SIF analytical model has been demonstrated in the study.The proposed method for predicting strip edge crack is helpful in producing defect-free products and providing an understanding of the mechanics of edge crack propagation in cold rolling of thin strip.

The edge crack problem for an orthotropic functionally graded strip under concentrated loads

The plane crack problem of an orthotropic functionally graded strip under concentrated loads is studied. The edge crack is perpendicular to the boundary and the elastic property of the material is assumed to vary depending on thickness. By using an integral transform method, the present problem can be reduced to a single integral equation which is solved numerically. The influences of parameters such as the nonhomogeneity constant and the geometry parameters on the stress intensity factors (SIFs) are studied. It is found that the nonhomogeneity constant has important influences on the SIFs.

Prediction of crack location and propagation in stretch flanging process of aluminum alloy AA-5052 sheet using FEM simulation

The stretch flanging process is significantly affected by various geometrical,material and process parameters.The punch-die clearance and initial flange length are main parameters which have major effects on the edge crack location and strain distribution along die profile radius in the flange.Non-axisymmetric stretch flanging process of AA-5052 sheet metal blanks was carried out by numerical simulation to predict the deformation behavior of flange,location and propagation of crack in flange and to investigate the effect of punch die clearance,flange length,die and punch profile radius and friction in the stretch flanging process.The experimental investigations were made to validate the simulations results.The results reveal that the crack length increases with the increase in the flange length.It is found that the flange length has a significant effect in circumferential direction as compared with the radial direction.The punch die clearance has the most significant effect in crack propagation in comparison with flange length.The circumferential strain is found to be larger in the case of punch having the profile radius less than the die profile radius,which leads to faster edge crack propagation.A close agreement is found between simulation and experimental results in terms of location of edge crack and forming load.

WEIGHT FUNCTION FOR STRESS INTENSITY FACTORS IN ROTATING THICK-WALLED CYLINDER

The equation of stress intensity factors（SIF） of internally pressurized thick-walled cylinder was used as the reference case. SIF equation of rotating thick-walled cylinder containing a radial crack along the internal bore was presented in weight function method. The weight function formulas were worked out and can be used for all kinds of depth of cracks, rotating speed, material, size of thick-walled cylinder to calculate the stress intensity factors. The results indicated the validity and effectiveness of these formulas. Meanwhile, the rules of the stress intensity factors in rotating thick-walled cylinder with the change of crack depths and the ratio of outer radius to inner radius were studied. The studies are valuable to engineering application.

Unveiling the underlying mechanism of forming edge cracks upon high strain-rate rolling of magnesium alloy

In the current study,high strain-rate rolling(≥10 s-1) has been successfully employed to produce Mg-3 A1-1 Zn alloy sheets to a high reduction of 82% with a fine grain structure in a single pass.The underlying mechanism of forming primary and secondary edge cracks has been investigated.It is found that dynamic recrystallization(DRX) induced by subgrains tends to blunt cracks,while twinning-induced D RX is mainly observed around sharp crack tips.The motion of emitted dislocations from blunted cracks is inhibited by the DRX grain boundaries.This,on one hand,increases local work hardening,and on the other hand,causes stress concentration alo ng grain boundaries especially in the triple junctions leading to the formation of secondary cracks.

Effect of edge cracks on critical current degradation in REBCO tapes under tensile stress

The slitting process for manufacturing REBa2Cu3O7
δ(REBCO,RE=Rare earth)tapes of required width significantly improves the production efficiency and reduces production costs.However,edge cracks induced by the slitting process of wide REBCO tapes may cause premature degradation under high tensile stress in highfield magnets.Therefore,it is necessary to evaluate the effect of edge cracks of REBCO tapes on the critical current(Ic)degradation.Firstly,Ic degradation under artificial cracks was measured to validate the applicability of linear elastic fracture mechanics for the REBCO layer.The maximum circumferential stress criterion was used to derive the mixed-mode stress intensity factor of multiple oblique edge cracks.A semi-analytical model considering edge crack properties such as angleβ,spacing d,and length a,was built to evaluate the critical load and critical crack.We found that when the stress intensity factor at the crack tip is below KIC?2:3 MPa ffiffiffiffim p,edge cracks did not propagate.We examined commercial REBCO tapes manufactured by two different processes,concluding that edge cracks in these tapes will not cause premature degradation.

Nonlinear vibration of edged cracked FGM beams using differential quadrature method

This paper investigated the nonlinear vibration of functionally graded beams containing an open edge crack based on Timoshenko beam theory.The cracked section is modeled by a massless elastic rotational spring.It is assumed that material properties follow exponential distributions through the beam thickness.The differential quadrature(DQ) method is employed to discretize the nonlinear governing equations which are then solved by a direct iterative method to obtain the nonlinear vibration frequencies of beams with different boundary conditions.The effects of the material gradient,crack depth and boundary conditions on nonlinear free vibration characteristics of the cracked FGM beams are studied in detail.

Formation of Edge Crack in 1.4%Si Non-oriented Electrical Steel during Hot Rolling

Microstructure evolution, dynamic recrystallization, high temperature oxidation and hot ductility of 1.4 % Si non-oriented electrical steel sheets were investigated to reduce edge cracking. The causes of cracking were found to be coarse as-cast microstructure, grain boundary oxidation in reheating furnace, lack of dynamic recrystallization during hot rolling and increase of temperature, resulting in reduced hot ductility in strip edge region. Countermeas- ures against the edge crack are proposed accordingly. Lowering reheating temperature and reducing holding time re- duced oxidation and decarburization. Hot charging temperature was increased to decrease reheating temperature. And using an edger can refine microstructure in strip edge region. Finally, edge heater can be added to increase edge re- gion formability by inducing dynamic reerystallization and ductility by increasing temperature.

SINGLE AND DOUBLE EDGE INTERFACE CRACK SOLUTIONS FOR ARBITRARY FORMS OF MATERIAL COMBINATION

In this paper interfacial edge crack problems are considered by the application of the finite element method. The stress intensity factors are accurately determined from the ratio of crack-tip-stress value between the target given unknown and reference problems. The reference problem is chosen to produce the singular stress fields proportional to those of the given unknown problem. Here the original proportional method is improved through utilizing very refined meshes and post-processing technique of linear extrapolation. The results for a double-edge interface crack in a bonded strip are newly obtained and compared with those of a single-edge interface crack for different forms of combination of material. It is found that the stress intensity factors should be compared in the three different zones of relative crack lengths. Different from the case of a cracked homogeneous strip, the results for the double edge interface cracks are found to possibly be bigger than those for a single edge interface crack under the same relative crack length.

PARAMETER AND INTERACTION STUDY OF EDGE CRACK PROBLEM USING MESHFREE METHOD

In this work,element free Galerkin method(EFGM)has been used to obtain the solution of edge crack problem under mechanical loads as it provides a versatile technique to model static as well as moving crack problems without any requirement of remeshing.At first,some techniques are presented for enriching the EFG approximations near the crack tip such as extrinsic and intrinsic enrichment.Extrinsic enrichment involves the addition of solution form to the trial function,whereas the EFG basis is expanded to include few terms from crack tip solution in intrinsic enrichment.Apart from enrichment techniques,four basic techniques of smoothing meshless approximations near nonconvex boundaries are also presented such as diffraction,transparency,see through and wedge model.These techniques are then used for the parameteric analysis of an edge crack problem under mode-1 loading and results obtained using different approaches are compared with each other as well as with exact solution.Among these techniques,the extrinsic PU enrichment technique was found to be more accurate as compared to other approaches.Extrinsic PU enrichment technique has also been used for the analysis of a shear edge crack problem.In all these techniques,the value of mode-1 stress intensity factor and mode-2 stress intensity factor has been evaluated by interaction integral approach.Effect of crack orientation is also studied for different cases.

Effect of cold rolling and annealing on microstructure and properties of a new resource-saving duplex stainless steel Fe–19Cr–0.6Al–12Mn

An Fe-19Cr-0.6Al-12Mn duplex stainless steel with an optimized alloy composition of Ni replaced by Mn and Cr partially replaced by Al was developed to avoid the edge cracking, which is a common defect in the hot rolling of traditional twophase stainless steels. The newly developed duplex stainless steel could be hot-rolled in the single-phase ferrite (α) region by controlling rolling temperature and the single-phase ferrite microstructure was retained on water cooling. To obtain the two-phase stainless steel product with ferrite and austenite (γ) microstructure, cold rolling and annealing were carried out,and appropriate cold rolling reduction and annealing process parameters were determined. The significant impact of annealing on microstructure, mechanical properties and pitting resistance of the experimental steel was studied. It was observed that with the increase in cold rolling reduction, the number of γ nucleation points was dramatically increased leading to the precipitation of more γ at α grain boundaries after annealing. During annealing at 800 ℃ and with the increase in annealing time, the austenite fraction was increased with a lower rate and remained almost constant when the annealing time was greater than 4 h. With the increase in annealing temperature, the austenite fraction decreased gradually in the temperature range of 750-860 ℃. Good combination of strength, ductility and excellent pitting resistance was obtained by cold rolling to 80% reduction and annealing at 800 ℃ for 4 h. Grain refinement and the existence of Σ3 boundaries played a vital role in improving the pitting resistance of the experimental steel. With good combination of strength, ductility and corrosion resistance, the newly developed duplex stainless steel is expected to be a new resource-saving dual-phase stainless steel.