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Here - the ESAFORM 2008 Conference - INSA de Lyon

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case). The same pattern has been found by [9] on hotrolled strips. This proves <strong>the</strong> relevance of thisphenomenon, tentatively attributed to <strong>the</strong> presenceof significant shear stress (die edge / friction) whichinduces <strong>the</strong> rotation of principal axes.zx3.3 Interface3.3.a Delamination / spallingThis is ano<strong>the</strong>r failure mechanism whereby oxi<strong>de</strong>fragments may be spalled off <strong>the</strong> sample surface; inrolling, such fragments may <strong>the</strong>n be embed<strong>de</strong>dinsi<strong>de</strong> <strong>the</strong> strip surface by <strong>the</strong> contact pressure.zyFigure 5: oblique cracks (top) near <strong>the</strong> PSCT die edge,(bottom) on a rolled strip [9].3.2 Roughness transferFigure 6: comparison of <strong>the</strong> oxi<strong>de</strong> surface state after PSCT1with rough / smooth dies. Die width 12 mm. ε = 0. 4 , & ε = 1.s− ,T = 900°C, oxi<strong>de</strong> thickness 50 µm.Figure 8: two examples of <strong>de</strong>lamination. Left: interfacial<strong>de</strong>lamination on <strong>the</strong> flank of a groove. Right: <strong>de</strong>laminationwithin <strong>the</strong> oxi<strong>de</strong> layer.In figure 8 (left), bending of <strong>the</strong> sample in <strong>the</strong> flankof a grooved die (representing <strong>the</strong> “roll banding”<strong>de</strong>fect, i.e. peeling of an orthoradial strip of rolloxi<strong>de</strong>) has resulted in a normal, through-thicknesscrack which has bifurcated along <strong>the</strong> interface; insuch situations, <strong>the</strong> formation and embedding of afragment becomes highly probable. The die grooveis oriented in <strong>the</strong> die width direction, equivalent to<strong>the</strong> rolling direction. Such a crack would thus belongitudinal, contrary to those shown above. Figure8 (right) shows <strong>de</strong>lamination within <strong>the</strong> oxi<strong>de</strong>. Linesof pores have occasionally been found in oxi<strong>de</strong>layers, parallel to <strong>the</strong> interface; <strong>the</strong>y may be <strong>the</strong>origin of such <strong>de</strong>fects. Yet <strong>de</strong>lamination might alsohave taken place at <strong>the</strong> interface, with subsequent reoxidationduring cooling in imperfectly pure N 2 .<strong>Here</strong> again, fragmentation and embedding of <strong>the</strong>spalled layer in <strong>the</strong> next rolling stand is inevitable.Figure 7: cross-section of <strong>the</strong> samples shown in figure 5,showing <strong>the</strong> smooth metal (white) – oxi<strong>de</strong> (grey) interface,whatever <strong>the</strong> die roughness.Ano<strong>the</strong>r possible <strong>de</strong>fect is interface waviness due totool roughness printing, in particular when rolls areseverely worn. Figure 6 shows that <strong>the</strong> oxi<strong>de</strong>surface, to a large extent, takes <strong>the</strong> roll roughness,which suggests a certain <strong>de</strong>gree of plasticity of <strong>the</strong>oxi<strong>de</strong>, but <strong>the</strong> oxi<strong>de</strong> – metal interface remainssmooth (figure 7). This may not be a generalconclusion however, certainly <strong>de</strong>pen<strong>de</strong>nt (i) on <strong>the</strong>ratio of <strong>the</strong> tool roughness to <strong>the</strong> oxi<strong>de</strong> thickness,and (ii) of <strong>the</strong> temperature-<strong>de</strong>pen<strong>de</strong>nt mechanicalproperties of <strong>the</strong> oxi<strong>de</strong> (toughness, oxi<strong>de</strong>-to-metalyield stress ratio). <strong>Here</strong> again, numerical simulationcan contribute in <strong>the</strong> study of <strong>the</strong>se parameters.3.3.b Interface instabilityIn a series of tests <strong>de</strong>voted to varying strain rate, asinusoidal interface waviness has been observed at<strong>the</strong> lowest strain-rate, <strong>de</strong>creasing and disappearingas ε & increases (figure 9).Figure 9: Interface waviness without cracking. Strain rateincreases from top to bottom (0.1, 1 and 10 s -1 ).There is no evi<strong>de</strong>nce of any crack / micro-extrusionphenomenon, hence <strong>the</strong> interpretation by plastic co<strong>de</strong>formationinstability (see [10] e.g.). It is not surethat this can occur in strip rolling, since it has been

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