One of the principal forming processes for aluminum is the hot rolling of ingots into thick slabs and further rolling to form plate and sheet material of various thicknesses. Multiple passes in a reversing rolling mill of a hot slab are required to produce semi-finished aluminum plate. However, the large deformations encountered while rolling may lead to failure modes that result in loss of part or even the entire slab. The formation of defects within the plate, such as edge cracking, delamination, alligatoring (center splitting near the front and rear), and the formation of undesirable rolled end shapes, all lead to product losses.
Processing parameters could be chosen that improve product yield if the slab material response to the hot rolling process were sufficiently well understood. We have worked with a major aluminum manufacturer to develop models that: