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High-reduction radial shear rolling of aluminum alloy bars using custom-calibrated rolls

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A Correction to this article was published on 15 January 2024

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Abstract

The article presents a novel technique for performing high reduction radial shear rolling (HRRSR) of aluminum alloy bars. For this purpose, rolls with a special calibration were developed, including a high reduction section and a roll feed angle of 20°. The proposed process was investigated using FEM simulation, first. The temperature, stress-strain state, and force parameters analysis showed that the proposed method can produce defect-free bars with a natural gradient microstructure. Afterward, the experimental alloy Al-3Ca-2La-1Mn (wt%), was processed by a single-pass HRRSR process, resulting in a bar with an elongation ratio of 5. High compression and shear strains provide severe deformation of the initial cast microstructure and form a uniform distribution of small eutectic inclusions of the Al4(Ca, La) phase in the aluminum matrix. The obtained results, indicate the possibility of severe deformation of aluminum alloys using the radial shear rolling method. The proposed method of deformation can be the basis for an effective technology for obtaining bulk, long-length bars from various aluminum alloys, with a high reduction in a single pass.

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The data presented in this study are available on request from the corresponding author.

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Acknowledgements

The author Ibrahim Saad ELDeeb expresses his gratitude to the Egyptian ministry of higher education and scientific research (missions’ sector) for funding his postdoctoral scholarship to produce the experimental material at National University of Science and Technology MISIS University, 4 Leninsky pr, Moscow 119049, Russia.

Funding

This work was financially supported by the Moscow Polytechnic University within the framework of the grant named after Pyotr Kapitsa.

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Authors and Affiliations

  1. National University of Science and Technology MISIS (NUST “MISIS”), 4 Leninsky pr., Moscow, 119049, Russia

    Yu V. Gamin, S. P. Galkin, A. Mahmoud Alhaj Ali, X. D. Nguyen & I. S. ELDeeb

  2. Moscow Polytechnic University, Scientific Activity Sector, Avtozavodskaya Str. 16, 115280, Moscow, Russia

    A. N. Koshmin

  3. Department “Production Engineering and Mechanical Design”, Faculty of Engineering, Tanta University, Tanta, 31527, Egypt

    I. S. ELDeeb

Authors
  1. Yu V. Gamin
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  2. S. P. Galkin
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  3. A. N. Koshmin
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  4. A. Mahmoud Alhaj Ali
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  5. X. D. Nguyen
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  6. I. S. ELDeeb
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Contributions

Conceptualization was contributed by Gamin Yu.V., Galkin S.P.; Methodology was contributed by Gamin Yu.V., Galkin S.P., Koshmin A.N.; Formal analysis and investigation were contributed by Mahmoud Alhaj Ali A., Nguyen X.D., ELDeeb I. S.; Writing—original draft preparation, was contributed by Mahmoud Alhaj Ali A., Nguyen X.D., ELDeeb I. S.; Writing—review and editing, was contributed by Gamin Yu.V., Mahmoud Alhaj Ali A., ELDeeb I. S.; Funding acquisition was contributed by Koshmin A.N.; Resources were contributed by Gamin Yu.V., Galkin S.P., Supervision was contributed by Gamin Yu.V., Galkin S.P.

Corresponding author

Correspondence to I. S. ELDeeb.

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The original online version of this article was revised: the text indicating the numbers of the cross-sections of a workpiece, which are indicated in the figures, were incorrectly converted to citations of section headings in the article.

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Gamin, Y.V., Galkin, S.P., Koshmin, A.N. et al. High-reduction radial shear rolling of aluminum alloy bars using custom-calibrated rolls. Int J Mater Form 17, 5 (2024). https://doi.org/10.1007/s12289-023-01801-z

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