A microstructural analysis of aluminum buildup during thermomechanical processing
Highlights: • Microstructure of roll coating developed on a ground steel work roll was examined. • Roll coating was formed during the 20 pass hot rolling schedule of an Al-Mg alloy. • The roll coating had a complex layered nanocrystalline and amorphous structure. • The roll coating layers were composed of metallic Al, porous MgO and C. • Work roll debris, Fe and Cr, were observed embedded within the roll coating. - Abstract: The microstructure and composition of a roll coating built-up on an AISI M2 steel work roll during a 20 pass hot rolling schedule using a laboratory rolling tribo-simulator with a roll-on-block configuration was examined. The AISI M2 steel work roll was characterized by grinding grooves and possessed a surface roughness (R{sub a}) of 0.17 μm. The roll coating developed under these lubricated conditions was discontinuous, patchy and streaked out in the rolling direction. The microstructure and chemical composition of the material transfer that made up the roll coating was analysed and revealed to possess a complex composite microstructure consisting of nanocrystalline aluminum, nanocrystalline/amorphous MgO and amorphous carbon layers. The nanocrystalline MgO layers were porous structures lying between the solid metallic aluminum layers. Debris particles from the wear of the work roll were detected embedded within the carbon layer and at the base of the roll coating. The microstructure of the roll coating appear to be determined by the deformation conditions experienced during the rolling process, while its composition is dependent on the composition of the rolled alloy, the work roll and the lubrication conditions employed.