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Michele De Santis (RINA Consulting - Centro Sviluppo Materiali SpA)13/10/2026, 09:20Oral Presentation
The deployment of numerical modelling in continuous casting (CC) is increasingly recognized as a strategic enabler for process control, quality improvement and operational efficiency. Nevertheless, its systematic adoption across steelmaking organizations remains limited by technical, organizational and cultural barriers. Within this context, the RFCS Accompanying Measure METACAST was launched...
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Matteo Marten-Perolino (AIM)13/10/2026, 09:50Oral Presentation
Manufacturing and Remelting Technologies
It is proposed a depth exploration of manufacturing and remelting technologies, with a focus on processes related to Nickel base alloy ingots. The aim is to outlines the sequence of steps before the hot transformation of a Nickel base alloy ingot, including the selection of raw materials, melting in furnaces such as EAF (Electric Arc Furnace), AOD...
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Benedikt Blitz (SMR Premium GmbH)13/10/2026, 10:20Oral Presentation
The presentation will highlight the recent developments in the world of forged special steels and remelted steels as well as titanium products and provides an overview about supply and end-user demand / structures of these special products including summarizing the actual status of installations (forging presses and remelting units) on a global scale. The speech will also focus on future...
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Shintaro Yano (Material technology laboratory, The Japan Steel Works, Ltd.)13/10/2026, 11:20Oral Presentation
Partition coefficients are key parameters to predict compositional segregation in large steel ingots. The random sampling method combined with mass-balance analysis or Scheil-Gulliver’s equation has been widely used to determine partition coefficients. However, these approaches have mainly focused on steels exhibiting single-phase solidification, and no reports have been found that address...
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Prof. Yu-Chiao Lu (KTH Royal Institute of Technology)13/10/2026, 11:40Oral presentation (paper for journal’s special issue)
Minimizing the melt disturbance at the beginning of the teeming process during ingot casting is the key to ensuring high-quality steel production since this would minimize mould flux entrapment and decrease the reoxidation of the liquid steel. This study performs computational fluid dynamics (CFD) modeling to simulate the initial stage of the ingot casting process with different runner and...
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Sara Busolini (Acciaierie Bertoli Safau)13/10/2026, 12:00Oral Presentation
The critical shortage of fly ash has driven a multistage transition in carbon fluxes for ingot casting: moving from traditional formulations, to fly ash free versions and finally to fully synthetic alternatives. While these alternatives aim for chemical equivalence, they exhibit fundamentally divergent melting kinetics and thermophysical properties. This study analyses the operational issues...
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Ms Qingxin Xu (KTH Royal Institute of Technology)13/10/2026, 12:20Oral presentation (paper for journal’s special issue)
Non-metallic inclusions (NMI) are detrimental for the mechanical properties of steel since they usually act as defect initiation sites. NMIs could assume exogeneous (e.g. refractory, mould flux) or endogenous (e.g. re-oxidation) origins. The number and sizes of NMI that can be tolerated in tool steels which are used for demanding applications are even more stringent than regular steel grades....
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Mrs Noura BELAICHA (MinesParis - PSL - CEMEF)13/10/2026, 12:40Oral Presentation
In ingot casting, powder bags are placed inside the mold to release a complex mixture of oxides during filling. Their melting and spreading over the liquid metal form a protective layer that serves as an insulating barrier, prevents re-oxidation, and ensures mold lubrication. Effectiveness depends on the powder melting rate, governed by the free carbon content through a complex interplay of...
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Prof. Lev Medovar (CFHI, ELMET--ROLL)13/10/2026, 14:00Oral Presentation
Ingots used for manufacturing pipes, vessels, and shells can be either solid or hollow in cross-section. The technical and economic advantages of hollow forging ingots over solid ones have long been recognized. However, because casting hollow ingots is more complex than casting solid ones, both technologies are still used to produce thick-walled pipes, shells, and high-pressure vessels made of...
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Norbert ASAMER (BRAUN Maschinenfabrik GmbH)13/10/2026, 14:00Oral Presentation
Large-scale forgings and special alloy products need to be conditioned at various stages of their manufacturing processes, e.g. by cutting the cast or forged material to intermediate or final lengths as required free from heavy burr and surface hardening.
For cutting-off the deformed end pieces, for taking samples to check the material quality but also by removing scale, cracks, or other...
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Thomas Holzgruber13/10/2026, 14:20Oral Presentation
The quality of steel ingots is strongly influenced by melt flow during solidification, which remains difficult to control in conventional ingot casting and often leads to segregation defects and porosity. While various flow-control strategies exist, no widely adopted industrial solution is available for ingot casting.
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The Rotating Casting Mold (RCM) technology, developed by INTECO, introduces... -
Mr Andrei Filatov (NLMK DanSteel)13/10/2026, 14:20Oral Presentation
This work presents an investigation of pressure vessel steels P355NL2 and P460NL1 according to EN 10028-3. Heavy plates in the thickness range of 16-50 mm were rolled at NLMK DanSteel for CCS projects using controlled alloying, optimized rolling and heat treatment routes. P355NL2 was supplied in normalized condition (+N) and exhibits a homogeneous ferrite-pearlite microstructure ensuring...
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Anna-Lena Schäfer13/10/2026, 14:40Oral Presentation
Ingot-casting continues to play an important role in producing high-quality semi-finished products of high-alloy steels for large machinery. The final products are critical components, including crankshafts, which are exposed to elevated levels of mechanical stress. Therefore, it is essential that they meet high quality standards. The quality of the steel is influenced by various factors...
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Dr Martin Wolfgarten (SMS group GmbH)13/10/2026, 14:40Oral Presentation
Radial forging is a pivotal incremental forming process for manufacturing high-performance components with superior mechanical properties, particularly for aerospace applications and semi-finished products in medical engineering. Due to narrow processing temperature windows, strain-rate sensitivity, and stringent requirements regarding microstructural integrity, titanium and nickel-based...
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Dr Yanzhao Luo (Shougang Research Institute of Technology)13/10/2026, 15:00Oral Presentation
Non-metallic inclusions severely affect ultra-low carbon steel properties and continuous casting efficiency. This study applies pulsed electric current (PEC) to regulate inclusions by leveraging the positive charge of Al2O3 in molten steel. Industrial practice confirms PEC’s feasibility: it reduces nozzle inner wall adhering layer thickness, enables 7-heat continuous casting (≥1000 tons with...
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UDAY SHANKER GOEL (TATA STEEL INDIA)13/10/2026, 15:00Oral Presentation
Understanding and investigating roll failures in the hot mill is a very complicated subject. Post-mortem analysis requires for precision insights and actual data of the rolling mill. It requires deep technical knowledge of the subject of rolls and the rolling process.
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The present papers captures the journey into the investigation of Tata Steel’s Compact Strip Process (CSP) Back Up Roll ( BUR... -
Paixian Fu (Institute of Metal Research, Chinese Academy of Sciences)13/10/2026, 15:20Oral Presentation
The solidification of a 100 ton hollow steel ingot was simulated. In this approach the heat transferring into the core was extracted by a flow of fluid consisting of a mixture of liquid nitrogen and air. The heat transfer between the core and the casting was studied and found to depend on the engineering design of the core, the proportion of gases in the mixture, and the rate of flow. A...
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Falk Snatkin (Deutsch)13/10/2026, 15:20Oral Presentation
Fly-ash–based casting fluxes have been widely applied in ingot casting due to their advantageous physical properties such as low bulk density, good thermal insulation, and favorable flowability. However, current market and regulatory developments are increasingly challenging the availability and consistency of fly ash, creating significant impacts on flux formulation and casting performance....
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Dr Edgar Ivan Saldana-Garza (FRISA)13/10/2026, 16:10Oral Presentation
Ni-Fe superalloys are used for the fabrication of forged components for turbine applications with a maximum service temperature of around 600°C (1100°F) due to their excellent properties retention at elevated temperatures such as strength, corrosion, creep (time-dependent deformation), stress-rupture (time to fracture) and thermal stability. However, the trade-off from a manufacturing...
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Anna Mantelli (University of Brescia)13/10/2026, 16:10Keynote Presentation (paper for journal's special issue)
In steel industry, ensuring high steel quality is essential to guarantee superior performance of final components. However, defects such as shrinkage porosity, macrosegregation and non-metallic inclusions in steel ingots can adversely affect mechanical properties. Various software tools are currently used to simulate ingot filling and solidification. However, while these tools are known to be...
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Orlando Di Pietro (RINA Consulting - Centro Sviluppo Materiali SpA)13/10/2026, 16:30Oral Presentation
The growing use of machine learning (ML) in continuous casting offers new opportunities for process monitoring and quality optimisation. However, ML approaches that do not explicitly incorporate physical knowledge often show limited robustness, interpretability and extrapolation capability when dealing with complex defect phenomena such as crack formation.
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This contribution reports original... -
Mr Ovidiu Bogdan13/10/2026, 16:50Oral Presentation
Ingot size and shape, porosity, segregation and CET (columnar to equiaxial transition) zone position in steel ingots have significant influence on the quality of final product and are the main reasons why the ingot manufacturers need the right tools to choose the technology parameters to get a cost effective product and improve the internal quality of the ingots.
The goal of this work was...
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Dr Mikhail Trull (Sheffield Forgemasters)13/10/2026, 17:10Oral Presentation
Steels for fusion applications will have stringent chemical requirements due to the activation potential arising from the high energy neutrons – therefore prediction of casting-induced segregation is important to ensure specifications can be met. The NEURONE (NEUtron iRradiatiOn of advaNced stEels) programme is a UKAEA-led consortium looking to develop advanced reduced-activation...
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Matteo Gregori (RINA spa)13/10/2026, 17:30Oral presentation (paper for journal’s special issue)
This project focuses on the development of an advanced numerical modeling platform based on OpenFOAM for the simulation of remelting and solidification processes of metallic alloys through ESR and VAR. The modeling activity was validated through experimental trials carried out at both pilot scale and industrial scale for ingots with diameter above 1000 mm.
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The experimental campaign included... -
Prof. Valentina Colla (Scuola Superiore Sant'Anna)13/10/2026, 17:54Poster Presentation
The production of cast-iron disc brakes demands tight control over metallurgical and process parameters, as defects can compromise critical product properties. Defects compromising mechanical strength, alter natural frequency response, promote the formation of cementite and cause micro-shrinkage porosity, which represent frequent quality issues in ferrous metal foundries. They are particularly...
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71. Automatization of Barkhausen noise measurements for high resolution quality evaluation of steel.Mr Patryk Rybicki (Gdańsk University of Technology)13/10/2026, 17:56Poster Presentation
Introduction
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Understanding the stress distribution on the surface of a welded sample is crucial for evaluating the structural integrity of the product and ensuring the safe operation of industrial components. Measuring stress in such material can be done by utilizing Barkhausen effect phenomenon. During sample magnetization, movement of magnetic domain walls (DW) causes generation of... -
Roberto Fernandez Martinez (University of the Basque Country (UPV/EHU))13/10/2026, 17:58Poster Presentation
The application of machine learning techniques to the development of regression models aimed at minimizing electrical energy consumption in industrial heating processes has gained significant relevance in recent years. This approach enables accurate prediction of process behavior under specific operating conditions in a fast and cost-effective manner. One particularly relevant case study is...
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DİDEM KILIÇ OĞUROL (KARDEMİR ÇELİK SANAYİ AŞ.), CEYHUN KOZAK (KARDEMİR ÇELİK SANAYİ AŞ.)13/10/2026, 18:00Poster Presentation
This project aims to present an innovative solution for improving product quality and process efficiency in the production line through the analysis of the structural and operational limitations of existing straightening systems. Within the scope of the project, the design of a high-capacity straightening machine capable of accommodating various profile types is proposed in order to minimize...
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Dr Guoyi Shen (Key Laboratory of Advanced Forging & Stamping Technology and Science，Ministry of Education of China，Yanshan University; School of Mechanical Engineering, Yanshan University; National & Local Joint Engineering Research Center for Advanced Manufacture Forming Technology and Equipment，Yanshan University)13/10/2026, 18:02Poster Presentation
This study investigates the bulging deformation and poor dimensional accuracy observed during the roll bending of longitudinal pipes with a large length-to-diameter ratio, which arise primarily from insufficient upper-roll stiffness and a lack of external support. To address these issues, a novel anti-deflection roll bending (ADRB) process is proposed in combination with an optimized...
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Mr Thanh Chung Nguyen (Framatome)13/10/2026, 18:04Poster Presentation
Within the context of hot forming of metallic alloys and the optimization of process parameters, an intelligent surrogate model would be of interest for the identification of material behavior using industrial data. An accurate constitutive equation aims to improve the ongoing forging process. Furthermore, online calibration of the physical and/or constitutive parameters of the working...
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Mr Luca Bertoldi (Sales Director)14/10/2026, 08:50Oral Presentation
Over the past few years, Vecchiato has dedicated significant resources to researching and applying energy-saving technologies for Open Die Forging Presses. Building upon our patented HP3 flywheel system for hydraulic pumps, we have engineered and tested additional features to further optimize energy utilization.
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This paper presents a case study of a recent upgrade, wherein a new 4’000-ton... -
Arianna Gotti (Trasnvalor SA)14/10/2026, 08:50Oral Presentation
The internal quality of large steel ingots is an important target when designing and conducting the casting and solidification process.
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In bottom-poured ingots, exogenous inclusions must be minimized through proper filling system design and optimized casting practice, including suitable casting rates and correct distribution of casting powder on the liquid metal. This is often achieved by... -
Mr Stefan Pahnke (Pahnke Systems)14/10/2026, 09:10Oral Presentation
- Presentation Abstract
Abstract
This presentation explores the application of the Pahnke Modified Sinusoidal Drive (PMSD) as an
advanced, universal drive solution for hydraulic presses in the metal forming industry. Traditional
hydraulic drive systems often face challenges related to energy inefficiency, dynamic shock
loads, and control precision during heavy-duty operations. The PMSD...
- Presentation Abstract
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Chaouki TAHRI (ArcelorMittal)14/10/2026, 09:10Oral Presentation
Ductile damage is a major concern in hot forming processes, particularly in hot rolling, where it can compromise the mechanical integrity and performance of the final product. This work aims to minimize ductile damage risks in as-rolled bars through a combined approach of process optimization and advanced damage modeling. The optimization is carried out using Forge®, a simulation platform...
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Qi Liu (College of Mechanical Engineering. Taiyuan University of Technology, Taiyuan 030024, China)14/10/2026, 09:30Oral presentation (paper for journal’s special issue)
Forging simulation involves large deformation, material nonlinearity, and complex contact between the billet and dies. To support the development of independent finite element software for metal forming, this study develops linear elastic and elastoplastic solvers for forging analysis within a static implicit finite element framework. The computational procedure is organized using an...
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Prof. Mu Wangzhong (Lulea University of Technology)14/10/2026, 09:30Oral Presentation
Detection and characterization of non-metallic inclusions in casting (including continuous casting and ingot casting) is essential for ensuring steel quality. In recent years, image analysis processing of metallic materials based on machine learning and deep learning has developed rapidly, which a new technical tool for detecting defects in engineering materials, e.g. steels. There are several...
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Gulvir Singh (Guru Nanak Dev Engineering College, Ludhiana)14/10/2026, 09:50Oral Presentation
Steel ingot reheating and hot rolling are among the most energy-intensive stages of steel manufacturing, where significant thermal losses occur due to furnace inefficiencies, unplanned rolling delays, and lack of coordination between reheating and rolling operations. Conventional furnace control systems typically operate independently of downstream rolling conditions, resulting in overheating,...
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Qingshan Ding (College of Mechanical Engineering, Taiyuan University of Technology, Taiyuan 030024, China)14/10/2026, 09:50Oral presentation (paper for journal’s special issue)
Titanium/steel bimetallic composite tubes combine the excellent corrosion resistance of titanium with the high strength and low cost of carbon steel, and therefore have considerable application potential in demanding service environments such as petrochemical engineering, marine engineering, and shipbuilding. Owing to its high forming efficiency, simplified processing route, and high...
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Dr Hannu Suopajärvi (Sapotech Oy)14/10/2026, 10:10Oral Presentation
Sapotech’s Reveal CAST surface inspection system has been successfully implemented in Grinding Machine-3, marking a significant advancement in automated quality control for ingot processing. The collaboration with Daido Steel began in 2019 with a demonstration project using a portable inspection unit, highlighting the high-resolution imaging capability for both forged and ground surfaces....
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Pello Jimbert (University of the Basque Country UPV/EHU)14/10/2026, 10:10Oral presentation (paper for journal’s special issue)
On the path towards achieving the EU's 2050 net-zero steel emissions target, one strategy related to the steel making industry involves transitioning from heating processes that emit greenhouse gases (such as natural gas furnaces) to electric heating processes (such as resistance furnaces or induction heating systems). This study presents a methodology for this industrial transition using...
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Dr Zhiqiang He (Yanshan University)14/10/2026, 11:00Oral Presentation
Forging presses are key equipment for the high-precision forming of large forgings, and their hydraulic systems directly determine the loading capacity, motion accuracy, and forming stability of the equipment. To address the problems in the traditional design process of forging press hydraulic systems, such as reliance on engineering experience, data disconnection between CAD structural models...
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Mr Christof Dratner (Dipl.-Ing., Dipl.-Wirt. Ing.)14/10/2026, 11:00Oral Presentation
The transformation of the steel industry toward more sustainable and efficient production routes requires continuous innovation in remelting technologies such as Vacuum Arc Remelting (VAR) and Electroslag Remelting (ESR). High-performance copper components are essential in this context, as they directly influence process stability, product quality, and resource efficiency. This contribution...
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Chunhui Luo (Swerim AB)14/10/2026, 11:20Oral presentation (paper for journal’s special issue)
An Integrated Computational Materials Engineering (ICME) framework is presented for physics-based prediction of microstructure evolution in industrial steel processing, including ingot casting, reheating, and forging. The framework explicitly links macroscale process simulations with mesoscale, physics‑based, and CALPHAD‑based thermodynamic and kinetic models, enabling consistent mapping from...
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Henrik Franz14/10/2026, 11:20Oral Presentation
VIM/VIDP-Process is widely used for melting high value charge materials, refining, alloying under vacuum or protective atmosphere and finally for casting under defined environmental conditions. The equipment is suitable and dedicated for manufacturing high end grades, especially used in the aerospace industry. Besides those well-defined and specified alloy manufacturing routes where the...
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Mr Mohammed Kedir Mustofa (Indian Institute of Science Bangalore, Karnataka, India-560012)14/10/2026, 11:40Oral Presentation
This study investigates the effect of Cu addition (0, 0.5, 1, and 2 wt.%) on the microstructure, mechanical properties, and heat treatment response of in-situ Al-15Mg₂Si-4.5Si composites. These composites are fabricated using gravity-assisted Low Superheat casting (LSC) technique and characterized by optical microscope, X-ray Diffraction (XRD), Scanning Electron Microscope (SEM), Electron...
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Georg Maier (voestalpine Böhler Edelstahl GmbH & Co KG)14/10/2026, 11:40Oral Presentation
The forging industry is increasingly turning to data-driven process optimization and artificial intelligence systems to enhance efficiency, product quality and sustainability. These technologies rely heavily on robust, high-quality databases that provide consistent and reliable data for analysis and decision making. However, in many forging shopfloors, data is often dispersed across multiple...
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Gustav Häggström (Swerim AB)14/10/2026, 12:00Oral presentation (paper for journal’s special issue)
Open-die forging of ingots is one of the main hot metalworking operations in the metal industry. The operation improves the quality of the material by void removal and grain structure refinement, especially in the cogging process. To access the material quality, the internal strain evolution and final distribution are important. Previous work has focused on the use of empirical knowledge, FEM...
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Eike Schmilinsky14/10/2026, 12:00Oral Presentation
White spot defects continue to present a serious risk for critical components in aerospace (and other) applications where material integrity is essential. Despite more than 50 years of investigation into white spots and related segregation defects in alloys such as Inconel 718, their precise origins and reliable prevention remain only partially understood. Even with advanced melting practices,...
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John Campbell (University of Birmingham, UK)14/10/2026, 12:20Oral Presentation
A low cost adaption of bottom teeming of ingots, contact pouring, is found to raise the toughness of super duplex stainless steels by nearly an order of magnitude (ten times) by reducing the density of the damaging bifilm defect population. Simple additional features to divert the first damaged steel through the runner and away from the ingot, is predicted to further improve the ingot,...
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Mr Jörg Blum (DANGO & DIENENTHAL Maschinenbau GmbH)14/10/2026, 12:20Oral Presentation
Heavy-duty forging manipulators and handling systems are typically designed for operational lifetimes extending over several decades.
Many systems installed worldwide continue to operate successfully after more than 25 years of service.
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However, forge shop operators increasingly face challenges related to changing production requirements,
higher load demands, outdated automation systems,... -
Joachim von Scheele (Linde GmbH)14/10/2026, 14:00Oral Presentation
Since 1990 Linde has converted 190 reheat furnaces to oxyfuel operations; 62 of them for heating of ingots before rolling or forging. Oxyfuel combustion can significantly increase energy efficiency and immediately reduce the carbon footprint, paving the way for the efficient future use of hydrogen as fuel. An overview of these installations and technology used, Flameless Oxyfuel, is...
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Shufeng Wei (College of Mechanical Engineering, Taiyuan University of Technology, Taiyuan 030024, China)14/10/2026, 14:00Oral presentation (paper for journal’s special issue)
Pure titanium ultra-thin strips have extensive applications in the aerospace, new energy, and electronic communication industries. However, pure titanium exhibits poor formability at room temperature and high deformation resistance; conventional cold rolling processes for producing pure titanium ultra-thin strips face challenges such as significant work hardening, limitations on rolling...
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Takahiro Makiyama (Institute of Technologists)14/10/2026, 14:20Oral Presentation
To reduce CO2 emissions in the transportation industry, weight reduction and resource efficiency are crucial issues. Tubes with variable cross-sections offer significant advantages in meeting these needs. This research examines the effects of different axial feed directions on the forged shape in the proposed mandrel-less incremental forging. Compared to conventional forming processes such as...
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Milan Hnizdil (Brno University of Technology, Heat transfer and fluid flow laboratory, Faculty of Mechanical Engineering)14/10/2026, 14:20Oral presentation (paper for journal’s special issue)
Efficient control of heat transfer during hot rolling is essential for both product quality and rolls lifetime. This paper presents results from research on various descaling strategies and work-roll cooling.
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Experimental investigations of various descaling systems—including conventional high-pressure nozzles, opposite-nozzle configurations, hydromechanical rotary descaling (HIDROD), and shot... -
Alberto Vazquez14/10/2026, 14:40Oral Presentation
The supply of large-diameter bars in stainless and special steels has historically been constrained by process limitations, with forging routes dominating production above 6 inches due to perceived advantages in internal soundness and metallurgical control. However, increasing demand for consistency, productivity, and cost efficiency in critical applications is progressively redefining the...
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Gustav Häggström (Swerim AB)14/10/2026, 14:40Oral presentation (paper for journal’s special issue)
Dimethyl ether (DME) has emerged as a promising renewable alternative to natural gas and liquefied petroleum gas (LPG), producible through both thermochemical and electro‑fuel pathways. With combustion characteristics comparable to methane and a similar Wobbe index, DME offers favorable handling properties as a condensable gas that can be stored long‑term at moderate pressures (<10 atm). These...
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SHUO GUO (Policlinico di Milano)14/10/2026, 15:00Oral presentation (paper for journal’s special issue)
Predicting hot workability is a critical challenge in thermomechanical processing. Traditional approaches are primarily based on the theory of hot processing maps, which evaluate power dissipation efficiency and deformation instability factor under various deformation conditions. The power dissipation efficiency characterizes the kinetics of microstructural evolution, whereas the deformation...
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Matteo Gregori (RINA Consulting – CSM S.p.a.)14/10/2026, 15:00Oral presentation (paper for journal’s special issue)
The modern steel industry is undergoing a profound paradigm shift driven by digital transformation and the urgent need for process decarbonization.Central to this evolution is the electrification of reheating processes before rolling, a fundamental necessity for the abatement of CO2 emissions of existing steel plants.Within this context, electromagnetic induction stands out as a primary...
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Ruowei Li (Politecnico di Milano)14/10/2026, 15:20Oral presentation (paper for journal’s special issue)
FeMnAlC lightweight steel exhibits a narrow hot-working window. In industrial rolling, shear stress and dynamic parameter variations are unavoidable and may induce defects. This study compares the hot deformation behavior of Fe-25Mn-5Al-0.7C steel under uniaxial compression versus shear compression using Gleeble 3800 tests at 950–1100 °C and 0.01–10 s⁻¹, including sudden temperature/strain...
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Mr Angelo Ferranti (Contec Industry)14/10/2026, 15:20Oral Presentation
This study analyzes the application of WASM - Water Assessment for Sustainability Method, a structured decision-support framework that enables the evaluation of scenarios, risks and technological alternatives prior to operational investments.
The method is structured into 4 phases—Decision Governance, Technical Validation, Solution Design and Implementation—ensuring an...
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Božidar Šarler (University of Ljubljana and Institute of Metals and Technology)14/10/2026, 16:10Oral Presentation
A part of the digitalisation efforts in the steel industry concerns the numerical optimisation of the steel production chain to increase quality, productivity, and sustainable production. We present the multiscale computational modelling of a typical steel processing route, comprising continuous casting, controlled cooling, annealing, reheating, reverse and continuous hot rolling, cooling bed,...
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Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano), Prof. Davide Mombelli (Politecnico di Milano - Dipartimento di Meccanica)14/10/2026, 16:10Oral presentation (paper for journal’s special issue)
The integrity of large forged components is strongly influenced by macrosegregation phenomena inherited from ingot solidification. In this work, the failure analysis of a large forged turbine shaft (built by 1.6311 steel) is presented to investigate the relationship between manganese segregation, hydrogen-assisted cracking and MnS inclusion formation.
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Ultrasonic inspections revealed an... -
Haoran Xu (Institute of Metal Research, Chinese Academy of Sciences)14/10/2026, 16:30Oral Presentation
A dynamic permeability model based on real-time local solidification time (LST) is proposed to improve macrosegregation prediction in alloy directional solidification. By tracking the solidification history of each computational cell with a state-machine algorithm, the model dynamically updates the secondary dendrite arm spacing (SDAS) using an experimental LST–SDAS relationship and evaluates...
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Dr Sunrui Tao14/10/2026, 16:30Oral presentation (paper for journal’s special issue)
High speed steel work rolls in hot rolling are subjected to severe conditions involving high temperature, heavy load, and complex sliding behaviors, where surface damage affects roll service life and strip surface quality. The coexistence of forward and backward slip zones within the deformation region leads to periodic reversal of friction direction during rolling process. However, its...
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Nikolay Biba14/10/2026, 16:50Oral Presentation
The work introduces a unified virtual process chain for rail production that combines roll pass design, hot rolling, differential quenching of the rail head, and final straightening within a single simulation route. The first stage is carried out in QKaliber, where analytical models are used to evaluate pass geometry together with the main process variables, including deformation, thermal...
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Christian Redl (INTECO melting and casting technologies GmbH)14/10/2026, 16:50Oral Presentation
The modernization of the Plate Mill at People Steel Mills (PSM) focused on the implementation of an advanced descaling system to enhance operational efficiency, product quality, and energy performance. Supplied by INTECO Rolling Mill Technologies, this targeted upgrade improves the production of alloy and special steels while contributing to more sustainable plant operation.
A key element...
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Cristian Viscardi (ECOTRE Valente srl)14/10/2026, 17:10Oral Presentation
ESR (electroslag remelting) process is fundamental in heavy forgings manufacturing, especially for energy and aerospace application. The aim of this paper is to analyze the quality and grain size of a nickel based remelted ingot using casting simulation software ProCAST. Melt pool profile, temperature distribution and solidification structure will be used to analyze quality; focus will be...
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Xiaomiao Niu (Taiyuan University of Technology)14/10/2026, 17:10Oral Presentation
The interfacial bonding strength of bimetallic composite strips remains a major limiting factor for their application in high-end engineering fields. Roll bonding is commonly used to fabricate bimetallic composite thin strips, and post processing is required in order to improve the interfacial bonding strength. Conventional annealing processes after roll bonding often lead to excessive...
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Claudia Solari (AIM)14/10/2026, 17:30Oral Presentation
OMEGA: 2 machines in one!
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Historically two types of machines being based on different technologies and with a very high productivity have been built: double station radial-axial hydraulic ring mills as well as multi-mandrel ring mills for closed-tool ring rolling.
Based on an over 20 year’s experience with multi-mandrel and radial-axial ring mills, we have designed a new machine type... -
Dr Ferruccio Pastorino14/10/2026, 17:30Oral Presentation
Uphill casting is widely used to cast high quality ingots in order to reduce several defects coming from gas or solid trapped inclusions, inhomogeneity, holes consequent to the direct pour casting etc. Uphill casting reduce turbulence, improve slag removal by floating slag particles on the ingot top. Notwithstanding that, there are several reasons that can generate troubles in the final...
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Alberto Nardini15/10/2026, 08:40Oral Presentation
The billet welding machine is an efficient and effective solution to improve the productivity and reduce consumptions, applicable both on new as well as existing long products mills. The Third Generation of the ERT-EBROS billet welder by POMINI Long Rolling Mills is equipped with several advanced functions. The first part of the paper focuses on the layout and technical features. In the second...
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Marco Alloni (Prosimet S.p.A.)15/10/2026, 08:40Oral Presentation
Casting powders for ingot production have evolved from generic insulating materials to highly tailored products designed for specific steel and alloy families. Early powders, largely based on fly ash, provided basic thermal insulation and surface protection for ingot casting but offered limited control over melting behavior, viscosity, and steel–slag interactions.
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The introduction of... -
Mr Andrea Canal15/10/2026, 09:00Oral Presentation
QSP-DUE® direct casting and rolling technology allows three production modes: coil-to-coil, semi-endless, and full endless. These modes enable the production of various steel grades and strip formats, meeting end-user needs. The technology's maturity is evidenced by concrete applications.
The process offers a wide product mix, catering to various market needs, with perspective towards...
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Prof. Ganna Stovpchenko (CFHI, UDUNT)15/10/2026, 09:00Oral Presentation
Additive Manufacturing (AM) has become a mainstream technique for layer-by-layer fabrication of parts with complex geometries directly from digital files. For metal parts, two primary limitations hinder widespread industrial adoption: low productivity and high cost, driven by the use of small-sized powder and wire feedstocks. As a result, AM is currently used mainly for critical parts in...
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Alberto Nardini15/10/2026, 09:20Oral Presentation
The Horizon platform by POMINI Long Rolling Mills represents a transformative approach to digital twin technology in the metals industry. Horizon enables the creation and management of comprehensive digital twins, serving as virtual counterparts to physical assets and processes throughout the entire plant lifecycle. By integrating advanced knowledge engines and a suite of dedicated...
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Mr Alexander Weigl (Inteco melting and casting technologies GmbH)15/10/2026, 09:20Oral Presentation
Vacuum ingot casting is experiencing a strong revival driven by rising demand for large, high-integrity forged components in critical applications such as power generation and heavy machinery. This paper outlines the metallurgical principles and modern technological developments of the process to enhance degassing and minimize reoxidation. Focus is placed on current plant concepts, such as...
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Mr Julio Espinoza15/10/2026, 09:40Oral Presentation
Since its startup ten years ago, FRISA Steelmaking has continuously advanced its production routes to achieve ultra-clean specialty steels, targeting increasingly stringent requirements in critical applications. Through advanced data-driven and predictive process control at the end of vacuum treatment, FRISA consistently achieves hydrogen levels below 0.80 ppm, virtually eliminating...
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Ulrich Koppers (KOMETeso GmbH & Co KG)15/10/2026, 09:40Oral Presentation
“KoPROFILE” is the first analytical simulation program for profiled ring rolling with calculations times of less than 1 minute for a whole process.
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The user can now make multiple calculations with variations of process parameters. “KoPROFILE” is the first real optimization tool for ring rolled products.
It reduces significantly the development costs of a product (tool, material and... -
Ravi Kumar (Indian Institute of Science, Bangalore, Karnataka, India-560012)15/10/2026, 10:00Oral Presentation
Aluminum-based hybrid foams are emerging as advanced lightweight materials owing to their excellent energy absorption capability, corrosion resistance, and enhanced impact performance, making them highly suitable for aerospace, automotive, and defense applications. In the present study, the strain rate-dependent compressive behavior of in-house developed Novel Al–Cenosphere–MWCNT composite...
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Alberto Nardini15/10/2026, 10:00Oral Presentation
To optimize the product cost realization, increase yield and plant efficiency, decrease energy consumption and envirovment, the effect of verticalization and the dynamic control of process are fundamental key factors.
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In this study will figure out how last technology solutions for hot rolled bar along the production line can give advantage relative for operations and quality aspects... -
Dr Peng Li (Taiyuan University of Technology)15/10/2026, 10:50
A novel “electric current pre-treatment + corrugated–flat rolling” (E-CFR) process was developed to fabricate high-strength and high-ductility Ta-12W refractory alloy, effectively suppressing macroscopic delamination during plastic deformation and achieving a superior strength–ductility synergy. The process involves two rolling passes: corrugated rolling in the first pass to introduce a wavy...
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Thomas Leitner (voestalpine BÖHLER Edelstahl GmbH & Co KG)15/10/2026, 10:50Keynote Presentation
The precise control of grain size during hot deformation is paramount for the mechanical integrity of aerospace-grade nickel-base superalloys. This study investigates the recrystallization behavior of Nickel-base alloy 718 by employing classical hot deformation experiments in combination with a novel experimental setup: a DSI Gleeble 3800 thermal-mechanical simulator integrated with a Laser...
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Mahesh Venkataraman (OFFICINE NICOLA GALPERTI E FIGLIO SPA), Mattia Gianola15/10/2026, 11:10Oral Presentation
This project aims to qualify the heat treatment cycle for a Ti 6Al 4V (Grade F5) component produced by forging and ring rolling, in order to ensure compliance with the mechanical properties and microstructural requirements. The ring (OD 720 mm x WT 17 mm x H 885 mm) has been manufactured for particle physics research, as a part of an accelerator beam system.
A structured manufacturing and...
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Dr Antonio Di Mauro (Nippon Sanso Industrial)15/10/2026, 11:30Oral Presentation
Tuur De Preter1, Joaquín de Diego2, Akira Morokuma3, Yoshiyuki Hagihara4, Jorge Visús5
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tuur.depreter@eu.nipponsanso.com
1 Nippon Sanso Euro-Holding, Lammerdries Oost 29, 2250 Olen, Belgium
2 Nippon Sanso Euro-Holding, Orense 11 9ª, Madrid 28020, Spain
3 Nippon Sanso Holding Corporation, 3054-3 Shimokurosawa, Yamanashi, Japan
4 Nippon Sanso Holding Corporation, 1-3-26 Koyama, Tokyo... -
Dr Ettore Anelli (Franchini Acciai SpA)15/10/2026, 11:50Oral Presentation
The results of the development of normalized (P355NH) and quenched and tempered (P355QH) forged pipes (thickness from 20 mm to 70 mm) and P355QH connecting parts (thickness up to 420 mm) are described in this work. In the light of the target properties, concepts for proper steel design are discussed. A metallurgical analysis, including the role of chemical composition, forging and heat...
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Prof. Andrea Di Schino (Dipartimento di Ingegneria, Università di Perugia, Via G. Duranti 93, 06125 Perugia, Italy)15/10/2026, 12:10Keynote Presentation (paper for journal's special issue)
The development of steel “lean” chemical composition to be adopted for cylinders application is increasingly requested, aimed to reduce the critical alloying elements content while preserving adequate mechanical performance. In this framework the analysis of the heat treatment effect (temperatures and cooling rates) on microstructure evolution (hence mechanical properties) is a key issue. This...
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