ICRF 2026 - 5th International Conference on INGOT CASTING, ROLLING & FORGING

13 Oct 2026, 08:15 → 15 Oct 2026, 13:00 Europe/Rome

Hotel Caesius Terme & SPA Resort - Bardolino - Verona

Alessandra Saleri (Forge Fedriga srl), Jacopo Longhi Vienna (GIVA group)

ABOUT ICRF Advancing the Future of Steel Manufacturing Through Innovation and Sustainability. The global steel industry is at a pivotal moment, navigating the dual challenges of technological advancement and environmental responsibility. The hot deformation production chain—spanning ingot casting, forging, and ring rolling—must evolve to meet rising demands for efficiency, precision, and sustainability. ICRF 2026 will serve as a critical forum for industry leaders, researchers, and innovators to explore the latest breakthroughs in improvement of product quality, process optimization, digital transformation, and AI-driven manufacturing. As the sector embraces simulation systems, smart automation, and data-driven decision-making, this congress will foster essential dialogue on how to integrate these technologies while reducing environmental impact. By bridging cutting-edge research with industrial applications, ICRF 2026 aims to shape a more sustainable, competitive, and innovative future for ingot casting, forging and ingot rolling. WHO SHOULD ATTEND? The intention is to involve the entire production chain, such as steelmakers, forging and rolling companies as well as research centres, laboratories and universities for an important comparison on the best practices used nowadays in field of ferrous and non-ferrous hot deformation.

              SUBMIT YOUR ABSTRACT BY MAY 18, 2026!

              REGISTRATIONS ARE OPEN!
              To register go to: https://register.m-n.marketing/aim/icrf2026/

Flyer

Tuesday 13 October

08:15 Registration of attendees

Registration will be possinel at all times

Opening session

Conveners: Alessandra Saleri (Forge Fedriga srl), Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)

09:00 Welcome addresses

1 Current Practices, Challenges and Industrial Perspectives in Modelling of Casting Processes

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 to enhance dissemination, training, networking and awareness on casting modelling practices (at first focused on continuous- , but relevant also for ingot casting).
This contribution presents quantitative results from a cross stakeholder survey carried out at the conclusion of the METACAST project, focusing on the role of modelling in continuous casting of steel. A structured questionnaire was submitted to European stakeholders targeting three main perspectives: modelling users, training approaches, and management views. The survey explored familiarity with modelling tools, current usage patterns, perceived value, bottlenecks, and expectations for future developments. The results demonstrate a broad consensus on the strategic relevance of modelling to support process optimization, defect mitigation and metallurgical understanding, especially when applied as a fast and reliable support to operational decision making. Model users emphasize its usefulness for process understanding and troubleshooting, while reporting significant variability in expertise levels and frequency of use. Training related feedback reveals fragmented and uneven capability building practices. Formal training programmes are often absent or limited to R&D profiles, mainly due to resource constraints, lack of specialised trainers and insufficient alignment with plant level needs. From a management perspective, modelling is largely perceived as valuable, but investments are hindered by unclear return on investment, high costs and time to answer constraints. Rapid delivery of actionable results and concise evidence of benefits are identified as decisive factors to foster stronger organisational commitment.
Successful digitalisation of casting processes relies not only on advanced modelling capabilities, but also on structured capability building, evidence‑based dissemination and stakeholder coordination.

Speaker: Michele De Santis (RINA Consulting - Centro Sviluppo Materiali SpA)

2 Manufacturing and Remelting Technologies

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 (Argon Oxygen Decarburization), VOD (Vacuum Oxygen Decarburization), and VIM (Vacuum Induction Melting), followed by remelting processes like ESR (Electro-Slag Remelting) and VAR (Vacuum Arc Remelting). Each process is described in terms of its operational parameters, productivity, and metallurgical outcomes.
VIM and EAF-AOD manufacturing are compared, highlighting differences in furnace size, capacity, flexibility, productivity, and charging costs. Metallurgical comparisons emphasize the advantages of VIM in casting under vacuum, for high flexibility and handling narrow analytical ranges, while EAF-AOD excels in capacity, productivity, lower costs and slag metallurgy.
The remelting processes, VAR and ESR, are analyzed in detail, including their recipes, trends, and benefits. VAR focuses on vacuum remelting for gas reduction and solidification control, while ESR utilizes slag to refine the alloy and obtain better ingot surface quality.
Electrode preparation is another critical aspect, with steps such as grinding, extremities cutting, and stub welding to ensure proper geometry, cleanliness, and alignment. During these phases it is essential to maintain cleanliness, to avoid contamination during remelting operations.
The final aim of this overview is to focus on remelting best practices, emphasizing the importance of cleaning and protecting equipment to ensure high-quality outcomes in remelting processes. A meticulous attention to contamination prevention and process optimization is the base to build the mindset that "Every remelt is a new beginning”.

Speaker: Matteo Marten-Perolino (AIM)

3 'Update on Special Steels, Titanium and Powder Metallurgy’

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 promising market segments and touches on the production of Metal Powders and Powder Metallurgical Steels and especially its associated production technologies like HIP, MIM and AM. As they are and will become key future core technologies for a number of demanding products and thus for the usage in different associated industries. The presentation will also highlight the actual supply and demand situation of metal powders and the manufactured metal powder steels, will introduce leading manufacturers of both powders and steels, and summarizes installed capacity and new capacity that are on the way.

Speaker: Benedikt Blitz (SMR Premium GmbH)

10:50 Coffee break

Numerical Simulation, AI & Digital Innovation I

Convener: Daniele Brunelli (GIVA spa)

4 Experimental determination of partition coefficients considering peritectic reactions and application to macro-segregation simulation in a large steel ingot

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 Fe‑based alloys involving a peritectic reaction that changes the solid phase during solidification. In this study, an experimental method accounting for changes in partition coefficients associated with the peritectic reaction was developed by combining random sampling method, mass-balance analysis, and unidirectional solidification.
A low‑alloy steel exhibiting the peritectic reaction was used. The specimen was unidirectionally solidified upward in a resistance‑heating furnace and quenched during solidification. Two regions on a vertical cross‑section were sampled before and after the onset of the peritectic reaction, exhibiting ferritic and austenitic solidification, respectively. Solute concentration distributions of Mn, Ni, Cr, Mo and V were obtained using an electron probe microanalyzer (EPMA). Random sampling was applied to determine solute concentration profiles, and partition coefficients for each element were calculated through mass-balance analysis.
The partition coefficients of Mn and Cr showed no significant change across the peritectic reaction. In contrast, those of Mo and V decreased, while that of Ni increased after the reaction. These variations were attributed to changes in the solidification phase induced by the peritectic reaction. The partition coefficients obtained by the proposed method showed slight deviations from equilibrium values due to back diffusion. Solidification simulations of compositional segregation using the determined partition coefficients showed good agreement with the segregation in an actual steel ingot.

Speaker: Shintaro Yano (Material technology laboratory, The Japan Steel Works, Ltd.)

5 Minimization of mould flux entrapment during ingot casting through CFD modelling

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 inlet designs, such as by adding baffles to the runner, by placing the inlet tangential to the mould, and by modifying the trumpet’s design. Both qualitative (e.g. hump height, free surface area) and quantitative (e.g. velocity profile, oscillation of surface) evaluations are performed for the different designs and are benchmarked against today’s standard uphill ingot casting process. The results can be used to improve the existing casting geometry, and also to gain in-depth knowledge about the transient flow behavior during the ingot casting process to facilitate further process optimization.

Speaker: Prof. Yu-Chiao Lu (KTH Royal Institute of Technology)

6 Transition to synthetic casting fluxes in ingot casting area, Acciaierie Bertoli Safau case study: analysis of process variables and qualitative impact following the fly ash supply crisis.

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 encountered in the casting phase, focusing on how the change in raw material matrix has triggered instabilities, with a subsequent impact on both the surface integrity and macro-cleanliness of the ingots.

The current industrial framework demands a paradigm shift in the steel plant - supplier relationship; manufacturers must move beyond mere chemical specification compliance toward active co-engineering of flux performance. Current production scenario shows a significant qualitative regression compared to historical benchmarks. Current traditional powders no fly ash based, give extremely irregular surfaces and a critical frequency of powder entrapment. Conversely new synthetic solutions do not yet guarantee results equivalent to the past.

This paper documents a comprehensive optimization period focused on recalibrating specific consumption rates and flux positioning strategies, Furthermore, all the surrounding variables are analysed inherent to ingot casting. Findings demonstrate that the adoption of synthetic fluxes is not a "drop-in" replacement but an unresolved metallurgical challenge. The identification of a stabilized equilibrium remains a work in progress, requiring rigorous, continuous monitoring to mitigate material-specific limitations and restore process stability.

Speaker: Sara Busolini (Acciaierie Bertoli Safau)

7 Characterization of mould flux-originated non-metallic inclusions in ingot casting

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. At Uddeholm AB in Sweden, some of the cast steel ingots are used as consumable electrodes in electroslag remelting (ESR) treatment to decrease macrosegregation and also the number and size of NMIs to obtain high-quality clean steel products. As the final cleanliness of the remelted ingot is partly inherited from the incoming electrode, it is crucial to develop a comprehensive understanding of its cleanliness. This study investigates the occurrence of mold-flux-originating NMIs by a combination of 2D and 3D methods in a cast tool steel electrode, motivated by such NMIs often have been found to be of large size. 2D inclusion analysis was performed using SEM-EDS on a polished metal surface to study the elemental distribution within the NMIs; 3D inclusion analysis was carried out using electrolytic extraction (EE) technique followed by an analysis of the filtered inclusions using SEM-EDS to gain large statistics of the location, size, morphology, and the compositions of the NMIs. Then, thermodynamic calculation was performed to evaluate the interaction between mould-flux inclusions and ESR slags. The results of this study could be used to improve the existing ingot casting process and also to optimize the ESR process for the production of high cleanliness steels.

Speaker: Ms Qingxin Xu (KTH Royal Institute of Technology)

8 A Multiphysics Front-Tracking Model for Thermochemical Evolution of Casting Powders during Ingot Casting

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 heat transfer, combustion kinetics and gas transport phenomena (Mills and Däcker, 2017). No model fully captures this complexity. Purely thermal models neglect chemical effects, kinetic models reduce reactions to temperature dependence, and the most complex approaches remain restricted to 850 °C, far below the 1500 °C of industrial conditions (Supradist et al., 2004).
A novel one-dimensional multiphysics front-tracking model is being developed to investigate powder evolution during bottom-pouring ingot casting and describe the melting stage. The powder bed is represented as three successive domains: liquid slag, a mushy zone and loose casting powder, bounded by liquid steel below and open air above. Coupled energy and mass conservation equations are solved within a transient moving-grid framework and integrated with CALPHAD-based thermodynamic calculations, describing phase transformations and interface positions. Each interface evolves according to a local mass balance equation. Phase change, carbon combustion, powder densification and multi-component gas transport are treated simultaneously within a unified formulation.
The model predicts the spatial and temporal evolution of temperature, carbon concentration, gas species composition and liquid slag thickness. Carbon concentration is tracked because residual carbon threatens steel quality through carburization (Supradist et al., 2004), while O₂, CO and CO₂ profiles help identify whether oxidation governs carbon removal. Simulations are expected to reveal the dominance of the Boudouard reaction above 1000 °C and that exothermic carbon combustion paradoxically slows melting, as energy is transported away by product gases rather than transferred to the powder.

Speaker: Mrs Noura BELAICHA (MinesParis - PSL - CEMEF)

13:00 Lunch

Lunch is served as seated buffet at the restaurant Benacus on the 1st floor

Ingot casting and remelting I

Convener: Annalisa Pola (University of Brescia)

9 Features of the solidification of large ESR hollow ingots

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 alloy steels for critical applications, particularly in power and petrochemical engineering. A similar situation arises regarding the products required ESR (electroslag remelting) quality. In many cases, forging or rolling critical components is performed from solid ESR ingots, despite the undeniable advantages of ESR hollow ingots for increased production efficiency and improved physical and mechanical properties of the steel used in such components. Initially, ESR hollow ingot technology was developed and applied in Ukraine and several other countries to produce thick-walled pipes and pressure vessels made of high-strength steels using remelting consumable electrodes.
CFHI has recently been exploring the potential of a new ESR technology for large hollow ingots, developed by ELMET-ROLL. The technology involves directly introducing refined liquid metal into a current-supplying mold (CSM), eliminating the need for consumable electrodes. Using two transformers offers additional possibilities for controlling solidification. A mathematical model of hollow ingot solidification was developed, providing a general picture of the temperature distribution in hollow ingots of type 316 steel for various internal mold applications. Key attention is focused on the solidification characteristics of large hollow ingots for power-generating machines and units, primarily made of stainless steel. Comprehensive, step-by-step modeling of the temperature distribution in ingots weighing up to 200 tons and with outside diameters reaching 3000 mm has indicated the need to reduce the cooling rate of the hollow ingot wall near the lower section of the internal mold, a significant factor to consider in their production.

Speaker: Prof. Lev Medovar (CFHI, ELMET--ROLL)

10 Improving Ingot Quality Through Controlled Melt Flow: Industrial Application of Rotating Casting Mold (RCM) Technology

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.
The Rotating Casting Mold (RCM) technology, developed by INTECO, introduces a mechanical approach to actively control melt flow during solidification. By inducing rotational motion of the mold, forced convection is generated throughout the ingot, promoting a more uniform grain structure and improving central soundness.
In this study, industrial-scale casting trials were conducted on two 21-ton steel ingots to compare conventional ingot casting with the RCM technology. The results demonstrate a significantly improved solidification structure, characterized by a finer and more homogeneous grain structure, an increased equiaxed region, and reduced segregation and porosity.
To support the experimental findings, a physics-based CFD model was applied. The simulations indicate that mold rotation promotes fragmentation and enhances equiaxed grain formation, leading to the observed structural changes. Good agreement between experimental and numerical results confirms the predictive capability of the model.
Overall, the results highlight the strong potential of RCM technology for improving ingot quality and provide a basis for further process optimization.

Speaker: Thomas Holzgruber

11 Closing the quality Chain: Refractories and their Influence on Ingot Steel Quality

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 throughout the entire process. During casting, the use of suitable refractory materials with appropriately designed channel geometries is crucial to prevent the formation of inclusions or surface defects. Whilst products must meet the highest quality standards, economic factors frequently influence the selection of refractory materials, resulting in the application of low-quality materials.
It is well known that certain alloying elements can reduce components of Al₂O₃-SiO₂ refractory materials, such as free SiO₂ and Fe2O3, which leads to the re-oxidation of the alloying elements. The specific elements involved can be estimated by consulting the electrochemical series. Based on this knowledge, suitable materials can be selected to decrease the reactions between liquid steel and the refractory material and thus inclusions in the product.
An additional measure that has the potential to enhance the quality of the ingot surface is the creation of an advanced channel design to ensure a constant flow of steel with minimal turbulence. A stable steel flow is crucial for producing an ingot with good surface quality, which subsequently results in reduced scrap. The innovative SmartCast spider brick design and customized endrunners are possibilities to ensure this.
The refractory material used during casting has a clear impact: Investing in refractory material means investing in the quality of the ingots.

Speaker: Anna-Lena Schäfer

12 A Novel Method to Regulate Non-metallic Inclusions by Pulsed Electric Current in Ultra-Low Carbon Steel and Industrial Practice

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 single nozzle), and eliminates >20 μm inclusions. The proportion of ≤5 μm inclusions increases, mold-level stability improves. Overall, PEC regulation improves steel cleanliness, inclusion size distribution, mold-level stability, and reduces defects, providing technical support for high-quality ultra-low carbon steel production.

Speaker: Dr Yanzhao Luo (Shougang Research Institute of Technology)

13 Current challenges of fly ash-based casting fluxes

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. High carbon fly ash, formerly produced by older, less efficient coal-fired power plants, is becoming scarce as modern plants generate ash with considerably lower residual carbon contents (<5%). At the same time, political decisions and the progressing coal phase-out across Europe drastically reduce overall fly ash supply, leading to rising costs and stronger fluctuations in composition.
Compensating the missing residual carbon solely by adding pure carbon carriers affects combustion behavior, resulting in accelerated burning, increased consumption, reduced insulation, higher slag viscosity, and impaired lubrication—effects that can directly influence surface quality and inclusion pick-up behavior during casting. In addition, material segregation and transport-induced consolidation pose further risks for mixture homogeneity, emphasizing the need for adapted handling procedures.
To address these challenges, several strategic pathways are emerging. The qualification of granulated casting powders helps stabilize physical properties such as flowability and homogeneity. Moreover, semi-synthetic fluxes—which limit fly ash content and compensate chemical and physical fluctuations by targeted raw materials—provide more consistent performance. Fully synthetic fluxes, formulated without fly ash and based on controlled oxides and mineral raw materials, minimize property variations and reduce the need for frequent recipe adjustments. These approaches mirror earlier developments in continuous casting and represent robust solutions for ensuring process reliability and casting quality under changing raw material conditions.

Speaker: Falk Snatkin (Deutsch)

Rolling, Forging & Hot Deformation I

Convener: LUIGI CHINAGLIA (FOMAS S.p.a.)

14 LATEST DEVELOPMENTS IN ABRASIVE CUTTING AND GRINDING OF LARGE-SCALE FORGINGS

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 defects from the product surface the temperature of the workpiece could be in a range from ambient to forging temperature.

In additon, prior to further processing of semi-finished steel and special alloy products, it must be also ensured that the surface of the work pieces is free from scale and flaws.

For both applications, even for increasingly large product dimensions and regardless of if the product to be ground or cut is cold or hot, a state-of-the-art solution, either with the multi-functional HP (high-pressure/high-performance) grinding machine or with the dry abrasive cut-off machine is required.

Speaker: Norbert ASAMER (BRAUN Maschinenfabrik GmbH)

15 Weldability Investigation of Industrial Heavy Plate Steels for Pressure Vessels Designed for Mobile CO₂ Storage Applications

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 strength and high low-temperature toughness. P460NL1 was produced in normalized rolled condition (+NR) and provided increased yield strength while maintaining sufficient toughness.
These steels represent two engineering approaches for pressure vessel construction: normalized plates with stable weldability and higher-strength plates allowing reduction of structural weight. For P355NL2, testing included plate-by-plate tensile tests, impact toughness at -50 °C and -45 °C, hardness measurements, and samples after simulated post-weld heat treatment (sPWHT). For P460NL1, testing included tensile tests, impact toughness testing at -20 °C and -40 °C, and hardness measurements. Weldability was evaluated on 37 mm P355NL2 plates welded with symmetric X-groove preparation by SAW process 121 LSO at 2.1 ± 0.1 kJ/mm, and on 34 mm P460NL1 plates welded with V-groove preparation by SAW process 121-2 at 1.5 ± 0.1 kJ/mm. Welded joints were characterized by macro- and microstructural analysis, hardness measurements, segmented impact toughness testing across weld zones, and, for P460NL1, CTS and BoP tests.
The results confirm that both steels meet EN 10028-3:2017 requirements and demonstrate stable mechanical properties and weldability for mobile CO₂ pressure vessels.

Speaker: Mr Andrei Filatov (NLMK DanSteel)

16 Latest developments in radial forging technology for titanium and nickel alloys

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 alloys pose significant challenges to process management. To enhance process efficiency, ensure reproducible quality, and reduce energy consumption, this paper presents the latest developments by SMS group in the fields of automation, process technology, and machine drive concepts. Particular focus is placed on a novel forging strategy ("2+2 forging") as well as an energy-efficient drive concept for hydraulic forging presses and radial forging machines.
The current challenges in radial forging can be categorized into four primary areas of action: First, process reproducibility requires precise control to ensure consistent component quality and homogeneous properties. Second, the shortage of skilled labor intensifies the need to reduce operator dependency and design highly automated, robust operations. Third, energy efficiency must be improved to mitigate rising energy costs and reduce the carbon footprint through lower energy consumption and reduced connected electrical loads. Fourth, the requirements for material properties continue to increase, necessitating innovative forging techniques to achieve microstructural homogeneity, fine grain size, and exceptional material performance in titanium and nickel-based alloys. To address these challenges, SMS group has developed an automated forging line alongside a new, energy-efficient drive concept for hydraulic forging presses and radial forging machines. In combination with proprietary forging strategies, this system enables the attainment of superior material properties resulting in improved grain size, which were validated with several forging trials.

Speaker: Dr Martin Wolfgarten (SMS group GmbH)

17 Investigating & Understanding Hot Mill Back Up Roll Failures at Tata Steel India

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.
The present papers captures the journey into the investigation of Tata Steel’s Compact Strip Process (CSP) Back Up Roll ( BUR ) failure and Roughing Mill Back Up Work Roll ( RMBUR ) Failure of the conventional Hot Strip Mill (HSM) at Jamshedpur.
In the case of CSP BUR, it was found that the failure was due excess rolling contact fatigue damage accumulation on the edges of the BUR.
In the case of HSM RMBUR failure, it was found that it was a case of barrel edge push off which is due to high contact stress accumulation due to chamfer design and excess differential roll forces in the roughing mil.
Detailed investigations in both the cases were done through visual examination of the spalled roll surfaces, rolling signals analysis, metallographic examination and literature review.
The proposed corrective actions taken have helped us in preventing further roll failures till date.

Speaker: UDAY SHANKER GOEL (TATA STEEL INDIA)

18 Controlling A‑Segregation in a 100‑Ton Hollow Steel Ingot via Liquid Nitrogen‑Air Core Cooling

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 solution was developed that achieved the end of solidification throughout the ingot located almost in the center of the wall thickness, and the A-segregation defects were avoided.

Speaker: Paixian Fu (Institute of Metal Research, Chinese Academy of Sciences)

15:40 Coffee break

Numerical Simulation, AI & Digital Innovation II

Convener: Arianna Gotti (Trasnvalor SA)

19 Numerical simulation of carbon macrosegregation in large steel ingots

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 reliable in predicting some defects, accurately modeling macrosegregation remains challenging due to the complex and concurrent phenomena occurring during the process. A dedicated user-defined function was created to simulate carbon macrosegregation in steel ingots of medium to large dimensions to be applied during the post-processing phase of casting simulations. The function integrates key solidification factors such as cooling rate, thermal gradient, and ingot geometry and can be incorporated into commercial simulation software to estimate local carbon distribution. The approach was initially tested on a 36-tonne industrial ingot, whose simulation results were compared with experimental data obtained through sectioning and chemical analysis. The comparison revealed a strong correlation between the simulated segregation index and the measured values. A second validation was then performed on a 40-tonne ingot using the same methodology, confirming the consistency and reliability of the model. Overall, the study demonstrates that the developed function is an effective tool for assessing carbon macrosegregation in medium- to large-scale ingots, with relevance for medium- and low-alloy steel grades.

Speaker: Anna Mantelli (University of Brescia)

20 Physics Based Modelling as an Enabler for Machine Learning Defect Prevention in Casting

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.
This contribution reports original work carried out within the RFCS SUNSHINE project, Here, physics‑based numerical modelling is used as a backbone to support data‑driven approaches for surface quality improvement and crack prevention. The work focuses on integrating models describing key physical phenomena during continuous casting — including fluid flow, heat transfer, solidification and shell growth — with ML workflows for process and quality optimisation, but it can properly addresses to ingot casting too. Thermo‑fluid‑dynamic models capture melt flow behaviour, turbulence, meniscus conditions and local heat flux distributions, while thermo‑mechanical and solidification models provide insight into shell growth, thermal gradients and stress–strain development relevant to crack susceptibility.
Attention is devoted to techniques used to merge fluid-dynamics with thermodynamics and solidification, for a physically coherent description of flow‑driven heat transfer and phase‑change. Rather than acting as standalone predictor, coupled modelling generates physically meaningful indicators — such as critical thermal and mechanical conditions, and heat extraction patterns —exploited as high‑quality features for ML algorithms developed within SUNSHINE.
The resulting hybrid modelling–ML framework improves prediction robustness and generalization across steel grades, caster configurations and operating conditions. The contribution highlights how knowledge consolidation activities, accelerating the deployment of explainable and industrially applicable digital tools for quality, productivity and sustainability improvement in casting and solidification frame, either in a continuous or ingot production frame.

Speaker: Orlando Di Pietro (RINA Consulting - Centro Sviluppo Materiali SpA)

21 Using AI models to mould design, predict segregation, porosity and CET zone in steel ingots

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 to describe the models employed to design the ingot shape, asses segregation, porosity and CET zone in steel ingots, models that may help to take decisions during the technology improvement.

The ingot and mould design module uses minimal input data (ingot and hot top weight, height and medium diameter ratio, ingot taper, number of sides, etc) to generate in several minutes 2D drawings and 3D files of the whole mould assembly project for round, rectangular, corrugated or hollow ingots.

To predict the segregation, a model that takes into account the chemical composition and cooling conditions of the ingot has been used. The results we got by simulation have been compared to sulphur print of a cut ingot.

To asses the porosity, the Niyama criteria has been used, a method that gives good results in steel ingot manufacturing practice. To calibrate the model and get the Niyama constant value, a 8T cut ingot has been used.

The CET prediction technique implemented is based on Hunt criteria. To calibrate the model and get the constant parameters, experimental data have been used.

Several examples will show how to use the proposed models in optimization of the ingot chemistry, pouring variables, ingot mould projects or choosing the right ingot size and shape for a particular steel.

Speaker: Mr Ovidiu Bogdan

22 Development of Industrial Processing Models for Prediction of Micro-segregation in Advanced Fusion Steels

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 ferritic-martensitic (A-RAFM) structural steels capable of withstanding this neutron damage and operating at 650°C.
Sheffield Forgemasters has developed thermo-mechanical models for melting and casting of potential fusion alloys as part of the NEURONE programme. Recent work has modelled a 7-tonne ingot from a nominal 35 tonne minimum cast quantity, based on an A-RAFM steel developed within the programme.
Material files with thermal-mechanical properties were generated using specialized software, and the 7-tonne ingot casting models were developed using Thercast commercial software. The combined computational fluid dynamic and finite element simulations included an ingot filling stage, solidification of the ingot with thermal-mechanical behaviour, exothermic powder reactions and micro-segregations development.
Micro-segregations were simulated, and the results of six elements are presented. Carbon, Silicon, Chromium, Manganese, Tungsten and Vanadium predicted concentrations are shown. The highest concentrations of all elements were found at the head of the ingot. Si and Mn concentrations were predicted to have a small spread of segregations. W segregation predictions showed a high concentration at the ingot head peaking at around 10%, with concentrations as low as 1% in the central part of the ingot. Prediction of V segregation behaviour showed very similar results to W.
Further modelling of the thermo-mechanical processing of the ingot will be presented, highlighting the potential effect that segregation would have on such and ingot; with comparisons drawn with existing modelling completed on a pilot-scale procedure undertaken in the NEURONE programme.

Speaker: Dr Mikhail Trull (Sheffield Forgemasters)

23 Modeling Remelting and Solidification: An OpenFOAM-based Approach for ESR and VAR Processes

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.
The experimental campaign included instrumented molds equipped with thermocouples to record temperature evolution along the mold wall. The produced ingots were then sectioned and analyzed metallurgically. Macrographic examinations provided information on molten pool shape and depth, as well as dendrite morphology, while microstructural analyses supplied data on hardness, SDAS and local chemical composition. These results were used to calibrate and validate the developed numerical models.
The main objective of the modeling framework is to describe the coupled thermal and fluid-dynamic fields within the ingot, in order to predict the evolution of the solidification front and the local conditions governing final ingot quality. Particular attention is given to key thermal parameters at the solidification front, such as thermal gradient, solidification rate, and cooling rate, which directly affect macrostructure, microstructure, segregation, and defect susceptibility.
OpenFOAM was selected because of its capability to represent the strong coupling between temperature and convection in the molten metal in a physically consistent way. Material properties such as density, viscosity, specific heat, and thermal conductivity are temperature-dependent, while fluid flow significantly affects heat transfer and therefore the shape and extent of both the molten pool and the solidification front.
The platform was further extended with a Cellular Automata-based module for macrosegregation prediction and with post-processing tools for microsegregation assessment, including phase fractions and local phase chemistry. The final goal is to support optimized remelting procedures within a digitalized and vertically integrated production chain.

Speaker: Matteo Gregori (RINA spa)

24 Hybrid Generative-Neurosymbolic AI for Explainable Quality Certification in Industrial Forging

Quality certification remains one of the most knowledge-intensive and time-consuming activities in the industrial forging sector, regardless of the manufacturing route, including open-die forging, closed-die forging, ring rolling, upset forging and precision forging. In many companies, certification still depends heavily on experienced engineers who manually collect production records, interpret customer specifications, verify laboratory and inspection results, and resolve inconsistencies across multiple technical documents. Although production processes differ significantly, certification invariably requires demonstrating compliance among production data, customer requirements and international standards, while maintaining full traceability of materials, heat treatments, mechanical testing and non-destructive examinations.
This paper presents a hybrid Generative-Neurosymbolic Artificial Intelligence framework for automating both the preparation and the engineering verification of quality certificates. The proposed architecture combines Large Language Models, used to extract and normalize information from heterogeneous engineering documents, with a symbolic reasoning engine based on a forging-domain knowledge graph. The symbolic layer performs deterministic compliance checks against applicable standards, customer-specific requirements and engineering rules, thereby producing explainable and auditable decisions.
Unlike conventional document-automation solutions, the framework introduces a dual verification mechanism. First,it assesses whether customer specifications are technically consistent with the referenced standards before manufacturing begins,enabling early identification of conflicting, incomplete or infeasible contractual requirements. Second, it verifies that production and inspection data satisfy every applicable requirement, including derived properties, process constraints, material characteristics and test results, before authorizing certificate generation.
The proposed approach transforms certification from a manual document-preparation task into a formal engineering verification process. By combining the linguistic capabilities of genAI with deterministic symbolic reasoning,it can reduce engineering effort,improve consistency and traceability,minimize human error,and support explainable, audit-ready certification in safety-critical manufacturing environments. Although developed for forging,the architecture provides a practical pathway for introducing trustworthy AI into other hot-deformation processes where compliance with technical standards, rather than document generation alone,represents the true industrial challenge.

Speaker: Giacomo Bottoli

Rolling, Forging & Hot Deformation II

Convener: LUIGI CHINAGLIA (FOMAS S.p.a.)

25 Hot workability of Ni-Fe high-temperature alloy.

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 perspective is that the processing window demands careful control of hot working and heat treatment parameters to develop an optimal microstructure, reduce the presence of detrimental phases and ensure target mechanical properties.

The processing of this material may include combinations of remelting techniques along with open-die forging, ring rolling, heat treatment, and machining.

On this basis, the present work explores the hot workability window of a Ni-Fe superalloy with a composition of Ni 40-45%, Cr 11-14%, Mo 5-7%, Ti 2.35-3.10%. in terms of the resultant microstructure by using different temperatures under industrial scale conditions. This type of superalloy is strengthened primarily by the precipitation of Gamma prime γ'[Ni₃(Ti,Al)] an intermetallic strengthening phase within a face-centered cubic (FCC) Gamma (γ) matrix among other metallurgical features.

To approach this from a reliable yet practical perspective, the wedge-forging test was selected. In this test, a wedge-shaped piece made of the selected melt is machining from the starting material for the forging process and forged (upset) between flat parallel dies. This technique as a whole allows the effects of the production environment to be evaluated. The outcome of the test is a strain gradient across the test specimen under the influence of different temperatures.

The findings of this work will provide a technical basis for optimizing microstructure for the manufacturing of Ni-Fe high temperature alloy components, targeting specific requirements. Finally, the experimental results are expected to be validated by means of FEA mathematical models.

Speaker: Dr Edgar Ivan Saldana-Garza (FRISA)

26 Role of Manganese and Sulphur Segregation in Hydrogen-Assisted Cracking and MnS Formation in Large Forged Steel Ingots

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.
Ultrasonic inspections revealed an extended internal defect located within the central segregated region of the forging. Chemical characterization showed local enrichment in carbon and manganese, while metallographic investigations highlighted pronounced dendritic structures and severe segregation bands associated with insufficient ingot core consolidation. These segregated regions exhibited significant microstructural heterogeneity, including bainitic and locally martensitic constituents, resulting in hardness values up to 420 HV, compared with approximately 280 HV in the surrounding matrix.
Fractographic and microstructural analyses demonstrated that crack propagation preferentially followed manganese-enriched segregated bands. Secondary microcracks, characteristic of hydrogen-assisted damage, were frequently observed within these areas, indicating that manganese segregation promotes local hydrogen accumulation through microstructural hardening and increased lattice trapping. Furthermore, the same segregation phenomena enhance sulfur partitioning during solidification, favoring the formation of MnS inclusions along interdendritic regions. These inclusions act as additional stress concentrators and hydrogen trapping sites, further reducing local fracture resistance.
The results demonstrate that manganese segregation plays a dual detrimental role: it increases the susceptibility to hydrogen-induced cracking through the formation of hard segregated microstructures and simultaneously promotes MnS precipitation, generating preferential paths for crack initiation and propagation. Both effects originate from the solidification behavior of large steel ingots and are amplified by inadequate homogenization and insufficient forging reduction of the segregated core. The study highlights the critical importance of controlling macrosegregation during ingot production and subsequent forging operations to improve the reliability of large structural steel components.

Speaker: Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)

Poster session

27 AI-Powered decision support system for early defects prediction in cast-iron products

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 critical since their root causes lie in the liquid metal processing stage, but their effects often become detectable only through downstream testing. This results in production waste and rework costs, which can be mitigated through anticipatory digital tools.
This work presents a Decision Support System (DSS) designed for foundry environments, integrating machine learning models to enable predictive quality control in cast-iron manufacturing. The considered process includes cupola furnace melting, secondary refining of liquid metal through ferroalloy additions, and a final inoculation stage during mould filling. The DSS continuously ingests real-time process data, including chemical and thermal analysis of the refined melt, pouring temperature, inoculant flow rate, and casting duration, useful for monitoring the current production state and feeding predictive models based on Artificial Intelligence (AI). The models are trained on historical data and forecast the occurrence of specific casting defects such as micro-shrinks, cementite and deviations on natural frequency, up to three to four hours in advance compared to the production window. This predictive horizon is operationally significant, as it provides process engineers and metallurgists with actionable time to adjust melt chemistry, refine inoculation parameters, or intervene in secondary treatment before non-conforming parts are cast.
The system was validated against historical production data from an industrial foundry environment, demonstrating reliable predictive accuracy across multiple defect categories. This work demonstrates the concrete applicability of AI-based approaches in conventional production route, contributing to the ongoing digital transformation of foundries and offering a replicable framework for quality-oriented predictive systems in similar metallurgical contexts.

Speaker: Prof. Valentina Colla (Scuola Superiore Sant'Anna)

28 Automatization of Barkhausen noise measurements for high resolution quality evaluation of steel.

Introduction
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 Barkhausen noise (BN) signal. External and residual stresses cause modification of domain wall structure, modifying the BN signal which allows for correlation between signal and stress distribution.
Results and discussion
In this work, MagStress BURN measurement set equipment was used. Wedge shaped probe with detecting coil wound on a 1 mm diameter core, was used to test surface of welded sample. Multiparameter BN analysis software, provided 16 descriptors that were derived from different signal features.
Robotic arm provided with MagStress BURN allows for movements with 0.1 mm accuracy. This pairing allows for high-resolution testing and imaging of samples. Mesh of points with resolution of 0.5mm over 20x18mm area provides 1440 data points. This covers 3 electron welds and heat-affected zone (HAZ).
Chosen descriptor peak values corelate with location of electron welds present in the sample. Values over different welds vary, which can be explained by weld fabrication process. Subsequently placed welds cause relaxation process to occur where the first weld is relaxed by next welds. Analysing obtained values, we can also see that HAZ generated in this process is extremely small compared to traditional welding methods. This combined with small weld surface necessitates usage of high-resolution measurement techniques.
Presented system allows for near instant evaluation of ferromagnetic samples thus combining non-destructive evaluation with rapid diagnostics not available with other testing apparatuses.

Acknowledgements: Proprietary system for inspecting the surface condition of ferromagnetic steel products intended for operation in conditions with increased strength requirements; Polish grant POIR.01.01.01-00-1168/21

Speaker: Mr Patryk Rybicki (Gdańsk University of Technology)

29 Data-Driven Regression Modeling for Energy Efficiency Optimization in Industrial Induction Heating Processes

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 the heating of steel billets using induction furnaces, where energy efficiency is a critical factor due to the high electrical power required to achieve the desired temperature profiles. However, induction heating involves complex interactions among electromagnetic fields, induced currents, and heat transfer mechanisms, which are difficult to analyze using purely physical models. These traditional modeling approaches often face limitations in accurately representing these dynamics under variable operating conditions. In contrast, machine learning–based regression models provide a flexible, data-driven framework capable of capturing such complexities. Moreover, the proposed linear models demonstrate how current intensity and energy consumption are influenced by factors such as frequency, heating time, and material properties. Methods such as multiple linear regression and other linear models incorporating regularization terms can be trained using experimental or historical data to predict the temperatures achieved as a function of current intensity and other relevant parameters. Once calibrated, these models enable rapid evaluation of different operating scenarios, facilitating the identification of optimal current intensity levels that minimize electrical consumption while ensuring compliance with constraints such as target temperature and heating uniformity. Additionally, these models support sensitivity analysis, offering clear and valuable insights into the relative influence of current intensity. Overall, this approach establishes a solid foundation for improving the efficiency and sustainability of induction heating processes.

This work received financial support from the Basque Government through projects KK-2025/00041 and KK-2023/00020 under the ELKARTEK Research Program.

Speaker: Roberto Fernandez Martinez (University of the Basque Country (UPV/EHU))

30 Improvement of Product Quality and Production Efficiency through a Profile Straightening System

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 production line downtime by reducing roller replacement durations.
In the production line, profiles are first transferred to the cooling bed after the rolling process and subsequently subjected to straightening operations. The primary reason for this process is the formation of internal structural stresses (residual stresses) in the profiles following rolling operations. Therefore, the straightening process performed prior to the packaging stage improves the geometric accuracy of the profiles while minimizing the induced residual stresses. However, frequent roller replacements and production line stoppages occurring during this process significantly reduce overall production efficiency.
The project proposes a high-capacity straightening machine design capable of providing sufficient operational flexibility for profiles of various types and dimensions. The proposed system is designed to accommodate different profile geometries while minimizing production interruptions through reduced roller change durations. In addition, the insufficient single-bar straightening capacity encountered particularly in wide and thick-section profiles will be eliminated by implementing a dual-bar straightening system. Furthermore, energy efficiency will be enhanced through the use of multiple low-power drive motors at the entry and exit sections of the straightening machine. Consequently, the proposed system is expected to improve operational performance while supporting a sustainable manufacturing approach.

Speakers: DİDEM KILIÇ OĞUROL (KARDEMİR ÇELİK SANAYİ AŞ.), CEYHUN KOZAK (KARDEMİR ÇELİK SANAYİ AŞ.)

31 Research on anti-deflection roll-bending process for longitudinal pipes with a large length-to-diameter ratio

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 upper-roll profile design. Analytical models for the rolling force and side-roll displacement are developed under conditions where the plate's entry end is straight and where the C value is taken into account. Based on the principle of superposition, deflection models of the upper roll for both conventional roll bending and anti-deflection roll bending are established, and a mathematical model together with an optimization algorithm for the anti-deflection compensation displacement is formulated. Finite element models are constructed in ABAQUS to perform process parameter optimization and to correct the proposed theoretical models. Numerical results indicate that, compared with conventional roll bending, the maximum upper-roll deflection during the pre-bending and roll-bending stages is reduced by 77% and 71%, respectively, leading to a significant improvement in pipe geometry. To further mitigate the residual deflection of the upper roll in the ADRB process and enhance forming accuracy, a Fourier series fitting method is employed to optimize the upper-roll profile. After optimization, the maximum generatrix straightness in both forming stages is reduced by more than 80%, resulting in a substantial improvement in forming precision. The results demonstrate the feasibility and effectiveness of the combined anti-deflection compensation and roll-shape optimization strategy for improving the dimensional accuracy of large-diameter welded pipes with large length-to-diameter ratios.

Speaker: 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)

32 Intelligent surrogate model for the calibration of Hansel-Spittel flow stress model

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 material enables process monitoring that integrates artificial intelligence and our knowledge of the mechanics of materials [1]. We expect more interpretable process monitoring. For a preliminary feasibility analysis, we consider a synthetic dataset for training, but both experimental and synthetic data for testing set. The calibration process uses a dataset of strain-stress curve at different temperatures and strain rates as input data. The calibration step's output is the ten coefficients of the Hansel-Spittel flow stress model. We propose comparing the classical optimization process for finding optimal parameters with the model parameters predicted by an intelligent surrogate model. This intelligent surrogate model is a specialized artificial neural network consisting of fully connected layers. In this work, the training objective is to perform a regression task as in [2], we discuss the size of the required training dataset, calibration accuracy, and new opportunities enabled by intelligent surrogate modeling. This discussion covers cases of experimental data that do not conform to the Hansel-Spittel flow model. This results in a calibration error.

Speaker: Mr Thanh Chung Nguyen (Framatome)

18:10 Welcome cocktail

A light aperitif will be offered in the exhibition area at the of the sessions

Wednesday 14 October

Numerical Simulation, AI & Digital Innovation III

Convener: Dr Ettore Anelli (Franchini Acciai SpA)

33 Discrete Particle Modelling of Inclusion Transport and Localization in Bottom-Poured Ingots

The internal quality of large steel ingots is an important target when designing and conducting the casting and solidification process.
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 placing powder bags at different heights inside the mould or at its bottom; as they burn upon contact with hot steel, they release powder. However, bags can ignite prematurely due to radiative heat: in this case the powder falls from height onto the steel surface, causing disturbances.
The metal jet from the ingot bottom can also disturb the free surface, especially at the beginning of filling.
Even with state-of-the-art practices, these aspects can contribute to powder entrainment, leading to inclusions, as observed by NLMK Verona in some cases after hot forging.
Numerical simulation allows to identify the causes of inclusions and their final position in the solid material, to assess whether they may lead to rejection.
This work presents a joint study by NLMK Verona and Transvalor on the simulation of a 115 ton ingot casting, where particles were introduced to model slag entrainment; their trajectories and final positions in the solid ingot were computed, with results consistent with NLMK Verona’s experience.
Particle behaviour in liquid metal was simulated in Thercast® using a Discrete Particle Model with a Eulerian–Lagrangian approach: liquid steel flow is computed by fluid dynamics (Eulerian), while inclusion transport is obtained from the force balance on each particle (Lagrangian).

Speaker: Arianna Gotti (Trasnvalor SA)

34 Optimization of Hot Rolling Processes Using Temperature-Dependent Ductile Damage Modelling

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 developed by Transvalor, employing its automatic optimization module to refine key process parameters.
To accurately predict damage, a new ductile damage model is introduced. Unlike conventional models that primarily rely on stress triaxiality and the Lode parameter, the proposed formulation integrates the evolution of material ductility as a function of temperature. Since ductility varies significantly with thermal conditions, this dependency plays a critical role in damage initiation and progression during hot rolling. Incorporating this effect enables a more realistic representation of material behavior under severe thermo-mechanical loading.
The study presents a practical case of hot rolling optimization using the enhanced damage model. A detailed description of the optimization workflow, the theoretical basis of the damage model, and the implementation of temperature-dependent ductility within the simulation environment is provided. Results highlight the benefits of coupling automated optimization with advanced damage prediction, demonstrating a substantial reduction in damage indicators and improved product quality.
This approach offers a robust framework for industrial applications, enabling manufacturers to design processes that balance productivity and material integrity. The integration of ductility evolution into damage modeling represents a significant step toward more accurate and reliable predictions in hot forming operations.

Speaker: Chaouki TAHRI (ArcelorMittal)

35 Machine learning models to classify non-metallic inclusions in as-cast steel ingots

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 kinds of inclusions in continuous casting slabs. Different kinds of inclusions have the obviously different features in in SEM, which lays the foundation for the use of machine learning to distinguish between the types of inclusions. This work firstly selected MnS and Al2O3, two typical types of inclusions in casting slabs of duplex stainless steels (DSSs) as experimental objects and established a semantic segmentation machine learning (ML) model to identified MnS and Al2O3 particles using SEM images. The U-Net architecture is selected in this work due to its excellent performance in image segmentation tasks with limited data. Different types of inclusions were characterized by EDS for the model prediction. Furthermore, the established model for inclusions classification is not limited to distinguishing between MnS and Al2O3, other types of inclusions such as MgO, SiO2, and MgAl2O4 etc. as well as casting defects (pore, crack, etc.) in the continuous casting slabs can be detected by applying the current semantic segmentation model. A reasonable prediction accuracy of the established methodology demonstrates the potential for employing AI-based method machine learning in the continuous casting process for high quality steel production.

Speaker: Prof. Mu Wangzhong (Lulea University of Technology)

36 Intelligent Integration of Reheating Furnace Control and Hot Rolling Process to Reduce Energy Losses and Delays in Steel Bar Manufacturing

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, increased scale formation, and non-uniform temperature distribution at the rolling mill entry.
This study presents an intelligent integrated framework that links reheating furnace operation with hot rolling process parameters through real-time monitoring and data-driven optimization. The proposed approach incorporates delay-aware furnace control, adaptive reheating strategies, and rolling schedule synchronization to minimize fuel consumption and thermal losses during both planned and unplanned mill stoppages. The temperature evolution of steel blooms from furnace exit to final rolling passes is analyzed, and the influence of rolling delays on heat loss, scale formation, and dimensional accuracy is evaluated.
An AI-assisted decision model dynamically adjusts furnace temperature set-points and soaking time based on rolling availability, process feedback, and delay duration. The methodology enables proactive control actions to prevent overheating during delays while ensuring adequate rolling temperature at mill entry. Industrial-scale implementation results demonstrate a reduction in specific fuel consumption, improved temperature uniformity, reduced scale loss, and enhanced overall process efficiency.
The proposed approach provides a practical and scalable pathway for integrating reheating and rolling operations in modern steel plants, contributing to improved product quality, energy efficiency, and reduced environmental impact. The framework is well aligned with ongoing efforts toward digital transformation and sustainable manufacturing in the hot deformation production chain.

Speaker: Gulvir Singh (Guru Nanak Dev Engineering College, Ludhiana)

37 AI-Driven Surface Inspection Enabling Automated Grinding of Forged Ingots

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. Following this successful demonstration, Sapotech developed a dedicated Surface Inspection System (SIS) designed to detect surface defects across forged and ground ingots.

The Reveal CAST system was commissioned in January 2023, and within a few months, it met all defined performance criteria, providing reliable defect detection and image quality suitable for integration into production processes. This deployment has enabled a more precise understanding of surface characteristics, paving the way for targeted process improvements.

Building on these results, ongoing work focuses on automating the grinding process using insights from Reveal CAST. Integration of automation systems is underway, with rules being established for spot grinding based on detected defects. The goal is to enhance grinding throughput, ensure consistent ingot quality, and reduce manual inspection efforts.

This presentation will outline the development journey of Reveal CAST, from the initial demo to full-scale commissioning, and highlight the system’s contribution to process optimization in ingot forging and grinding. Additionally, it will discuss the automation strategy and expected impact on production efficiency and product quality. Sapotech’s approach demonstrates how advanced surface inspection, combined with automation, can deliver measurable improvements in metallurgical manufacturing operations.

Speaker: Dr Hannu Suopajärvi (Sapotech Oy)

Rolling, Forging & Hot Deformation III

Convener: Caiyi Liu (Yanshan University)

38 Advanced Energy-Saving Technologies in Open Die Forging Presses: A Case Study on Press Upgrade

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.
This paper presents a case study of a recent upgrade, wherein a new 4’000-ton capacity press equipped with the advanced HP3 system was installed on existing foundations of a standard 2’500-ton press, previously operating with a fixed-speed motor and standard hydraulic features.
The newly integrated energy-efficiency features, entirely developed by the Vecchiato Engineering Team, includes: (i) Ecomodus speed management of the main pumps, which automatically reduces rotation speed during idle times; (ii) a servobalance system, an experimental device designed to recover the potential energy of the movable crosshead; (iii) variable speed drives for the piloting and filtration circuits; (iv) optimized hydraulic manifolds to minimize pressure drops.
This new installation enabled the Customer to achieve two primary objectives:
- Capacity upgrade without electrical overhaul: installing a significantly larger press without requiring additional electrical power infrastructure
- Enhanced energy efficiency: reducing energy consumption per ton of forged product by approximately 30% on similar product mix, as validated by empirical data gathered before and after the replacement.
By achieving these goals, the Customer successfully minimized both the CAPEX and the OPEX of the investment, leading to a substantial reduction in overall transformation costs.

Speaker: Mr Luca Bertoldi (Sales Director)

39 Next-Generation Metal Forming: Utilizing the PMSD as a Universal Drive for Hydraulic Presses

1. 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 addresses these issues by
   utilizing a uniquely modified sinusoidal kinematics profile. This innovative design ensures
   exceptionally smooth operation, minimizes harmful hydraulic shocks, and significantly improves
   overall energy efficiency.
   The session will cover the core mechanical and hydraulic principles of PMSD technology, its
   seamless integration into various hydraulic press architectures, and its tangible operational
   advantages. Key benefits discussed will include increased forging precision, reduced
   maintenance costs, and extended equipment lifespan. By demonstrating its versatility,
   scalability, and high performance across different operational parameters, this presentation will
   highlight why the PMSD stands out as a highly effective, universal, and future-proof drive system
   for modern metal forming operations.

Speaker: Mr Stefan Pahnke (Pahnke Systems)

40 Development of Linear Elastic and Elastoplastic Finite Element Solvers for Forging Simulation

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 incremental-iterative strategy. The finite element model is established from input data, including nodes, elements, material parameters, boundary conditions, contact definitions, and loading steps. In each increment, active degrees of freedom, single-point constraints, multi-point constraints, contact pairs, and load information are updated. The global equilibrium equation is then formed through element stiffness calculation, internal force evaluation, and sparse matrix assembly. The linear elastic solver adopts Hooke’s law and is used to verify the basic finite element formulation, constraint treatment, matrix assembly, and linear equation solution. Based on this framework, an elastoplastic solver is developed by introducing incremental plasticity, stress integration, and history-variable updating. The nonlinear equilibrium equation is solved using the Newton–Raphson method. During each iteration, the residual force vector is assembled from the imbalance between external and internal forces, while the tangent stiffness matrix, material state, and contact constraints are updated consistently. A penalty-based contact formulation with Coulomb friction is used to describe billet–die interaction. Representative forging examples are used for verification. The results are compared with commercial finite element software in terms of deformation, equivalent stress, forming load, and convergence behavior. The comparison shows that the developed solvers can reproduce the main mechanical responses of forging processes and provide a basis for remeshing, thermo-mechanical coupling, and parallel computation.

Speaker: Qi Liu (College of Mechanical Engineering. Taiyuan University of Technology, Taiyuan 030024, China)

41 Three-Roll Skew Rolling of Titanium/Steel Bimetallic Composite Tubes: Simulation and Experiment

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 dimensional accuracy, three-roll skew rolling is an effective method for fabricating seamless composite tubes with large length-to-diameter ratios. In this study, a dynamic three-dimensional finite element model was developed in Abaqus to simulate the three-roll skew rolling process of such composite tubes. The motion trajectory, metal flow behavior, distributions of stress, strain, and temperature fields, and evolution of interfacial bonding during skew rolling were systematically investigated. In addition, titanium/steel bimetallic composite tubes with uniform wall thickness and high-strength metallurgical bonding at the interface were successfully fabricated through rolling experiments, and their interfacial shear strength reached 260 MPa. The results show that the composite tube undergoes a typical helical forward motion driven by the three circumferentially arranged rolls. As a result of coupled circumferential and axial metal flow, the tube cross-section exhibits a periodic “round–triangular–round” geometric evolution. The numerical simulation further reveals the spatiotemporal distribution characteristics of stress, strain, and temperature during deformation, and elucidates the dynamic mechanism of interfacial bonding under thermomechanical coupling. The experimental results confirm the reliability of the finite element model and demonstrate that three-roll skew rolling can effectively produce high-quality titanium/steel bimetallic composite tubes. This study provides a theoretical basis and technical guidance for optimizing skew rolling process parameters and improving the bonding quality of bimetallic interfaces.

Speaker: Qingshan Ding (College of Mechanical Engineering, Taiyuan University of Technology, Taiyuan 030024, China)

42 Efficient electrification of round steel bars heating during rolling process

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 finite element simulations with ANSYS Multiphysics ® and adjusting the model with laboratory experiments applied to the induction heating process of round steel bars during the rolling process (but it can also be applied to heat treatments or preheating for hot forging). The results obtained demonstrate the usefulness of this methodology to help on the efficient optimization of this heating process. Once developed, it can be a very useful tool for designing and optimizing the appropriate parameters of this new electric heating process for round steel bar products, depending on the characteristics of the steel bar: such as its size, length or chemical composition or the process constraints: such as temperature gradients within the bar, energy consumption or process time. This research was funded by KK-2025/00041 and KK-2023/00020 projects by the Basque Government under its ELKARTEK Research Program.

Speaker: Pello Jimbert (University of the Basque Country UPV/EHU)

10:30 Coffee break

Ingot casting and remelting II

Convener: Marco Alloni (Prosimet S.p.A.)

43 Advanced Copper Solutions for Remelting Technologies

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 presents advanced copper solutions for remelting applications, focusing on crucibles, power rams, and alternative melting furnace concepts utilizing slab moulds or short collar moulds.

A central aspect is the comparison between forged, one-piece crucibles and longitudinally seam-welded designs. Forged crucibles, manufactured without welding seams, exhibit a homogeneous microstructure and uniform material properties over the entire circumference. This results in significantly increased lifetime, reduced distortion during operation, and enhanced process reliability. In addition, tighter manufacturing tolerances can be achieved, contributing to improved dimensional accuracy and reproducibility.

Material innovations further support these advancements. CuCrZr alloys, such as ELBRODUR® G, provide superior mechanical strength and elevated temperature resistance compared to conventional CuDHP copper. Their higher softening and recrystallization temperatures enable stable operation under demanding thermal conditions, reducing wear and extending service intervals. Complementary developments include Cu-HCP power rams with high thermal and electrical conductivity, ensuring efficient energy transfer in VAR and ESR processes.

For alternative furnace concepts, advanced slab moulds with reinforced steel frames offer improved structural stability and enhanced re-machining capability compared to tube-type designs. In addition, short collar moulds are analyzed, comparing deep-drilled and slotted configurations in terms of cooling efficiency and operational performance.

Overall, these innovations contribute to reduced downtime, optimized resource utilization, and improved energy efficiency, supporting the transition toward more sustainable and competitive steel production.

Speaker: Mr Christof Dratner (Dipl.-Ing., Dipl.-Wirt. Ing.)

44 PLASMA – Value add for metallurgical refining in VID-Processes

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 VIM/VIDP-Process acts as starting point of triple melting, there is a field of potential use of vacuum melting for grades with medium quality requirements. For this market segment ALD’s preferred technical approach is the VID as the primary melting and refining tool. While refining and alloying in VID is done under the same conditions as in VIM/VIDP-Process the ingot casting itself is performed under inert gas shrouding. Due to the easy furnace body accessibility even liquid charging is possible. In these production routes the VID is well integrated and is a valuable tool for fine trimming of quality requirements. However, due to the heat generation by induction this solution experiences some metallurgical restrictions. For example; managing slag is difficult.

In this paper it will be shown how plasma processes accelerate kinetics of gas/melt interface reactions and how the integration of thermal plasma sources opens the field of opportunities performing additional metallurgical refining treatments in VID. By this means, refining steps usually to be performed prior or after VID-Process could be integrated directly into the VID, allowing for higher quality or for reducing the number of additional melting and refining processes.

Furthermore, due to the nature of thermal plasma processes in situ gas alloying (e.g. nitrogenization) becomes very effective. With additional features even direct iron ore reduction by hydrogen could be performed in this equipment, combining the best of both worlds – the global melt bath movement by electromagnetic forces from induction and the enhanced interface activation by plasma.

Speaker: Henrik Franz

45 Effect of Cu addition on microstructure, mechanical properties, and Heat treatment response of in situ Al-15Mg2Si-4.5Si composite

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 Probe Microprobe Analysis (EPMA), Transmission Electron Microscope (TEM), and Atom Probe Tomography (APT). The results depicted that the addition of 2 wt.% Cu to the Metal Matrix Composite (MMC) changes the morphology of primary Mg2Si from irregular dendritic and hopper structure to polyhedral shape and reduces its average particle size from ~52 µm to ~19 µm. Bulk hardness of the composite shows ~45% increase in the as-cast state and about ~66% increase after heat treatment in the case of 2 wt.% Cu addition. Tensile tests revealed improvements in ultimate tensile strength (from 158 to 185 MPa in the as-cast condition and up to 308 MPa after heat treatment) and elongation (from 2.1% to 4.47% after heat treatment). These results demonstrate that Cu addition significantly enhances the microstructural refinement and mechanical performance of Al-15Mg₂Si-4.5Si composites, making them promising for advanced structural applications.

Speaker: Mr Mohammed Kedir Mustofa (Indian Institute of Science Bangalore, Karnataka, India-560012)

46 White Spot Origins, their Impact on Critical Components, and a Pathway for Prevention using VARmetric

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, including triple melt routes, these defects persist due to complex formation mechanisms and limited visibility into melt conditions during the Vacuum Arc Remelting (VAR) process.
This presentation provides a review of the primary mechanisms behind white spot formation, including discrete (clean and dirty), dendritic, and solidification-related. It also examines the source of foreign object contamination, such as iron particles and tungsten carbide fragments, and their impact on metal quality. These contamination pathways represent practical risks that can have significant downstream consequences, as demonstrated by the uncontained engine failure on American Airlines Flight 383 in October 2016.
Based on this survey, it is evident that traditional process controls alone do not fully address the root causes of white spot formation. The literature consistently points toward improved measurement of process conditions and tighter control of melt parameters—particularly arc dynamics and heat flux—as key drivers of melt pool behavior. These factors directly influence melt pool stability and solidification conditions.
To address these challenges, we introduce VARmetric™ and ARControl™ as a combined approach to process monitoring and control. VARmetric™ provides real-time insight into arc behavior and melt conditions through high-resolution magnetic sensing while ARControl™ actively manipulates the arc dynamics to control the heat flux distribution. Together, these technologies have been shown to enable the stabilization of the melt pool while tailoring of the solidification front, offering a practical path toward reducing the risk due to white spots and improving the quality of VAR-processed materials.

Speaker: Eike Schmilinsky

47 Improving ingot casting technology

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, achieving a higher quality than a vacuum cast ingot. Cracking of rolled or forged products is expected to be eliminated. Other benefits of elimination of the sensitization of steels by heat treatment, hydrogen embrittlement, and stress corrosion cracking are also expected.

Speaker: John Campbell (University of Birmingham, UK)

Numerical Simulation, AI & Digital Innovation IV

Convener: Cristian Viscardi (ECOTRE Valente srl)

48 A CAD/CAE Integrated Simulation Method for the Hydraulic System of Forging Presses Based on Model Parameter Mapping

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 and CAE simulation models, and the difficulty of quantitatively evaluating the dynamic response and performance influence caused by structural parameter changes at the design stage, this paper proposes a CAD/CAE integrated digital design and simulation verification method for forging press hydraulic systems. First, the structural composition and working mechanism of the forging press hydraulic system are analyzed, and parametric models of key components, including hydraulic cylinders, pumps, valves, accumulators, and pipelines, are established. Second, a cross-platform parameter-driven and automatic mapping mechanism between the design model and the simulation model is constructed, enabling the collaborative updating of geometric structural parameters, system configuration parameters, and simulation parameters. Furthermore, a digital simulation platform integrating parametric modeling, dynamic simulation, multi-source data import, result-curve analysis, and three-dimensional motion visualization is developed to analyze key indicators such as moving beam displacement, cylinder pressures, and valve opening states. The results show that the proposed method can integrate the design, simulation, and verification processes of forging press hydraulic systems, improve parameter iteration efficiency and simulation result traceability, and provide technical support for scheme optimization, virtual commissioning, and digital design of hydraulic systems in forging equipment.

Speaker: Dr Zhiqiang He (Yanshan University)

49 An ICME‑Enabled Digital Framework for Modeling of Microstructure Evolution during Industrial Steel Casting and Forging

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 processing conditions and thermomechanical histories to microstructural outcomes.
During casting, the transient temperature field is calculated using a macroscale finite element method (FEM) implemented in an in-house code. The resulting thermal histories are used as input to CALPHAD‑based models to predict the solidification path under non‑equilibrium conditions. Microsegregation is evaluated to capture local compositional variations arising during solidification, while precipitation behavior is predicted using CALPHAD thermodynamics and kinetics to quantify precipitate evolution as a function of composition and cooling rate.
During the reheating stage prior to forging, dissolution phenomena are modeled within the same CALPHAD framework, using reheating temperature profiles as input. This enables consistent tracking of the precipitate state and matrix chemistry and provides physically meaningful initial microstructural conditions for subsequent deformation.
During forging, temperature, strain, and strain-rate fields are calculated using a coupled thermomechanical FEM, developed in an in-house code. These fields are linked to microstructure evolution models to predict deformation‑induced phenomena, with particular emphasis on static and metadynamic recrystallization. The evolution of recrystallized fraction and grain size is calculated as a function of local thermomechanical conditions and the inherited microstructure from casting and reheating.
The proposed ICME‑enabled digital framework provides a unified and robust platform for predicting microstructure evolution across industrial steel casting and forging routes, enabling improved microstructural control, process optimization, and reduced reliance on empirical trial and error.

Speaker: Chunhui Luo (Swerim AB)

50 LEVERAGING DOWNSAMPLING AND EXPERT SYSTEMS FOR DATA-DRIVEN PROCESS OPTIMIZATION IN THE FORGING INDUSTRY

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 separate IT systems, creating significant challenges for integration and utilization of the data. Downsampling methods and expert systems are used to address these challenges and enable the consolidation of scattered data into valuable insights. Downsampling reduces the size of the data sets while preserving the critical information in the data, thus minimising the amount of storage and computing power required and allowing for faster visualisation and analysis of the data. Expert systems complement these efforts by incorporating domain knowledge into algorithms and translating raw data into key metrics that can be interpreted by human process experts. This paper not only describes how these techniques have been used to build a quality data set that contains all the relevant technical data for the forge shop, but also how this dataset was used to build a data visualization dashboard that delivers immediate business value.

Speaker: Georg Maier (voestalpine Böhler Edelstahl GmbH & Co KG)

51 Surrogate modeling of the cogging process in open die forging simulation

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 simulations and more recently neural network approaches. This work focuses on the neural network approach, with development of a 3D, fully data-driven artificial neural newtwork (ANN).

A quarter symmetric 3D FEM was used as a basis for generating training and validation datasets for the creation of ANNs. Two fully data-driven ANNs were created to predict the geometry change and equivalent strain evolution during the cogging process of rectangular cross-sections. A unique approach of individual node prediction was used to minimize calculation times and generate results instantaneously.

Preliminary results show that the geometric and strain models perform well, with less than 2 % (RMSE) prediction errors for nodes in the volume, while surface nodes experience larger error in the range of up to 10 % at nodes with high deformation.

The method developed appears promising for the prediction of geometry and equivalent strain and future work will focus on new geometries and variation of additional parameters and forging operations.

Speaker: Gustav Häggström (Swerim AB)

52 Revitalizing Lifecycle Support for Heavy Forging Equipment – Modernization and Upgrade Strategies for Existing Manipulator Systems

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.
However, forge shop operators increasingly face challenges related to changing production requirements,
higher load demands, outdated automation systems, spare part obsolescence and evolving safety standards.

At the same time, complete machine replacement is often associated with significant investment costs and resource consumption.
This contribution presents DANGO & DIENENTHAL’s approach to modernization, upgrade and lifecycle extension of existing forging manipulator systems.

The objective is to adapt long-life equipment to current and future production requirements while maintaining the robustness, precision and high availability required in demanding forging environments.

The paper discusses practical engineering approaches including retrofit concepts, control system modernization, component replacement strategies and structural evaluations for performance enhancement.
Particular attention is given to engineering-driven upgrade solutions that enable increased load capacities and operational improvements within the existing machine structure.
In addition, the integration of existing equipment into modern digital production environments is addressed.

Based on selected project examples and OEM experience, the contribution demonstrates how phased modernization concepts can extend operational lifetime,
reduce operational risks and improve production flexibility without complete machine replacement.

Furthermore, lifecycle extension represents a sustainable approach regarding resource utilization, investment protection and long-term industrial productivity.

The presented approaches highlight the growing importance of modernization and technological partnership concepts for the future operation of heavy forging equipment in the global forging industry.

Speaker: Mr Jörg Blum (DANGO & DIENENTHAL Maschinenbau GmbH)

12:40 Lunch

Environment, Emissions & New Technologies

Convener: Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)

53 Heating Ingots with Oxyfuel and Hydrogen before Rolling and Forging

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 presented.
The transition to green steelmaking is a multi-decade journey involving diverse technologies and pathways, in most scenarios with the use of hydrogen − both as reductant and as fuel − as the endgame. While its broader integration will take time, hydrogen as a fuel has already been proven to perform effectively in reheating operations, without compromising the preferred energy-efficient oxyfuel combustion or negative impact the steel product.
In early 2024, Ovako began the use of 100% hydrogen to fuel its existing Flameless Oxyfuel combustion systems in the soaking pit furnaces where steel is reheated before rolling at its plant at Hofors, Sweden. This was the successful conclusion of a five-year journey including laboratory scale tests and full-scale demonstrations in cooperation between Ovako and Linde. 48 furnaces, charged with about 25 tonnes of engineering or bearing steel grade ingots, are since then running permanently in this operation mode. The hydrogen is supplied by an onsite alkaline electrolyzer powered entirely by renewable electric power. The Flameless Oxyfuel combustion operates with 100% oxygen and 100% hydrogen. This technology, the challenges overcome, and the excellent results achieved are discussed along with the development of hydrogen-oxygen combustion.
At Ovako Hofors using 100% hydrogen as fuel at reheating is now a tangible and fully practical solution – to date successfully reheated more than 500,000 tonnes of ingots.
Operation with hydrogen in forge furnaces is the next step, also using Dual Momentum Lancing Flameless Oxyfuel burners.

Speaker: Joachim von Scheele (Linde GmbH)

54 Effects of Axial Feed Direction on Forged Shape in Mandrel-Less Incremental Forging of Circular Variable-Cross-Section Tube Ends

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 radial forging, rotary swaging, and drawing, this process provides a more flexible approach to producing tubes with variable cross-sections. A tube is compressed by a pair of simple flat dies without a mandrel, and its rotational and axial positions are numerically controlled by a manipulator. Previous research primarily focused on the forging of the center of the tube in the axial direction, and revealed that the rotational feed defined by 2π/k rad·blow⁻¹, where k is an odd number, is effective in reducing both the outer diameter and ovalization. As a next step, it is necessary to study the forging of circular tube ends to provide a wide range of forged shapes. While this previous research focused on the height reduction ratio of multi-pass on forged shapes without axial feed, the present research examines the effects of axial feed direction on forged shapes as a subsequent step. Finite element analysis using Elfen developed by Rockfield Software and forging experiments with a prototype CNC incremental forging machine were conducted to evaluate the effects of different axial feed directions. As a result, the feed direction from the fixed side to the free side was more effective in reducing ovalization than the feed direction from the free side to the fixed side. These results can be applied to determine efficient pass schedules for incremental forging of circular variable-cross-section tube ends.

Speaker: Takahiro Makiyama (Institute of Technologists)

55 Industrial trials with renewable dimethyl ether as fuel in an ingot reheating furnace

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 features also make it a viable replacement fuel for industrial sites lacking access to the natural gas grid. Prior to fuel substitution, however, the compatibility of gas delivery systems and the interaction between combustion atmospheres and heated materials must be assessed. This study presents practical experience from implementing DME as a fuel for ingot reheating and evaluates the effects of combustion atmospheres from LPG and DME on steel oxidation.

A 4.2 MW reheating furnace used for ingot heating before hot forging was commissioned and equipped with multifuel air burners capable of operating on both LPG and DME. Two parallel fuel‑gas supply systems were installed to demonstrate full‑scale delivery solutions. For DME pressure reduction, two approaches were tested: a mechanical PTFE‑coated membrane regulator and an electrically controlled valve system. Steel samples representing a range of grades, from low‑alloy steels to high‑strength specialty steels and stainless steels, were exposed for two hours to quantify oxidation behavior. Gas emissions (O₂, CO₂, CO, NOₓ) were continuously monitored.

Preliminary results show that oxidation rates and oxide products were comparable for LPG and DME combustion atmospheres across all tested steel grades. Additionally, DME combustion produced lower NOₓ emissions than LPG.

Overall, the trials indicate that DME is a technically suitable replacement for natural gas and LPG in steel reheating applications.

Speaker: Gustav Häggström (Swerim AB)

56 Optimizing Induction Heating for Steel Billets: A Multiphysics Approach to Electrification and Decarbonization

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 candidate due to its higher Technology Readiness Level(TRL) compared to other electrification methods evaluated in current research, such as direct resistance heating or the substitution of gas burners with electric resistances.Induction heating offers significant advantages, including instantaneous heat generation, rapid processing cycles, and superior thermal uniformity.Furthermore, by minimizing residence time at high temperatures, it drastically reduces scale formation and surface decarburization,ensuring enhanced product quality.From a sustainability perspective, this technology enables zero direct emissions and superior energy efficiency by heating the workpiece internally, thus eliminating the thermal losses typical of convective systems.In the scope of the EU Horizon project ModHEATech,this study presents a research activity developed by RINA-CSM focused on the decarbonization of the steel sector through advanced numerical simulation.A complex electromagnetic-thermal multiphysics model was developed using Comsol Multiphysics.This model simulates the heating of steel billets prior to rolling mills, controlled via power, voltage, or current, to determine optimal parameters that satisfy both production and quality requirements.The study is supported by laboratory testing campaign on billet specimens for calibration and validation of model’s results. The investigation focuses on thermal and current density distribution within the billet, considering variables such as steel grade, power supply, frequency, and productivity. The study improves production efficiency and product quality by integrating induction heating within industrial constraints. The approach enhances temperature uniformity, reduces thermal gradients and crack formation,and highlights billet geometry effects on performance.Although circular billets provide optimal heating, practical limits remain, making process refinement essential for sustainable and competitive steel production.

Speaker: Matteo Gregori (RINA Consulting – CSM S.p.a.)

57 Water Footprint Reduction in the Metallurgical Sector through Oily Emulsion Reuse and the WASM Method

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 integrated and strategy-oriented approach.

The case study concerns a metallurgical plant where spent emulsions from a forging press generated approximately 1,000 tons of wastewater per year, treated through physico-chemical processes and subsequently discharged. Through the first 3 phases of the WASM method, vacuum evaporation was identified as the optimal solution. This technology allows the separation of emulsions into a reusable distilled fraction and a reduced concentrated residue for disposal.

The outlined pathway suggests a significant improvement in environmental performance: following the Implementation phase, water consumption is expected to be reduced by up to 95% through internal reuse, while wastewater volumes will be significantly decreased. In addition, reduced waste transport is expected to contribute to lower indirect CO₂ emissions. From an economic perspective, a reduction in operating costs and a rapid return on investment are anticipated.

This case highlights the value of a structured methodological approach in supporting sustainable decision-making aligned with circular economy principles.

Speaker: Mr Angelo Ferranti (Contec Industry)

Rolling, Forging & Hot Deformation IV

Convener: Francesca Bonfanti (MIMETE Srl)

58 Research on Pulsed Current-assisted Rolling Forming and Microstructure–Properties of Pure Titanium Ultra-thin Strips

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 thickness and excessive residual stress. In this study, a pulse current-assisted rolling process was employed, utilizing the synergistic effects of the thermal and non-thermal effects of the pulse current to improve formability. Using TA1 pure titanium ultra-thin strips as the research subject, an experimental platform was established on a twelve-high rolling mill to systematically investigate the effects of parameters such as current magnitude, frequency and duty cycle on the material’s rolling deformation behavior, microstructure and mechanical properties. The results indicate that, compared to conventional cold rolling, pulse current-assisted rolling can effectively reduce deformation resistance, increase the rolling reduction rate, and suppress edge cracking defects; the pulse current promotes dislocation slip and dynamic recovery, attenuates the rolling texture, reduces anisotropy, and improves the uniformity of deformation in ultra-thin strips. Under equivalent deformation conditions, the pure titanium ultra-thin strips produced by this process maintain high strength while exhibiting an elongation after fracture approximately 15%~35% higher than that of conventionally cold-rolled strips, demonstrating a favorable strength-ductility balance. Pulse current-assisted rolling offers a new technical approach for the production of high-performance pure titanium ultra-thin strips.

Speaker: Shufeng Wei (College of Mechanical Engineering, Taiyuan University of Technology, Taiyuan 030024, China)

59 Heat Transfer Study in Descaling and Roll Cooling on Blooming Line

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.
Experimental investigations of various descaling systems—including conventional high-pressure nozzles, opposite-nozzle configurations, hydromechanical rotary descaling (HIDROD), and shot blasting—were conducted using laboratory heat-transfer measurements and real-scale trials. The results show that the descaling strategy significantly affects heat extraction, ranging from negligible heat loss with shot blasting to reductions exceeding 50% with optimized rotary systems.
Complementary laboratory measurements of roll cooling were performed to determine spatially resolved heat transfer coefficient (HTC) distributions under realistic spray conditions. It was demonstrated that HTC cannot be directly inferred from water distribution due to nozzle orientation and flow interactions, leading to substantial variations in cooling intensity along the roll circumference. These experimentally determined HTC fields were subsequently implemented into a thermo-mechanical model of the work roll.
Numerical simulations reveal that both descaling-induced heat losses and the roll-cooling strategy critically influence the thermal crown, temperature gradients, and the stress state in the roll. In particular, improper timing and positioning of cooling can increase maximum tensile stresses by more than 30%, significantly accelerating roll degradation. The results highlight that upstream descaling conditions modify the thermal input to the roll, while downstream cooling governs stress evolution.
The study demonstrates that integrated optimization of descaling and roll cooling provides a powerful pathway to reduce energy losses, improve surface quality, and extend roll service life, offering practical guidelines for modern hot rolling operations.

Speaker: Milan Hnizdil (Brno University of Technology, Heat transfer and fluid flow laboratory, Faculty of Mechanical Engineering)

60 Extending SBQ Rolling to Large Diameters: Stainless and Special Steels from 3.75 to 16 inches at FRISA Steel

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 processing landscape.
This work presents the commissioning of a new SBQ rolling mill at FRISA, enabling the production of round and square bars from 3.75 up to 16 inches in diameter, supported by integrated straightening, peeling, ultrasonic inspection (UT), and heat treatment facilities. This installation represents a significant expansion in the processing capability of large-section materials, traditionally considered unsuitable for rolling in high-integrity applications.
Particular emphasis is placed on precipitation hardening stainless steels such as 17-4PH, where large cross-sections have historically exhibited challenges related to segregation, microstructural variability, and inconsistent response to heat treatment. In addition, results are presented for austenitic grades (304, 316), hot work tool steel H13, and high-cleanliness steels for bearing applications, demonstrating the robustness of the process across multiple alloy systems.
Through the application of high total reductions (typically well above 4:1), controlled thermomechanical processing, and optimized heat treatment cycles, the developed route achieves enhanced microstructural homogeneity and property consistency. Industrial data show low mechanical property variations across the section, full compliance with ultrasonic quality requirements, and improved surface integrity after peeling.
The results indicate that modern SBQ rolling, when properly engineered, can deliver quality levels competitive with forging routes while offering increased productivity and process stability, particularly in applications where consistency and repeatability are critical.
This work positions large-diameter rolling not only as a complementary solution to traditional routes, but as a technically robust and industrially scalable alternative for selected high-performance applications, opening new opportunities in the supply of stainless and special bar products.

Speaker: Alberto Vazquez

61 Extension and Application of Hot Workability Prediction Model in Thermomechanical Processing

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 instability factor reflects the stability of plastic flow. Although the hot processing map theory has been widely applied to the hot deformation of various materials across a broad range of forming conditions, existing methods still exhibit limitations that hinder their practical application or lead to prediction inaccuracies. In this study, a data-driven model is developed based on the hot processing map theory to predict hot workability. Specifically, the conventional direct relationship between deformation conditions and hot workability is extended to a multidimensional space that incorporates deformation conditions, microstructural states, and hot workability. Based on the SHAP analysis, the relationships among these three factors are further quantitatively characterized. The influences of deformation conditions and microstructural states on hot workability under various processing conditions are systematically elucidated. To demonstrate the general applicability of the proposed approach, 316L austenitic stainless steel, low-carbon alloy steel, and nickel-based alloys are investigated. Furthermore, experiments involving dynamically varying deformation conditions and double-pass hot deformation are conducted to validate the method’s capability in handling complex thermomechanical processes. The proposed model demonstrates strong potential for application in complex thermomechanical processing and provides a powerful tool for the design and optimization of processing routes. Future work will focus on extending the model to more complex material systems, such as duplex stainless steels and titanium alloys.

Speaker: SHUO GUO (Policlinico di Milano)

62 Shear and dynamic effects on hot deformation of Fe-25Mn-5Al-0.7C lightweight steel

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 rate changes. Microstructure was characterized by OM, SEM and XRD, and a DRX kinetic model was implemented into Deform 3D. The results show that shear stress significantly enlarges the instability region on processing maps and narrows the safe window to T > 1075 °C and ε ̇< 0.015 s⁻¹. Direct comparison between uniaxial and shear compression tests confirms that the presence of shear stress is largely responsible for defect formation (e.g., banded structures, flow localization) during rolling. Increasing temperature or strain rate eliminates such defects, while a sudden strain rate rise promotes DRX nucleation and improves uniformity. A temperature modified DRX model well predicts the microstructural evolution. These findings provide a theoretical basis for minimizing shear induced defects in industrial hot rolling of FeMnAlC lightweight steel.

Speaker: Ruowei Li (Politecnico di Milano)

15:40 Coffee break

Numerical Simulation, AI & Digital Innovation V

Convener: Prof. Valentina Colla (Scuola Superiore Sant'Anna)

63 A Combined Physics-Based and Artificial Intelligence Through-Process Modelling of Steel Production Path

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, and heat treatment. The modelling concept is based on horizontal coupling, in which simulation codes for different processing or product use steps are connected to their associated multiscale structures and material properties, and on vertical coupling, in which simulation codes at multiple length scales are used to describe product properties. The scales we cope with range from the grain size to several tenths of a meter. The microstructure is formulated using the phase-field method, the mesostructure using the cellular automaton method, and the macroscopic electromagnetic, fluid mechanics, and solid mechanics fields using continuum mechanics. We present a solution framework for describing the related multiscale and multiphysics thermomechanical problems based on a space-time adaptive meshless solution procedure for the microscopic and macroscopic scales, and on the point automata concept for the mesoscopic scale. The phenomena addressed by this meshless technique range from large-eddy simulation of continuous casting to elastoplastic deformation of products on the cooling bed. Artificial intelligence is used to replace physics-based models when sufficient data are available (e.g., genetic programming) and for optimisation (e.g., evolutionary computing). The validation of some of the models and concepts based on plant and laboratory measurements is shown.

Speaker: Božidar Šarler (University of Ljubljana and Institute of Metals and Technology)

64 A dynamic permeability model based on real-time local solidification time for macrosegregation modeling in alloy directional solidification

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 permeability via the generalized West model. The mushy zone parameter and back-diffusion parameter are then derived from the permeability and the Clyne–Kurz model, respectively, thereby establishing a direct bidirectional coupling relationship between micro-component transport and macro-flow and heat transfer. The model is validated against electroslag remelting experiments of 40CrNi2Mo steel. Compared with a constant permeability model, the proposed model reduces the root‑mean‑square error of carbon macrosegregation predictions by over 70% and increases the coefficient of determination from 0.498 to 0.865, demonstrating significantly improved accuracy.

Speaker: Haoran Xu (Institute of Metal Research, Chinese Academy of Sciences)

65 Digital Twin–Based Simulation Chain for Rail Manufacturing: Roll Pass Design, Head Hardening, and Straightening

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 state, rolling speed, and force–energy characteristics. These fast calculations support selection of feasible pass schedules and allow potentially critical loads on rolls to be identified before detailed numerical analysis.
The verified roll pass design is subsequently imported into QForm UK for finite element simulation of rail rolling. For the heat-treatment stage, boundary conditions generated by a dedicated CFD model are transferred to QForm UK to reproduce differential cooling of the rail head. This coupled methodology captures nonuniform heat exchange, local temperature gradients, and phase transformation kinetics during quenching, while preserving process-specific effects such as air-flow distribution and cooling intensity.
The final stage addresses rail straightening and examines how inherited temperature fields and residual stresses affect the final geometry of the product. Taken together, the proposed framework provides an integrated digital representation of rail manufacturing and demonstrates the value of combining analytical design tools with FEM and CFD models. Such an approach can shorten process development, improve product consistency, and increase the durability of rolls in modern rolling mills.

Speaker: Nikolay Biba

66 ESR simulation: prediction of quality and grain size for nickel based ingot

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 run-out prevention and reduction of ingot piping. Final shape of ingot, microstructure and grain distribution will be finally transferred to forging simulation software DEFORM to show chaining capability and evolution of as-cast structure.

Speaker: Cristian Viscardi (ECOTRE Valente srl)

67 Ingot uphill casting defect potential reasons and forecast by different approach and analysis.

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 product with consequent technical and economic damages. Low or incorrect refractory qualities may release polluting parts to the final product, complicated shapes or layouts can reduce the casting speed and efficiency. Experience showed that the quality, shapes and layout of the caster refractories may affect the final products. Other possible analysis consist in:
- the use of post-mortem residual bones examinations to identify possible sources of defects
- casting simulations by means of Finite Elements Methods (F.E.M.) in order to develop better layouts and shapes to reduce potential defects.
This paper would like to resume these experimental approaches to promote new and more accurate systems to improve ingot quality with eventual use of AI.

Speaker: Dr Ferruccio Pastorino

Rolling, Forging & Hot Deformation V

Convener: Alessandra Saleri (Forge Fedriga srl)

68 The Effect of the Slip Transition in the Rolling Deformation Zone on the Wear Behavior of Hot Rolling Work Rolls

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 influence on wear behavior has not been fully clarified. In this study, two simulation experiments were designed to investigate, on an exploratory basis, the work roll wear behavior under reciprocating and unidirectional friction conditions. The results show that under unidirectional sliding, a continuous oxide layer forms on the surface, and the wear process is characterized by repeated formation and spallation of the oxide film, corresponding to typical oxidative wear and delamination. In contrast, under reciprocating friction, the formation and retention of the oxide layer are suppressed, resulting in reduced interfacial protection. Consequently, severe spalling accompanied by pronounced ploughing grooves is observed, and the dominant wear mechanism shifts to abrasive wear and fatigue induced delamination. It is demonstrated that friction reversal plays a key role in governing the transition of wear mechanisms by affecting the formation and stability of the tribo-oxide layer. Based on these findings, in industrial hot rolling processes, the distribution of reduction, the magnitude of front and back tensions, and the length ratio between forward and backward-slip zones can be optimized (avoiding symmetric distributions) to promote the formation and retention of protective oxide films, thereby reducing the friction coefficient and mitigating roll surface damage.

Speaker: Dr Sunrui Tao

69 Two-Stage Descaling at PSM Plate Mill for High-Alloy Plates

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 of the project is the installation of a two-stage descaling system, consisting of a primary descaler at the furnace exit and a secondary descaler at the roughing stand entry. This configuration effectively removes both primary and secondary scale, leading to improved surface quality and reduced defect rates. In particular, the surface quality of high-alloy plates is significantly improved through proper descaling of the slabs. The system is designed to handle a wide range of input materials, including blooms, slab ingots, and continuous cast slabs. It incorporates real-time laser-based thickness measurement for automatic height adjustment, optimized nozzle positioning, and adaptable descaling forces tailored to different steel grades.

The paper provides an overview of the entire project, from the early conceptual stage through to successful implementation. It outlines the key technical features of the installed system and presents operational results, as well as practical experiences gained during commissioning and production.

Speaker: Christian Redl (INTECO melting and casting technologies GmbH)

70 Rapid Interface Strengthening of Cold-Rolled Bimetallic Composite Strips via Electric Pulse Treatment

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 recrystallization of the matrix while offering limited improvements in bonding strength.
In this study, copper/stainless steel and copper/titanium composite thin strips were investigated, and a short-duration electric pulse treatment (EPT) was proposed to replace traditional annealing. Results indicate that while cold rolling only achieves preliminary mechanical interlocking, EPT significantly strengthens the interface within seconds through the synergistic coupling of Joule heating and athermal effects. Optimized EPT achieves a significant increase in peel strength, surpassing conventional annealing at equivalent temperatures while maintaining high tensile strength. Microstructural analysis reveals that EPT accelerates interfacial atomic diffusion and promotes grain refinement, forming a dense and continuous metallurgical bonding layer. Consequently, a synergistic enhancement of the bonding and tensile strength of the composite strips is achieved. The "Cold Rolling-EPT" process developed in this study provides a novel and efficient strategy for the fabrication of high-performance composite thin strips.

Speaker: Xiaomiao Niu (Taiyuan University of Technology)

71 ECAI Omega: 2 machines in one!

OMEGA: 2 machines in one!
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 bearing the main advantages of radial-axial ring mills as well as multi-mandrel ring mills for closed-tool ring rolling.
The ECAI Omega type is a very compact machine that can be installed on a very simple foundation and is entirely designed and built in France with exclusively European components.
With the Omega we have a modular machine that can be delivered with two stations, in this case productivity will be very high, as while rolling on one station the other station is being unloaded and loaded, or, in a first time, with one station, having the possibility to implement the other station in a second time.
The Omega® is suitable to be integrated in a fully automated line for high productivity requirements.
As the other machines in our range the Omega is based on our patented electromechanical technology: the radial and axial stands and the centring arms are moved by electromechanical drives, unlike traditional rolling mills that use hydraulic cylinders, eliminating, among other things, all maintenance and environmental problems associated with hydraulics.
The Omega ring mill, like all our machines, uses the highly intuitive RingLab® control system using graphic symbols instead of text and allowing to export and import data via files in CSV (Excel) format and an open SQL database
Thanks to RingLab® Supervisor, it is possible to track the recording of all rolling data (over 400 parameters), directly on the machine or on a computer connected to the machine.

Speaker: Claudia Solari (AIM)

19:00 Conference dinner

A transfer service (from the Conference venue) wiill be provided.
Departure from the Conference venue at 19:00
Dinner: 19:30-22:00/22:30
Return to Bardolino at around 22:30

Thursday 15 October

Hot rolling I

Convener: Caiyi Liu (Yanshan university)

72 Billet Welding Machine – Latest development description and real application results

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 part the application case at Ferriera Valsabbia S.p.A. mill is presented, with the data collected during over a year of endless operation and the remarkable achieved results.

Keywords: ERT-EBROS, Billet Welding, Long Products, Productivity, Endless Rolling Technology

EBROS is a registered trademark of Steel Plantech Co.

Speaker: Alberto Nardini

73 Danieli’s QSP-DUE®: Unlimited freedom for green HRC production

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 automotive exposed sector with dedicated features and production strategies. At the same time the commitment to sustainability is evident through the electrification efforts, setting new standards for high-quality, sustainable steel production, driving innovation, and meeting diverse market demands.

Speaker: Mr Andrea Canal

74 Concept to Operation: Digital Twin Integration and FEM Simulation in Horizon

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 applications, Horizon facilitates seamless IT-OT convergence, data-driven process optimization, and predictive maintenance. Central to Horizon’s innovation is the integration of Finite Element Method (FEM)-based simulations, enabling precise modeling and optimization of thermo-metallurgical processes. This capability is further enhanced by dedicated applications—AQUARIUS for thermal treatment simulation, DRACO for thermal treatment specific to wire rod, and EVO ROLL MASTER for rolling operations—providing advanced tools for comprehensive process analysis and continuous improvement in modern rolling mills.

Speaker: Alberto Nardini

75 Investigation on the crack resistance and strength–ductility synergy of Ta-12W alloy via corrugated–flat warm rolling

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 sheet structure, followed by flat rolling in the second pass with a reduction ratio of 40%. Prior to each pass, pulsed electric current heating was applied, maintaining the rolling temperature at 300 °C. Corrugated rolling disrupts the conventional plane-strain compression state and introduces a periodic strain gradient, while the subsequent flat rolling exhibits a pronounced stress–strain inheritance effect, resulting in a spatially heterogeneous stress state. This multi-axial stress condition activates additional slip systems, promotes grain rotation, and diversifies grain orientations and texture components, thereby suppressing the formation of sharp textures. Simultaneously, the periodic strain gradient transforms coincidence site lattice boundaries from banded to dispersed distributions, enhancing resistance to crack propagation. The Joule heating effect replaces conventional heating, enabling warm rolling at 300 °C and significantly reducing flow stress. Moreover, the electroplastic effect facilitates dislocation disentanglement and alleviates local stress concentration, ensuring stable deformation. After annealing, the microstructure becomes more homogeneous. The processed Ta-12W alloy exhibits an ultimate tensile strength of 969 MPa and an elongation of 34%, demonstrating excellent mechanical performance. This study provides an effective strategy for the advanced processing and high-performance fabrication of tantalum–tungsten alloys.

Speaker: Dr Peng Li (Taiyuan University of Technology)

76 Intelligent heat treatment in line applications for hot rolling process

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.
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 too.
With this prospective will be analyzed different types of heat treatment applications in dependence of final product dimensions, relative steel grade conditions and how the sensorization combined with vision/digital control can help to improve the process efficiency in direct and intelligent mode.

Speaker: Alberto Nardini

Ingot casting and remelting III

Convener: Michele De Santis (Rina Consulting - Centro Sviluppo Materiali SpA)

77 STAINLESS STEEL AND SPECIAL ALLOYS INGOTS. WHICH CASTING POWDER?

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.
The introduction of stainless steel ingot casting led to new powders, characterized by controlled CaO–SiO₂–Al₂O₃ chemistry, optimized basicity, and more stable viscosity. This marked a shift toward improved lubrication, heat transfer control, and surface quality suitable for stainless steels. Further refinement resulted in products specifically optimized for stainless steels and significantly improved performance in Ti‑stabilized grades by limiting titanium reactions and enhancing mould flux stability.
The need to cast increasingly complex materials drove the development of highly specialized powders.
A new casting powder with a balanced free carbon content to ensure adequate lubrication, accommodate varying solidification behavior, and minimize surface defects has been formulated for ferritic and martensitic steels with higher carbon and higher liquidus temperatures.
A product has been designed for special alloys with low melting temperatures, with characteristics that enable rapid slag formation and controlled heat extraction under extreme casting conditions.
Finally, a casting powder has been formulated for nickel‑based alloys. It combines a very low melting range, high basicity, and excellent fluidity to ensure immediate slag melting and stable heat transfer under tightly controlled superheat conditions required for these highly reactive alloys.
Overall, the evolution of casting powders reflects a transition from universal solutions to alloy‑specific formulations, enabling higher process stability, improved surface quality, and reliable casting of advanced stainless steels and special alloys.

Speaker: Marco Alloni (Prosimet S.p.A.)

78 ELECTROSLAG REMELTING: AN ADDITIVE APPROACH TO LARGE COMPOSITIONALLY HOMOGENEOUS AND COMPOSITE COMPONENTS MANUFACTURING

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 aerospace, avionics, and military applications, where cost is secondary. A key metallurgical advantage of AM is the reduction of segregation by minimizing the mushy zone through smaller liquid metal pools formed during layer-by-layer solidification.
Beyond conventional AM stereotypes, Electroslag Remelting (ESR) is an established AM technology for building heavy ingots layer by layer, offering superior quality with relatively high productivity. Solidification control is a major ESR benefit, ensuring high homogeneity and yield in heavy ingot production. By maintaining a shallow liquid pool, large cross-section ingots or billets can be produced — either using consumable electrodes with manageable segregation or by direct pouring of liquid metal.
Electroslag technology is also effective for manufacturing as-cast pipes and hollow ingots of various sizes and shapes, improving quality and efficiency compared to products derived from solid ingots. A significant advantage of hollow ingots is their favorable solidification pattern, achieved through effective cooling of the thin solidified layer between two concentric water-cooled molds. This allows large diameters and weights to be maintained while the volume of metal solidifying simultaneously remains considerably smaller than in a solid ingot of equivalent dimensions.

Speaker: Prof. Ganna Stovpchenko (CFHI, UDUNT)

79 Vacuum Ingot Casting in the Modern Era: Plant Concepts, Process Optimization, and Performance

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 direct ladle casting and pony ladle configurations, and their impact on process stability, cleanliness, and operational flexibility. Recent innovations—ranging from automated casting rate control to advanced vacuum pump systems—are presented as key enablers for improved efficiency, safety, and sustainability. Special attention is given to achieving ultra-low hydrogen levels and high cleanliness standards required for demanding steel grades. The contribution also includes selected recent operational results from a modern vacuum ingot casting plant, demonstrating achievable performance levels under industrial conditions, and highlighting the technology’s relevance for future steel production.

Speaker: Mr Alexander Weigl (Inteco melting and casting technologies GmbH)

80 Advances in the Production of Ultra-Clean Specialty Steels: Recent Strategies for Hydrogen Removal, Total Oxygen Reduction, and Nonmetallic Inclusion Control

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 flaking-related rejections in current operation.
In parallel, enhanced metallurgical practices have enabled total oxygen levels consistently below 12 ppm in finished products, with cleanliness performance characterized by narrow inclusion size distributions as measured by SEM-ASPEX (√area). These results reflect a high degree of process stability and repeatability across heats and product ranges.
These outcomes are supported by an integrated and tightly controlled secondary metallurgy framework, spanning from EAF deoxidation through LF slag and aluminum management to carefully controlled VD practices focused on inclusion flotation and reoxidation prevention. The approach is driven by rigorous process discipline, statistical control, and in-house metallurgical expertise.
The combined effect of predictive control, process robustness, and metallurgical precision enables FRISA to deliver steels with exceptional consistency, cleanliness, and reliability, meeting the demands of high-performance applications where defect tolerance is minimal.
This work demonstrates how modern steelmaking, leveraging advanced control strategies and disciplined execution, can systematically achieve ultra-clean steel conditions at an industrial scale, reinforcing FRISA’s position as a competitive supplier for the most demanding specialty steel markets.

Speaker: Mr Julio Espinoza

81 Experimental and Numerical Investigation of Novel Al–Cenosphere–MWCNT Composite Foams under Varying Strain Rate

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 foam fabricated through the stir casting route is investigated under quasi-static and high strain rate loading conditions. The incorporation of hollow ceramic cenospheres significantly reduces density while improving thermal stability, whereas the addition of multi-walled carbon nanotubes (MWCNTs) enhances shock resistance through effective load transfer and energy dissipation mechanisms. The synergistic effect of cenospheres and MWCNTs enables a tailored combination of lightweight characteristics and improved mechanical response. Numerical simulations are carried out using an explicit finite element approach incorporating the Johnson–Cook constitutive model to capture the nonlinear deformation behavior up to strain rates of 1000 s⁻¹. The developed finite element model is validated through experimental compression tests performed using a Universal Testing Machine (UTM) and Split-Hopkinson Pressure Bar (SHPB) setup. A good agreement between experimental and numerical results confirms the predictive capability of the proposed model. The study demonstrates the effectiveness of integrating experimental characterization with numerical modeling for evaluating the dynamic mechanical response of Novel Al–Cenosphere–MWCNT composite foams and highlights their potential for lightweight structural and energy-absorbing applications relevant to casting and advanced material processing industries.

Speaker: Ravi Kumar (Indian Institute of Science, Bangalore, Karnataka, India-560012)

10:20 Coffee break

Heat Treatment

82 Small-scale Experiments on the Recrystallization of alloy 718 and their Transferability to Industrial Production

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 Ultrasound system. This approach allows for the in-situ measurement of microstructural changes — specifically grain growth and recrystallization — during the actual deformation and following heat treatment.
Isothermal compression tests were conducted at different temperatures, partly with subsequent holding at temperature. The Laser Ultrasound system utilizes a pulsed laser to generate ultrasonic waves and a laser interferometer to detect them. By measuring the ultrasonic attenuation in real-time, the recrystallization and grain growth was quantified as it occurred.
Results indicate that hot deformation with Laser Ultrasound provides a very good correlation with post-mortem EBSD (Electron Backscatter Diffraction) analysis, particularly in identifying the necessary temperatures and holding times required for meta-dynamic recrystallization. This approach supports the optimization of thermomechanical processing routes for nickel base superalloys used in aerospace applications.

Speaker: Thomas Leitner (voestalpine BÖHLER Edelstahl GmbH & Co KG)

83 Qualification of Heat Treatment Cycle for a Forged blank in Ti-6Al-4V

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 testing program was developed to identify the most suitable heat treatment cycle capable of providing the required strength, ductility, and a homogeneous equiaxed α+β structure. Forged blank was sectioned into multiple sectors, each subjected to different heat treatment cycles involving solution treatment and aging at various temperatures under controlled conditions.

The heat-treated samples were subsequently subjected to tensile testing, Charpy impact testing, and metallographic examination, according to applicable standard code (ASTM, SAE AMS), in order to assess the influence of heat treatment parameters on the final material properties.

An optimal heat treatment cycle was selected, based on a solution treatment temperature followed by aging, guaranteeing adeguate isotropy of mechanical properties and compliance with microstructural requirements.

The project concludes with the definition of the heat treatment process to be used for components manufacturing, guaranteeing full compliance with the specified technical requirements and ensuring a homogeneous equiaxed α β microstructure of the final product.

Speaker: Mattia Gianola

84 THE INDUSTRIAL IMPLEMENTATION OF A BURNER CAPABLE TO OPERATE IN PREHEATED AIR-FUEL MODE, OXY-FUEL MODE OR PREHEATED AIR-OXY-FUEL MODE

Tuur De Preter1, Joaquín de Diego2, Akira Morokuma3, Yoshiyuki Hagihara4, Jorge Visús5
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 142-8558, Japan
5 Nippon Sanso España, Orense 11 5ª, Madrid 28020, Spain

The presentation discusses the latest developments of the Nippon Sanso DiluJet® Oxy-Air Burner: the burner concept, the benefits of this burner and its application in industrial furnaces.
The DiluJet® Oxy-Air Burner has been further developed with the aim to offer a maximum of flexibility when being implemented at existing furnaces. The burner is able to operate as a traditional Preheated Air-Fuel burner, as an Oxy-Fuel burner or as a hybrid Preheated Air-Oxy-Fuel burner. At the same time the fuel input of the burner can be modified between 100% natural gas, 100% (green) hydrogen or any mix of natural gas and (green) hydrogen. Switching between all these different operation modes, can be done in a straightforward way by the HMI of the PLC system.
The possibility to switch between these different operational modes, creates a very wide flexibility in several areas: furnace throughput, heat transfer mechanism inside the furnace, furnace atmosphere composition, amount of CO2 emissions, specific fuel consumption, furnace OPEX.
Since August 2025, the 4 MW version of this burner has been used non-stop in an European continuous reheat furnace for long steel products during the execution of the EU funded HyInHeat project. The different operation modes have been demonstrated during full-scale operation. Prior to August 2025, this burner has been implemented in several soaking pit furnaces.

Speaker: Dr Antonio Di Mauro (Nippon Sanso Industrial)

85 Metallurgical Design of Forged Pipes and Connecting Parts

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 treatment conditions on the microstructure and mechanical properties, was performed.
The promising chemical compositions and process conditions were identified based on background knowledge and application of thermal-metallurgical models able to predict the fraction of microstructural constituents and hardness/strength of heat treated parts.
The model is an effective tool for defining the optimum chemical composition and heat treatment conditions to match the required tensile properties. In addition to virtual simulations, also laboratory tests and industrial trials were carried out to assess the effect of microstructure on the strength-impact toughness combination, starting from promising chemistries.
Low-carbon steels containing V (0.07-0.10%) and Nb (0.025-0.04%) can be safely austenitized up to 920 °C-940 °C to dissolve V rich precipitates, without formation of coarse austenite grains (> 30 μm) due to the pinning effect of Nb (C, N) fine particles which hinder grain boundary movement. In case of Nb low contents (< 0.025%), austenitizing temperatures of 860 °C to 890 °C are preferred.
Uniform and fine ferrite-pearlite and bainitic microstructures are fundamental to achieve strength combined with good impact toughness values, even after simulated post welding heat treatment. Examples of microstructures and mechanical properties of forged pipes and connecting parts are given.
This work was supported by the Italian Minister of Economic Development under Grant F-220024-00-X47 (INNOTECH Project).

Speaker: Dr Ettore Anelli (Franchini Acciai SpA)

86 Effect of heat treatments on a "lean" chemical steel composition for cylinders

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 work focuses on the assessment of the heat treatment response of a steel with 0.6%C-5.0% Cr nominal composition with 0.9% C in segregated region. The effect of austenitization is studied by building grain growth curves in a temperature range typical of industrial process. Continuous Cooling Transformation (CCT) diagrams are built starting from two different austenitization temperatures, thus simulating the effect of the cooling stage on both the cylinder regions characterized by nominal and segregated region. The effect of tempering is studied after quenching of both the nominal and segregated region. Results show that, even with a lean chemical composition, a wide range of microstructures and mechanical properties can be achieved through proper control of heat treatment parameters. This study provides useful guidelines for the design of steels with reduced alloying content, contributing to more environmentally sustainable steel production.

Speaker: Prof. Andrea Di Schino (Dipartimento di Ingegneria, Università di Perugia, Via G. Duranti 93, 06125 Perugia, Italy)

Closing remarks

Conveners: Alessandra Saleri (Forge Fedriga srl), Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)