Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials
Ultrathin metal foils are essential for applications requiring miniaturization across modern industry. Nevertheless, it is challenging for conventional rolling mills and conventional rolling methods to reduce the thickness of single-layer foils to a scale approaching just a few micrometers. This dif...
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MDPI AG
2024-11-01
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| author | Ning Nie Rui Wang Guanyu Deng Hui Wang Pengfei Wang Anh Kiet Tieu Huijun Li Lihong Su |
| author_facet | Ning Nie Rui Wang Guanyu Deng Hui Wang Pengfei Wang Anh Kiet Tieu Huijun Li Lihong Su |
| author_sort | Ning Nie |
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| description | Ultrathin metal foils are essential for applications requiring miniaturization across modern industry. Nevertheless, it is challenging for conventional rolling mills and conventional rolling methods to reduce the thickness of single-layer foils to a scale approaching just a few micrometers. This difficulty arises from a range of inherent factors, including the elastic modulus, diameter of the rollers, resistance of rolled materials, and friction coefficient. To address these limitations, an accumulative pack rolling (APR) method has been developed in this work to fabricate ultrathin metal foils. Al foils down to ~2 µm have been successfully fabricated by using Al, Ta, and stainless steel (SS) as pack materials. The effects of the pack sheets on surface morphology, thickness reduction, and microstructural evolution were investigated. Key surface roughening behaviors, including ridging and particle-like surface roughening, were observed on the inner surface, which influences the roughening and thinning behavior of the target Al foils. This study also provides insights into surface roughening mechanisms, including rolling marks, ridging, and particle-like roughening, and demonstrates the critical role of pack sheet materials in controlling plastic instability, achieving uniform thickness reduction in ultrathin foils, and preventing severe deterioration of surface flatness during the APR process. |
| format | Article |
| id | doaj-art-2344dc45047b4bd7beb2045446a80f4b |
| institution | OA Journals |
| issn | 2075-4701 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | MDPI AG |
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| series | Metals |
| spelling | doaj-art-2344dc45047b4bd7beb2045446a80f4b2025-08-20T01:53:54ZengMDPI AGMetals2075-47012024-11-011411126210.3390/met14111262Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack MaterialsNing Nie0Rui Wang1Guanyu Deng2Hui Wang3Pengfei Wang4Anh Kiet Tieu5Huijun Li6Lihong Su7School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, AustraliaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, AustraliaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, AustraliaSchool of Mechanical Engineering, Nantong University, Nantong 226019, ChinaNational Engineering Research Center for Equipment and Technology of Cold Strip Rolling, Yanshan University, Qinhuangdao 066004, ChinaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, AustraliaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, AustraliaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, AustraliaUltrathin metal foils are essential for applications requiring miniaturization across modern industry. Nevertheless, it is challenging for conventional rolling mills and conventional rolling methods to reduce the thickness of single-layer foils to a scale approaching just a few micrometers. This difficulty arises from a range of inherent factors, including the elastic modulus, diameter of the rollers, resistance of rolled materials, and friction coefficient. To address these limitations, an accumulative pack rolling (APR) method has been developed in this work to fabricate ultrathin metal foils. Al foils down to ~2 µm have been successfully fabricated by using Al, Ta, and stainless steel (SS) as pack materials. The effects of the pack sheets on surface morphology, thickness reduction, and microstructural evolution were investigated. Key surface roughening behaviors, including ridging and particle-like surface roughening, were observed on the inner surface, which influences the roughening and thinning behavior of the target Al foils. This study also provides insights into surface roughening mechanisms, including rolling marks, ridging, and particle-like roughening, and demonstrates the critical role of pack sheet materials in controlling plastic instability, achieving uniform thickness reduction in ultrathin foils, and preventing severe deterioration of surface flatness during the APR process.https://www.mdpi.com/2075-4701/14/11/1262accumulative pack rollingultrathin metal foilsplastic instabilitysurface roughening |
| spellingShingle | Ning Nie Rui Wang Guanyu Deng Hui Wang Pengfei Wang Anh Kiet Tieu Huijun Li Lihong Su Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials Metals accumulative pack rolling ultrathin metal foils plastic instability surface roughening |
| title | Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials |
| title_full | Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials |
| title_fullStr | Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials |
| title_full_unstemmed | Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials |
| title_short | Fabrication of Ultrathin Al Foils by Accumulative Pack Rolling: Influence of Pack Materials |
| title_sort | fabrication of ultrathin al foils by accumulative pack rolling influence of pack materials |
| topic | accumulative pack rolling ultrathin metal foils plastic instability surface roughening |
| url | https://www.mdpi.com/2075-4701/14/11/1262 |
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