Tilt Rolling for Uniform Crystallographic Texture
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Solution Overview
Problem
Conventional rolling methods produce plates and sheets with non-uniform crystallographic texture, leading to unpredictable sputtering rates and film thickness variations, which are critical issues in thin film deposition and material properties such as magnetic permeability.
Innovation Solution
The introduction of shear strain through the thickness of plates and sheets via tilt rolling, where the workpiece is tilted during rolling to control the crystallographic texture, resulting in minimal through-thickness texture gradient and improved shear texture, enhancing the uniformity and predictability of film thickness and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional rolling methods are used, then the manufacturing process is simple, but the crystallographic texture is non-uniform through the thickness
Solution Approach 1:
The patent applies asymmetry by tilting the workpiece at a specific angle (5-15 degrees) relative to the rolling direction, creating asymmetric deformation conditions that produce uniform crystallographic texture through the thickness. This asymmetric rolling configuration transforms the conventional symmetric rolling process into one that generates desired texture uniformity without requiring complex additional equipment.
Solution Approach 2:
The patent introduces a new dimensional parameter - the tilt angle - to the conventional rolling process. By adding this angular dimension to the traditional planar rolling, the process achieves uniform texture distribution through the thickness while maintaining manufacturing simplicity. The tilt angle creates shear strain that redistributes crystal orientations uniformly across the material thickness.
2Reliability
If conventional rolling is used, then the processing time is short, but the sputtering rate is unpredictable due to non-uniform texture
Solution Approach 1:
The patent applies preliminary action by implementing the asymmetric rolling process with tilt angle during the manufacturing stage to pre-establish uniform crystallographic texture throughout the target material. This preliminary texturing ensures predictable sputtering rates during subsequent use, eliminating the need for time-consuming post-manufacturing texture analysis and adjustment cycles.
3Manufacturing precision
If conventional rolling is used, then energy consumption is low, but film thickness uniformity is poor
Solution Approach 1:
The patent employs asymmetry in the rolling configuration by tilting the workpiece, which creates a more efficient deformation pattern that produces uniform texture and consequently uniform film thickness. This asymmetric approach achieves better manufacturing precision without proportionally increasing energy consumption, as the tilt angle optimizes the stress distribution during rolling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Tilt rolling achieves improved uniformity and predictability of film thickness, better formability, and enhanced magnetic properties, reducing processing costs and energy consumption in industries relying on sputtering targets and grain-oriented silicon steel.
Implementation Method 1
The introduction of shear strain through the thickness of plates and sheets via tilt rolling
Data Source
AI summary
Methods and apparatus for rolling metal sheet or plate are provided. The method comprises the step of feeding the metal plate or sheet into a rolling mill at an angle. The apparatus comprises a rolling mill having a tilted feed table, or an apron upon which a transfer table and tilted feed table can rest. Through-thickness gradient and shear texture can be improved using the methods and apparatus of the invention.