A method for producing metal beams having a top-hat profile comprises the hot rolling of slabs (13), ingots (12), billets, preliminary profiles (14) or similar semifinished products in a rolling train. The rolling train comprises at least two roll stands. Using at least two shaping passes during a single rolling process in a number of rolling stations at hot-rolling temperature, preferably simple irregular pass design turns an entering cross section (10) of a one-part semifinished product into an exiting cross section having a top-hat profile (A), which corresponds geometrically more or less to the profile of the finished product.

Methods of forming a high-strength metal alloy precursor by tailor-casting strips having a tailored thickness across a width of a strip material are provided. The tailor-cast strips have varying thickness throughout the width, which can then be further tailor rolled to a final required thickness profile/tailored thickness. Such tailor-casting method can be conducted by contacting a patterned surface of a casting roller or a casting block with a liquid high-strength metal alloy in a continuous casting process. The present disclosure provides methods of continuously casting a strip having varying thickness across the width allows for improved product in subsequent processing, like tailor rolling. Methods of making a high-strength metal alloy structural automotive component from a tailor-cast blank having a tailored thickness are also provided.

Methods of forming a high-strength metal alloy precursor by tailor-casting strips having a tailored thickness across a width of a strip material are provided. The tailor-cast strips have varying thickness throughout the width, which can then be further tailor rolled to a final required thickness profile/tailored thickness. Such tailor-casting method can be conducted by contacting a patterned surface of a casting roller or a casting block with a liquid high-strength metal alloy in a continuous casting process. The present disclosure provides methods of continuously casting a strip having varying thickness across the width allows for improved product in subsequent processing, like tailor rolling. Methods of making a high-strength metal alloy structural automotive component from a tailor-cast blank having a tailored thickness are also provided.

Described herein is a method for rolling metal sheets of variable thickness. The method makes it possible to impress, during rolling, any distribution of areas of increased thickness within a figure corresponding to the plane development of a motor-vehicle component prior to the pressing operation. Impression of the desired distribution of areas of increased thickness envisages simultaneous impression, during rolling, of a further distribution of areas of increased thickness, or compensation areas.

Described herein is a method for rolling metal sheets of variable thickness. The method makes it possible to impress, during rolling, any distribution of areas of increased thickness within a figure corresponding to the plane development of a motor-vehicle component prior to the pressing operation. Impression of the desired distribution of areas of increased thickness envisages simultaneous impression, during rolling, of a further distribution of areas of increased thickness, or compensation areas.

Regarding each rolling mill, a rolling torque Gi before biting into a downstream stand is stored, the peripheral velocity of a most downstream stand Rn is controlled to be Gn1=Gn1* after biting into Rn, and a rolling torque Gn** of Rn after tension is stabilized is stored. After that, the peripheral velocity of a rolling mill Ri is controlled to be Gi=Gi* toward an upstream side, and the peripheral velocity of a rolling mill Rk at a downstream side of the rolling mill Ri is controlled to keep Gk=Gk** (k=i+1 to n) so that a rolling torque of a most upstream rolling mill R1 becomes equal to a stored G1*. Stabilization of material passage and improvement in accuracy of a product dimension are enabled by controlling tension between stands with high accuracy by using a simple control system without using table values or the like by each rolling condition even under a condition where a distance between stands is short.

Regarding each rolling mill, a rolling torque Gi before biting into a downstream stand is stored, the peripheral velocity of a most downstream stand Rn is controlled to be Gn1=Gn1* after biting into Rn, and a rolling torque Gn** of Rn after tension is stabilized is stored. After that, the peripheral velocity of a rolling mill Ri is controlled to be Gi=Gi* toward an upstream side, and the peripheral velocity of a rolling mill Rk at a downstream side of the rolling mill Ri is controlled to keep Gk=Gk** (k=i+1 to n) so that a rolling torque of a most upstream rolling mill R1 becomes equal to a stored G1*. Stabilization of material passage and improvement in accuracy of a product dimension are enabled by controlling tension between stands with high accuracy by using a simple control system without using table values or the like by each rolling condition even under a condition where a distance between stands is short.

Described herein is a method for rolling metal sheets of variable thickness. The method makes it possible to impress, during rolling, any distribution of areas of increased thickness within a figure corresponding to the plane development of a motor-vehicle component prior to the pressing operation. Impression of the desired distribution of areas of increased thickness envisages simultaneous impression, during rolling, of a further distribution of areas of increased thickness, or compensation areas.

Described herein is a method for rolling metal sheets of variable thickness. The method makes it possible to impress, during rolling, any distribution of areas of increased thickness within a figure corresponding to the plane development of a motor-vehicle component prior to the pressing operation. Impression of the desired distribution of areas of increased thickness envisages simultaneous impression, during rolling, of a further distribution of areas of increased thickness, or compensation areas.

Methods of forming a high-strength metal alloy precursor by tailor-casting strips having a tailored thickness across a width of a strip material are provided. The tailor-cast strips have varying thickness throughout the width, which can then be further tailor rolled to a final required thickness profile/tailored thickness. Such tailor-casting method can be conducted by contacting a patterned surface of a casting roller or a casting block with a liquid high-strength metal alloy in a continuous casting process. The present disclosure provides methods of continuously casting a strip having varying thickness across the width allows for improved product in subsequent processing, like tailor rolling. Methods of making a high-strength metal alloy structural automotive component from a tailor-cast blank having a tailored thickness are also provided.