Fabrication of 77 μm Mg‐0.5Ce Alloy Foil by Three‐Pass On‐Line Heating Rolling and a Single Annealing

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Mg‐0.5Ce alloy foils demonstrate significant potential as anodes for rechargeable magnesium ion batteries. However, the conventional rolling process of magnesium alloy foils faces challenges in complexity, leading to high costs. This study employs a large‐strain rolling strategy to fabricate Mg‐0.5Ce alloy foils through a three‐pass process with single intermediate annealing. The formability, microstructure, and mechanical properties of Mg‐0.5Ce alloy sheets and foils are characterized. Initial attempts using on‐line heating rolling reveal limitations in sheet formability below 0.25 mm thickness, preventing the achievement of large reduction rolling. The annealing at 300, 350, 400, and 450 °C for 1 h of 0.25 mm Mg‐0.5Ce alloy sheet largely improves its formability. The formability improves gradually as the annealing temperature rises from 300 to 400 °C, with optimal performance achieved at 400 °C (IE = 4.2 mm, tensile elongation = 10.0%). The reason of the change in formability are the moderate growth of grains, the improvement of recrystallization, and the change of texture. Then, rolling experiments of annealed sheet demonstrated that annealing at 400 °C enabled a single‐pass reduction of 70%, achieving a 0.077 mm foil.