The microstructures and mechanical properties of the hot-rolled Fe-6.5wt.%Si sheet are analyzed. The microstructure of the hot-rolled sheet is layered along the thickness direction. The surface exhibits fine and equiaxed grains, whereas the center part shows coarse and elongated grains with a <101> fiber texture along the rolling direction. Serrated flow behavior is observed during tensile deformation of both the hot-rolled sheet and its center samples at 350 °C; thus, the serrated flow of the hot-rolled sheet is mainly attributed to the serration of the center part. The analyses of dislocation configurations, ordered structures, and crystal orientation show that the serrated flow behavior results from the interaction of solutes with mobile dislocations. Mobile dislocations are pinned by combining parallel forest dislocations with the pipe diffusion of solution atoms. This study provides a new perspective for the deformation mechanism of the Fe-6.5wt.%Si alloy.

Cylindrical Fe-6.5wt.% Si bars with 7.5 mm in diameter were successfully fabricated from as cast ingot through three rolling stages within 10 passes: rough rolling at 850–900 °C and 8–10 m/min, medium rolling at 800–850 °C and 10–15 m/min, and finish rolling at 800–850 °C and 12–18 m/min. The evolution of microstructure, texture and ordered structure, and the mechanical property are investigated. The results showed that the grains were refined by the hot bar rolling. Area fractions of the {100}<011> oriented grains and the {011}<100> oriented grains decreased to 0 during the hot bar rolling. Whereas, the {100}<001> component, the {011}<211> component and the {112}<110> component increased, and γ fiber with {111}<110> component was dominant. DO₃ ordered phase were suppressed, and B2 ordered domains were refined after the hot bar rolling. Ductility of the as rolled bar was higher than that of the rotary swaged bar, due to the absence of the DO₃ ordered phase and the fine grains in the rolled bar. Hence, the hot bar rolling technology is an excellent process to fabricate the Fe-6.5wt.% Si bars.