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Bonding and Cladding of Composite Materials
Published in Pankaj Agarwal, Lokesh Bajpai, Chandra Pal Singh, Kapil Gupta, J. Paulo Davim, Manufacturing and Industrial Engineering, 2021
Multilayer composites have attracted increasing attention in industries because of their superior magnetic, mechanical and electrical properties. Among available technologies, such as explosive welding, electroplating and transfer welding, roll bonding has attracted researchers due to their specific advancements compared to the other methods. Cold roll bonding is a widely used solid-state bonding manufacturing process that has the capability of joining both similar and dissimilar metals (Jamaati and Toroghinejad 2011). Roll bonding is a solid-phase process in which the metals are bonded by rolling at an applied pressure. In roll bonding, two or more metals in the form of sheets, strips or plates are stacked over each other. Next, they are then roll bonded in order to achieve a suitable bonding among the metal strips. The performance of roll bonded composites is influenced by parameters like strength and the hardness of the workpiece material, deformation, applied pressure, time and temperature of roll bonding, post heat treatment, rolling speed, thickness and surface preparation.
Manufacturing Techniques
Published in Sumit Sharma, Composite Materials, 2021
Deformation processing of MMCs involves mechanical processing (swaging, extrusion, drawing, or rolling) of a ductile two-phase material. The two phases codeform, causing the minor phase to elongate and become fibrous in nature within the matrix. These materials are sometimes referred to as in situ composites. The properties of a deformation-processed composite largely depend on the characteristics of the starting material, which is usually a billet of two-phase alloy that has been prepared by casting or powder metallurgy methods. Roll bonding is a common technique used to produce a laminated composite consisting of different metals in the sheet form. Such composites are called sheet-laminated MMCs. Other examples of deformation-processed MMCs are the niobium-based conventional filamentary superconductors and the high-Tc superconductors. Figure 3.21 shows a roll bonding technique for making a laminated MMC, which produces a metallurgical bond.
An Overview of Viable Unconventional Processing Methods for Advanced Materials
Published in T. S. Srivatsan, T. S. Sudarshan, K. Manigandan, Manufacturing Techniques for Materials, 2018
Subramanian Jayalakshmi, Ramachandra Arvind Singh, Rajashekhara Shabadi, Jayamani Jayaraj, Sambasivam Seshan, Manoj Gupta
Recently, accumulative roll-bonding process has been employed to reinforce bulk metallic glass as reinforcements in aluminum matrices. The major advantage of using accumulative roll bonding is that it can give rise to high-density, ultra–fine-grained structured composites at room/low temperature without any protective atmosphere (unlike the high temperature required for casting or sintering methods) (Khoramkhorshid et al. 2016). Especially with bulk metallic glasses as reinforcements, which are metastable (nonequilibrium phases), exposure to increasing temperature and time would result in their devitrification. Aluminum-based composites reinforced with Al84Gd6Ni7Co3 glassy powders were produced by accumulative roll bonding (Khoramkhorshid et al. 2016). Microstructural studies and mechanical property evaluation indicated uniform distribution of glassy particles in the aluminum matrix, along with an improvement in tensile strength and microhardness (Khoramkhorshid et al. 2016). Accumulative roll bonding was used to produce a multilayer aluminum-based composite reinforced with Al–Ni–Sm metallic glassy alloy in both amorphous and fully crystallized state to produce aluminum composites with ultra-fine microstructure (Anghelus et al. 2015).
Investigations on the microstructural evolution and mechanical properties of Al-Cu-Al tri-metal strips fabricated through roll bonding and heat-treatment processes
Published in Canadian Metallurgical Quarterly, 2023
Samarjit Panda, R. Vaira Vignesh, M. Govindaraju
A few of the joining methodologies for aluminum alloys include diffusion bonding, diffusion welding, and friction welding [3,4]. Roll bonding, a severe plastic deformation process to fabricate ultrafine-grained metallic and composite materials, has gained interest in the research community. In this process, the stack of metal sheets is repeatedly rolled to induce a severe reduction in thickness and bonding [5]. Roll bonding is a viable technique from a technological standpoint since it includes creating novel ultra-fined-grained materials that can be readily incorporated into current industrial process chains [6]. Due to their significantly higher specific strength, ultrafine-grained materials have a high thin construction possibility for the automobile and aircraft industries [7]. At the same time, their enhanced ductility may contribute to good metal sheet formability using standard methods such as bulge testing or deep drawing. An overview of the available literature on joining aluminum and copper alloys through the roll bonding technique is discussed below.
Lattice severe deformation rolling (LSDR) for bimetal laminated composite preparation
Published in Materials and Manufacturing Processes, 2023
Guang Feng, Liang Wang, Haojie Gao
Bimetal laminated composite made from two dissimilar metals is capable of achieving excellent mechanical, electrical, thermal, corrosion-resistant performance and remarkable economic benefits that individual metal fails to provide.[1,2] These plates are widely used in a variety of fields such as aerospace, petrochemical, shipbuilding, nuclear energy, construction and electronic industry.[3–5] The quality of bimetal laminated composite directly affects its service period and determines whether it can be further developed for high-end applications. Many techniques have been explored to prepare such plates, including rolling, explosive bonding, diffusion bonding, extrusion bonding, hot-press bonding, friction-stir welding and cast-roll bonding.[6–8] In particular, rolling is nearly the most commonly used technique in comparison with others and has attracted extensive attention, as it is high-efficiency, low-cost, less pollution and owns the potential capability of mass production.
Effect of secondary rolling on the interfacial bonding strength and mechanical properties of Al/Mg/Al clad plates
Published in Philosophical Magazine Letters, 2022
Xiang Cao, Chun Xu, Yu Li, Xuecheng Cao, Ruizhi Peng, Junyi Fang
Magnesium and magnesium alloys have great potential for lightweight applications [1,2]. However, poor corrosion and oxidation resistance strongly limit their further applications, especially in rolling sheets [3–5]. One effective way to eliminate these problems is to design multilayer Al/Mg/Al clad sheets which have the combined advantages of excellent corrosion resistance, good formability and being lightweight [6–8]. Numerous works have been conducted on Al/Mg/Al clad sheets to achieve effective compounding and interface bonding [9–15]. However, there is a dilemma that the interfacial strength of the Mg/Al interface is always at a low level owing to the existence of the ductile MgO film [16], which impedes the direct bonding of the composites. Thus, various techniques of fabricating Al/Mg/Al clad sheets have been developed to obtain a good interfacial strength [17]. Among these, roll-bonding is widely applied owing to its good operability and low cost. However, some researches show that, under conventional rolling technologies, the bonding strength of the Mg/Al interface is still very low even under a large reduction, since the failure of the magnesium composite always occurs before breakage of the MgO film [9,18]. Although various techniques such as roll-bonding, explosive welding, diffusion bonding and friction stir welding have been adopted to enhance the interfacial strength of the clad sheets, few studies have paid attention to the detrimental effects of the porous MgO on the effective bonding of Mg/Al interface. It has been demonstrated that the MgO film is very difficult to be removed even if the rolling reduction increases, leading to a limited peel strength.