Computational Analysis of Thermo-Mechanical Fields in Hot Roll Bonding of Aluminum Validated by Experiments
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Roll bonding is extensively used in various industries for obtaining engineering components comprising several metallic layers. The load-bearing ability of such components strongly depends on the interface bonding strength between these layers. Nevertheless, the relation between the thermo-mechanical fields that develop at the interface during rolling and the resulting bonding strength is still not clearly defined. The current study presents a coupled thermo-mechanical computational investigation of a hot roll bonding process of aluminum plates validated by experiments. A novel experimental rolling configuration proposed in this study enables evaluating the interface strength by subsequent three-point bending tests. The rolling models were used for analyzing the time-dependent thermo-mechanical fields that develop at the interface for different reduction ratios. It is demonstrated that a 2D FE representation is not sufficient to accurately describe the interface conditions and a 3D analysis must be used. The computed fields in the deformation zone examined the bonding strength using a previously published bonding strength criterion for solid state bonding in bridge die extrusion.
The authors would like to thank M. Nahmany and Y. Benishti for assisting with specimen preparation and Y. Hadad, Y. Tzriker, and D. Hai David for assisting with the rolling experiments.
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