FEM simulation of fabrication of Al-steel layered composites with mechanical bonding through the interfacial concavo-convex lock effect

Abstract

Development of advanced cold pressure welding technique is needed for fabrication of Al-Steel layered composites with improved bonding strength between the stacked layers. Obtaining of elevated strain at the interface of the composite in combination with mechanical bonding through the interfacial concavo-convex lock effect can provide superior bonding strength. This paper presents the results of the finite element simulation of a special cold roll bonding technique. This technique consisted of two rolling passes. During the first pass the cold roll bonding was performed by work rolls with microscopic sine profile of the surface. During the second pass the cold roll bonding was performed by smooth work rolls. As a result, the Al-Steel layered composite with wavy interface was developed. Simulations of the process of fabrication of composites, consisted of aluminium alloy 6082 and DC04 steel were carried out using the commercial FEM code QForm. Effect of the sine profile of work roll on the composite layers behavior was analyzed. It was numerically shown that special cold roll bonding technique is able to introduce an additional mechanical clinching and elevated plastic strain to the interface of the composite in comparison with conventional roll bonding process. The FEM results of investigation of interface bond behavior can be useful for the development of the improved cold pressure welding technique for manufacturing of Al/Steel composites with high bond strength.