Abstract
In the present work, the warm roll bonding (WRB) technique was adopted to fabricate 3 layers of Aluminum-perforated Copper 260-Aluminum (AL/perforated CU/AL), and five layers of (AL/Polyurethane (PU)/perforated CU/PU/AL) sandwich composites. Two different tests were adopted, namely peel test and small punch test (SPT), to study the peel strength and flexural behavior of these sandwich composites, respectively. The main manufacturing parameters, including interface properties, rolling speed, and the number of passes, which control the strength and integrity of these sandwich composites were studied experimentally. Furthermore, the three-dimensional finite element method was carried out to study the effect of the presence of pre-crack on the peeling test and SPT specimens numerically. The present results indicated that the peeling resistance is mainly dependent on the roughness of the interface and elapsed time in manufacturing processes. The flexural behavior of sandwich composites measured from SPT agrees with the first principles of mechanics of materials, i.e. there is a marginal effect of the bond strength between the layers.
Highlights
To achieve superior properties, for instance, lightweight properties, good thermal conductivity, anti-corrosion properties, wear resistance, and so forth, the multilayer composites were innovated for these reasons
It can be concluded that the mechanism of the peeling test for sandwich composites contained more than two layers is different from the two-layer composites due to the horizontal movement of the interlayer
To verify the effect of interface conditions on the flexural strength of sandwich composites measured from small punch test (SPT) specimens, two extremes conditions, i.e. perfect bond and unbounded conditions, have been examined numerically
Summary
For instance, lightweight properties, good thermal conductivity, anti-corrosion properties, wear resistance, and so forth, the multilayer composites were innovated for these reasons. Multilayer composites can be used in many applications such as automobile and marine industries. Multilayer composites showed synergistic behavior, i.e. preserve the original properties of the constituent materials in addition to give extra characteristics[1,2,3,4]. AL/ CU multilayer composites are incorporated in the thermal conductivity products[3]. Several processes can be used to produce such composites, such as explosive bonding, adhesive bonding, or roll bonding (cold, warm, and hot). The roll bonding process is the most economical and productive manufacturing process that can be used to fabricate the multilayer composites[4]. Metal–polymer-metal multilayer composites produced using warm roll bonding (WRB) process and without any adhesive between the layers (direct adhesion)[8,9,10].
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