Notch strength evaluation for highly ductile Al/Cu bi-metal fabricated by the roll-bonding technique under pure mode I and pure mode II loading conditions

Abstract

In this work, the aluminum alloy AA1050 and copper sheets are cladded together using the roll-bonding technique to make rectangular bi-metallic joints. To examine the notch strength of this bi-metal under quasi-static loading, central slits with two U-shaped ends are introduced into the bi-metal. The slit orientation angle is adopted such that for horizontal slit, the notched rectangular specimen experiences pure mode I loading. However, when the slit orientation angle changes to about 67 degrees, which is obtained by the finite element (FE) analysis, the U-ends of the slit are subjected to pure mode II loading. Considering three different notch tip radii, two loading conditions, and three replicates for each test configuration, totally 18 U-notched specimens are produced and tested with the goal to measure the notch strength of bi-metal experimentally. According to the experimental observations, the bi-metal joint is perfect such that crack initiates from the notch in the whole thickness, proposing that the whole bi-metal joint can be considered as a single bulk material. Based on these observations and thanks to the virtual isotropic material concept (VIMC), the AA1050/Cu bi-metal is firstly equated with a virtual bulk material having homogeneous and isotropic behavior. Secondly, due to highly ductile behavior of the bi-metal joint proven by the associated tensile stress–strain curve, the fictitious material concept (FMC) is used to equate the virtual isotropic material obtained from the previous step having elastoplastic behavior with a fictitious material having perfectly linear elastic behavior. Finally, the VIMC and FMC are linked to the U-notch maximum tangential stress (UMTS), U-notch mean stress (UMS), and U-notch strain energy density (USED) criteria to predict the notch strengths of the bi-metal joint experimentally measured. With always higher than 92% accuracy for all VIMC-FMC-UMTS, VIMC-FMC-UMS, and VIMC-FMC-USED combined criteria, it is shown that the two-level strategy of material simplification, i.e., VIMC-FMC, is quite successful to be combined with different brittle fracture criteria for predicting the notch strength of AA1050-Cu bimetals under both pure tensile and pure in-plane shear modes of loading.