Abstract
The most complex issue related to the design of high efficiency composite materials is the behavior of the reinforcing component during the bonding process. This study presents numerical and experimental investigations of the shape change in the reinforcing inlay in an aluminum-steel mesh-aluminum composite during roll-bonding. A flat composite material consisting of two outer strips of an EN AW 1050 alloy and an inlay of expanded C10 steel mesh was obtained via hot roll bonding with nominal rolling reductions of 20%, 30%, 40% and 50% at a temperature of 500 °C. The experimental procedure was carried out using two separate rolling mills with diameters equal to 135 and 200 mm, respectively. A computer simulation of the roll bonding was performed using the finite element software QForm 9.0.10 by Micas Simulations Limited, Oxford, UK. The distortion of the mesh evaluated via the change in angle between its strands was described using computer tomography scanning. The dependence of the absorbed impact energy of the roll bonded composite on the parameters of the deformation zone was found. The results of the numerical simulation of the steel mesh shape change during roll bonding concur with the data from micro-CT scans of the composites. The diameter of rolls applied during the roll bonding, along with rolling reduction and temperature, have an influence on the resulting mechanical properties, i.e., the absorbed bending energy. Generally, the composites with reinforcement exhibit up to 20% higher impact energy in comparison with the non-reinforced composites.
Highlights
Sheet composite materials based on an aluminum matrix and reinforced with internal components, such as expanded steel mesh inlays, have great potential in the aerospace, automotive, and maritime industries
The solid state reinforcement of aluminum sheets results in a slightly increased specific weight, it extends the application of such composites for construction purposes requiring high impact energy absorption as well as fire resistance in comparison with conventional aluminum alloys
Experiments were carried out using two different rolling mills with similar rolling reductions to investigate the influence of the deformation zone length on the mesh distortion as well as the properties of rolled composites
Summary
Sheet composite materials based on an aluminum matrix and reinforced with internal components, such as expanded steel mesh inlays, have great potential in the aerospace, automotive, and maritime industries. The authors of [4] found a so-called “zip bonding” effect, in which soft matrix metal encloses the hard wires due to their consistent ovalisation and turning It provides an Metals 2021, 11, 1044 inherent, “mechanical” bond strength even at a rolling reduction about 25%. The results of the above-mentioned studies highlight the complexity of the plastic flow behavior of the composite elements during hot roll bonding; further investigation of this manufacturing process is required Some of these recommendations were implemented in [23], where the authors identified the following aspects as significant components of the expanded mesh deformation:. The development of an experimental as well as a simulation procedure to describe the deformation of expanded metal during roll bonding is the aim of the current study
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