Abstract
Roll bonding (RB) describes solid-state manufacturing processes where cold or hot rolling of plates or sheet metal is carried out for joining similar and dissimilar materials through the principle of severe plastic deformation. This review covers the mechanics of RB processes, identifies the key process parameters, and provides a detailed discussion on their scientific and/or engineering aspects, which influence the microstructure–mechanical behavior relations of processed materials. It further evaluates the available research focused on improving the metallurgical and mechanical behavior of bonded materials such as microstructure modification, strength enhancement, local mechanical properties, and corrosion and electrical resistance evolution. Moreover, current applications and advantages, limitations of the process and developments in dissimilar material hot roll bonding technologies for producing titanium to steel and stainless steel to carbon steel ultra-thick plates are also discussed. The paper concludes by deliberating on the bonding mechanisms, engineering guidelines and process–property–structure relationships, and recommending probable areas for future research.
Highlights
Most engineering structures are an assemblage of several distinct components that require the application of a joining process
In light-metal transportation structures exposed to a range of different environments, joining processes such as riveting are preferred compared to fusion welding processes to avoid the detrimental effects of melting leading to degradation of mechanical properties
Two functional requirements that have attracted increasing attention in the last few years include: (1) the ability to join dissimilar metals that cannot be welded by conventional processes, such as joining stainless steel or steel to nickel, titanium, copper, and aluminum alloys, (2) the development of thick or ultra-thick layered composite materials with potential applications ranging from simple bi-metal strips for engine components to complex turbine blades as functional gradient structures
Summary
Most engineering structures are an assemblage of several distinct components that require the application of a joining process. These processes are constantly being looked at for further development, as is evident from the six-fold increase in research citations related to solid-state joining processes during the last decade In this context, two functional requirements that have attracted increasing attention in the last few years include: (1) the ability to join dissimilar metals that cannot be welded by conventional processes, such as joining stainless steel or steel to nickel, titanium, copper, and aluminum alloys, (2) the development of thick or ultra-thick layered composite materials with potential applications ranging from simple bi-metal strips for engine components to complex turbine blades as functional gradient structures. Future research areas are identified based on modern manufacturing trends
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