Accumulative Roll Bonding Process Research Articles

Evolution of microstructure and texture and their influence on the strength of an accumulative roll bonded (ARBed) Al-Sc-Zr-Er-Ti alloy

Accumulative roll bonding (ARB) is an effective approach to improve the strength of metal sheets. This work studied the evolution of microstructure and texture and their influence on the strength of an ARBed Al-Sc-Zr-Er-Ti alloy, produced by multi-microalloying Sc, Zr, Er, and Ti into pure Al. A high-quality interface and a fine microstructure with an average grain size of ∼0.6 μm were achieved as by the ARB process. The Dillamore {4411} <11118> and the Copper {112} <111> components were sharpened in final texture as is common in ARB. However, after the 5th cycle, there was a new texture component along the α-fiber, at (φ1, Φ, φ2) ≡ (60°, 45°, 0°) in Euler space. The yield strength (YS) and tensile strength (UTS) increased with increasing the number of ARB cycles. The 7th ARBed Al-Sc-Zr-Er-Ti alloy had increased YS by 45% and UTS by 57%, respectively, compared to the initial cold rolled sheet. Strengthening was mainly attributed to dislocation strengthening, grain refinement and precipitation strengthening. There was little texture strengthening because of a strengthening and softening alternation with the change of ARB cycle.

Reactive Ti/Ni multilayer composites produced via accumulative roll-bonding (ARB): post-annealing treatment

ABSTRACT Ti/Ni multilayers, produced through the accumulative-roll bonding (ARB) process, serve as reactive multilayer, capturing energy to optimize manufacturing processes and contribute to TiNi (shape memory alloy) production. This research specifically examines the impact of the number of layers on microstructural and thermal properties after activation through heating. Energy-dispersive spectroscopy (EDS), field emission scanning electronmicroscopy (FESEM), and differential scanning calorimeter (DSC) were employed to analyse samples subjected to various ARB cycles. The findings indicate that in low-cycle ARB processing, the interdiffusion of Ni and Ti under normal conditions initiates the production of a very thin layer of TiNi at 800 °C, requiring extended holding times for increased thickness. Conversely, the formation of intermetallic compounds, particularly TiNi, and diffusion in high-cycle ARB-processed composites are accelerated. According to the DSC results, complete activation and phase transformation, accompanied by the release of energy (43–50 kJ/mol), occur at approximately 500–525°C without the need for any holding time. Consequently, for achieving a uniform TiNi phase, heat treatment of high-cycle ARB-processed composites up to 800°C – a temperature surpassing the activation temperature – without any holding time can be effectively employed.

Manufacturing of aluminium/copper/nickel(powder) metal intermetallic composite by accumulative roll bonding and subsequent heat treatment

This study investigates the annealing effect on the tensile properties of aluminium (Al)/copper (Cu)/nickel (Ni)(powder) composite fabricated utilising the accumulative roll bonding (ARB) technique up to 11 passes. The results showed that the composite transformed into a layer/powder-reinforced fabric by increasing the applied strain. After the 11th pass, the Al and Cu layers and Ni powder were uniformly distributed in the composite. The tensile strength decreased for the second pass and increased as the ARB process proceeded. Upon annealing temperature and time increase, the tensile strength of the 3rd pass increased and for the 11th pass decreased. Also, as the annealing temperature and duration extended, the elongation for the 3rd and 11th passes fluctuated and remained almost unchanged.

Carbon Fiber Breakage Mechanism in Aluminum (Al)/Carbon Fibers (CFs) Composite Sheet during Accumulative Roll Bonding (ARB) Process

Carbon Fiber Breakage Mechanism in Aluminum (Al)/Carbon Fibers (CFs) Composite Sheet during Accumulative Roll Bonding (ARB) Process

Study of changes in the aging process, microstructure, and mechanical properties of AA2024–AA1050 nanocomposites created by the accumulative roll bonding process, with the addition of 0.005 vol.% of alumina nanoparticles

We created AA2024–AA1050 and AA2024–AA1050/0.005 vol.% Al2O3 nanocomposites by six accumulative roll bonding (ARB) process cycles. We used AA2024 and AA1050 sheets with a thickness of 0.7 mm and plate-shaped alumina nanoparticles to create a composite. The two AA1050 and one AA2024 sheets (among the two AA1050 sheets) were ARB-ed up to six cycles with and without adding alumina nanoparticles. Also, a sample of the AA1050 without composite making was ARB-ed up to six cycles. We aged some composites after the ARB process in the furnace at 110, 150, and 190 °C. This project performed SEM, TEM, and EDS-MAP analyses, tensile strength, microhardness, and Pin-on-Disc tests to study the ARB-ed sheets. The results of the tensile tests showed that the tensile strength of AA2024–AA1050 created by the six cycles ARB process was two times more than primary AA1050. Also, the wear resistance of this composite was 74% more than six cycles ARB-ed the AA1050. Using 0.005 vol.% alumina nanoparticles in AA2024–AA1050 composite improved its wear resistance by 30%. In the following, the aging process caused an improvement in tensile strength and total elongation of AA2024–AA1050/Al2O3 nanocomposites.

Microstructure and Mechanical Properties of Copper/Graphene Composites Fabricated via Accumulative Roll Bonding and Heat Treatment without a Controlled Atmosphere

Copper and its alloys are structural materials used in industries and engineering applications due to their excellent thermal and electrical conductivity and chemical stability. Integrating graphene, known for its exceptional electrical conductivity, into the copper matrix is a promising strategy to enhance mechanical properties without sacrificing electrical conductivity. The Accumulative Roll Bonding (ARB) process can effectively and homogeneously introduce graphene into the metal matrix and is adaptable to an industrial scale. This study investigates the impact of varying graphene concentrations and two heat treatment protocols (without a controlled atmosphere) on the mechanical and electrical properties of ARBed copper/graphene composites. Optical microscopy revealed minimal voids and graphene clumps, and the energy dispersive spectroscopy analysis revealed the absence of copper oxide in some samples. The conductivity test showed little influence of the graphene content and stress relief heat treatment temperature on electrical conductivity (~86% of the International Annealed Copper Standard) within a limited number of ARB cycles. The tensile tests did not reveal a significant influence of the graphene content and stress relief heat treatment temperature on the ultimate tensile strength (220–420 MPa) and elongation (~2%).

The Effect of Air Exposure on the Hydrogenation Properties of 2Mg-Fe Composite after Mechanical Alloying and Accumulative Roll Bonding (ARB)

In this study, we successfully obtained a 2Mg-Fe mixture through mechanical alloying (MA) and processed it via accumulative roll bonding (ARB) (MA+ARB). Our primary focus was to analyze the impact of ambient air exposure while also evaluating the processing route. Some powder samples were exposed to air for 12 months (stored in a glass desiccator with an average yearly temperature and relative humidity of ~27 °C and 50.5%) before undergoing ARB processing. The Mg samples obtained after ARB processing exhibited a (002)-type texture. Our results demonstrate that all samples, including those processed via ARB, could rapidly absorb hydrogen within a matter of minutes despite considerable differences in surface area between powders and rolled samples. Grain size reduction by MA and ARB processing and texturing may have influenced this behavior. ARB-processed samples reached approximately 60% (~1.8 wt.%) of their maximum acquired capacity within just 24 min compared to powders (~2.2 wt.%) stored for a year, which took 36 min. In addition, the desorption temperatures (~300 °C) were lower than those of MgH2 (~434 °C). The absorption and desorption kinetics remained fast, even after prolonged exposure to air. Although there were minor variations in capacities, our overall findings are promising since scalable techniques such as ARB have the potential to produce hydrogen storage materials that are both safe and cost-effective in a highly competitive market.

Investigation into microstructural and mechanical properties of Al–Sn alloy fabricated using accumulative roll bonding combined with heat treatment

Al–Sn-based alloy was produced using the accumulative roll bonding (ARB) process followed by heat treatment. The effect of ARB cycles and various heat treatment temperatures (300–600 °C) and times (15–60 min) was studied. Microstructural, structural, and mechanical properties of the samples were examined using scanning electron microscopy (SEM) combined with energy dispersive spectrometry (EDS), hardness, tensile, and wear tests at room temperature. Microstructural observations featured aluminum grains with a grain-boundary distribution of the tin phase, confirming the successful production of Al–Sn alloy by using the ARB process followed by the heat treatment process. The ultimate tensile strength and hardness values of the produced alloys were 110 MPa and 45 HV, respectively, after 8th ARB cycles and heat treatment at 600 °C and holding for 30 min. Besides, the wear resistance of the prepared Al-12 wt% Sn alloy was increased when the ARB cycles increased from the first cycle to the 8th cycle. In conclusion, this study reflected that mechanical working (ARB process) combined with heat treatment is an appropriate route to achieve Al–Sn alloy with relatively suitable properties.

Effect of Al2O3 particle content on microstructure and mechanical properties of 1060Al/Al–Al2O3 composites fabricated by cold spraying and accumulative roll bonding

1060Al/Al–Al2O3 laminated particle-reinforced aluminum matrix composites (LPRAMCs) were successfully prepared using a combination of cold spraying (CS) and accumulative roll bonding (ARB) techniques, exhibiting a synergistic improvement in strength and plasticity. The effects of Al2O3 particle content on the microstructure, tensile properties and fracture morphology of LPRAMCs were studied. The results showed that compared with the 1# composites with higher Al2O3 particle content (20.1 vol%), the 2# composites with lower Al2O3 particle content (8.4 vol%) exhibited delayed necking fracture during the ARB process, with greater elongation (El) but lower ultimate tensile strength (UTS). After 5 passes of ARB, the UTS and El of the 1# and 2# composites were 345 MPa, 16.1%, and 293 MPa, 22.2%, respectively. This suggests that the mechanical properties of the Al–Al2O3 deposited layer have a significant impact on the mechanical properties of LPRAMCs. With an increase in ARB passes, the fracture mode of the LPRAMCs shifted from brittle to ductile fracture, displayed by equiaxed and shear dimples. These findings can provide novel insights and theoretical foundations for optimizing the mechanical properties of Al matrix composites.

On the microstructural and mechanical responses of dual-matrix Al-Ni/SiC composites manufactured using accumulative roll bonding

This article discusses the correlation between the microstructural and mechanical changes in the dual-matrix Al-Ni/SiC composites processed by Accumulative Roll Bonding (ARB) technique. Three different SiC concentrations, 1, 3, and 5% were considered to reinforce Al and Al-Ni dual-matrix composites. ARB process was applied up to 7 cycles to manufacture a composite with homogenous dispersion of the three phases. The results showed that the presence of Ni layer between Al and SiC particles enhanced the dispersion of SiC in the matrix, which positively affect the mechanical strength. The maximum tensile achieved was 257 MPa for composite containing 3 % SiC after 7 ARB cycles compared to 37.2 MPa for the AA1050. Increasing SiC content reduces the adhesion between Al and Ni layers, which reduces the elasticity of the composites. However, for the composites with 5% SiC, after 3 ARB cycles, the strength was reduced due to the cracking of the Ni layer caused by the stress concentration around the SiC particles. The hardness values of the ARBed AA1050, AA1050-Ni, and AA1050-Ni/5 wt% SiC are 85.5, 93.5, and 109.7, respectively, after 7 ARB cycles. In terms of strength, the samples with 3% SiC content showed the optimum stress enhancement with minimum reduction in the elongation, which achieve a compromised response for many applications.

On the microstructure and texture of intermetallics in Al/Mg/Al multi-layer composite fabricated by Accumulative Roll Bonding

The microstructure and texture of the intermetallics in Al/Mg/Al multi-layer composite fabricated by Accumulative Roll Bonding (ARB) at 400 °C up to 6 cycles were investigated using Electron BackScatter Diffraction (EBSD) and Synchrotron X-ray Diffraction (SXRD). EBSD and SXRD analysis have shown that ARB processing leads to the formation of Al3Mg2 and Mg17Al12 intermetallics soon after the second ARB cycle with a global thickness of 12 (N = 2) to 22 µm (N = 6). The polycrystalline intermetallics plates growth was columnar and normal to the bonding interface. A constitutional liquefaction region was depicted ahead of the plates with an unusual rugged migration front. The Al3Mg2 and Mg17Al12 intermetallic compounds which formed after 2 ARB cycles have approximately the same average grain size (1.0 µm) at this cycle. After 4 ARB cycles, the grain refinement of Al3Mg2 is more than 4 times higher than in Mg17Al12. The average grain size of Al3Mg2 and Mg17Al12 reach 0.2 and 0.9 µm, respectively. After 6 cycles of ARB, the average grain size of both Al3Mg2 and Mg17Al12 increased to 1.5 µm and 2.8 µm, respectively. The dislocation density obeyed a ρAl3Mg2 > ρAZ31 > ρAl 1050 ∼ ρMg17Al12 hierarchy after N = 4 and 6 ARB cycles and the Al3Mg2 was shown to store more dislocations. Through the ARB processing, a usual strong basal (0002) texture was depicted in AZ31 layers and a weak rolling texture was shown in Al 1050 layers with a dominant Rotated Cube (001) 110 > component that vanished after upon increasing ARB cycles. The Al3Mg2 and Mg17Al12 intermetallics were characterized by a random texture.

Study on microstructure evolution and fracture behavior of Al/Al/Cu multilayer composites

The microstructure evolution, mechanical properties, and the fracture mode of Al/Al/Cu multilayer structural composites produced by accumulative roll bonding (ARB) were investigated by optical microscopy (OM), scanning electron microscopy (SEM), energy dispersion spectrometry (EDS), electron backscattered diffraction (EBSD), tensile test at room temperature and microhardness tests. The results show that during the ARB process, the Cu layer undergoes the process from straightening, necking to fracture due to the difference in the strain hardening index and strength coefficient between Al and Cu. The shear stress caused by the severe plastic deformation makes the Cu grains elongated and flattened along the rolling direction, forming a fibrous shape. After the ARB5 cycles, the Cu grains undergo dynamic recrystallization, and a large number of equiaxed grains appear, with average grain size of 750 nm. After ARB3 cycles, the ultimate tensile strength (UTS) of the composite reaches the maximum value of 625 MPa, and the elongation is 6.67%. During the tensile process, the transverse microcracks are first initiated at the Al3003/Cu interface, and then the microcracks propagate longitudinally along the Al layer. Finally, the microcracks in the Al layer merge into the main cracks, which develops in the direction of the shear bands with the rolling direction. With the increase of ARB cycles, the bonding strength of the Al3003/Cu interface increases, and the Al/Al/Cu multilayer structural composite changes from delamination-necking fracture to delamination-shear fracture and finally to shear fracture.

Optimization of the accumulative roll bonding process parameters and SiC content for optimum enhancement in mechanical properties of Al-Ni-SiC composites

Accumulative Roll Bonding (ARB) is one of the main techniques to manufacture nanocomposites, however, due to the large number of parameters that control this process, its application is relatively expensive. The present work considers a simple response surface methodology to study the interaction effect between the selected ARB parameters on the tensile strength and the hardness of the ARBed composite sheets. We investigated the characterization, modeling, and numerical optimization of the accumulative roll-bonded (ARBed) AA1050 composite sheets produced using a number of passes ranging from 1 to 7 and reinforced with different SiC content (0, 1, 3, and 5 wt%). The effect of the number of passes and SiC content on the microstructure, phase analysis, tensile, and hardness properties have been investigated for the ARBed sheets and their composites. Also, the fracture surface of the tensile-tested specimens was studied using SEM analysis. Numerical optimization was conducted using the developed model to determine the optimum parameters of the ARB process in the designed experiments. The modelling analysis results confirm the significance of the applied ARB parameters on the properties of the ARBed sheet composites. The numerical optimization analysis indicates the optimum ARB factors are 7 passes and 3.2 wt% of SiC content to produce an AA1050/Ni-SiC composite sheet with 249.2 MPa tensile strength and 107.8 HV hardness.

On the impact of using alumina nanoparticles and initial aging on the microstructure and mechanical properties of the AA1050/AA2024 nanostructure composite, created by accumulative roll bonding (ARB) method

In this research, AA1050/AA2024 layered composites were created through six cycles of the ARB process. In this direction, the effect of using the reinforcing nanoparticles and the initial aging process on the mechanical properties and microstructure were researched. Two sheets of AA1050 and one sheet of AA2024 alternatively were used to create the composite. Also, 0.005 vol% Al2O3 nanoparticles were used. Moreover, the aging process lasted for 30 min at 190 ᵒC. Once the aging process was completed, the S′ precipitates with less than 100 nm thickness were formed. After six ARB cycles and using reinforcing particles, the equiaxed ultra-fine grain microstructures were created. The grains were about 500 nm in size. The S′ precipitates improved tensile strength. The alumina nanoparticles resulted in 38% and 32% improvements in the AA1050/AA2024 composite's wear resistance to the annealed AA1050 and AA1050/AA2024 composite sheets, respectively.

Production of Al-Ti Composite by a Combination of Accumulative Roll Bonding and Friction Stir Processing

Production of Al-Ti Composite by a Combination of Accumulative Roll Bonding and Friction Stir Processing

The Evolution of Microstructure and Electromagnetic Interference Shielding Effectiveness of Mg-2Mn-1Ce Alloy Prepared by Accumulative Roll Bonding Process

The Evolution of Microstructure and Electromagnetic Interference Shielding Effectiveness of Mg-2Mn-1Ce Alloy Prepared by Accumulative Roll Bonding Process

A novel Cu-carbon nanotube sheet composite manufactured via the ARB process: A microstructural and mechanical study

A Cu matrix composite was designed and produced successfully by adding carbon nanotubes (CNTs) as reinforcement particles. The accumulative roll bonding (ARB) process was used to introduce the material in the shape of the sheet. The process was repeated up to five ARB cycles to obtain a uniform composite with good mechanical properties. Different amounts of CNTs were added to the matrix of Cu in order to evaluate the behavior of the CNTs in the matrix of the Cu. Microstructural evaluations confirmed that by increasing the ARB cycles, a uniform distribution of the CNTs was achieved. However, for Cu-1%CNT considerable numbers of unbonded areas led to weak bonding. Also, the material responded differently to the applied tensile test during loading. For low amounts of CNT-contained composites, the ultimate tensile strength (UTS) was increased in each ARB pass, but, for Cu-1%CNT composite, the UTS was the lowest. Also, microscopy observations were used to study the distribution/configuration of CNTs. The weak bonding of the Cu layers in some spots was attributed to the agglomeration of CNTs between the layers. Fractography of the samples after the tensile test, also, showed remarkable separation between the unbonded layers.

Microstructure, Mechanical and Thermal Properties of Al/Cu/SiC Laminated Composites, Fabricated by the ARB and CARB Processes

The aim of the current work is to investigate the effect of SiC particle weight percent and rolling passes on Al/Cu/SiC laminated composites, fabricated by accumulative roll-bonding (ARB) and cross-accumulative roll-bonding (CARB) processes. The optical microscopy (OM) images of composites revealed that despite the good bonding of the layers, they underwent plastic instabilities as a consequence of strain hardening of the layers. However, these instabilities occurred more in ARBed composites than in composites fabricated by the CARB process. This is because in the latter process, the composites are rolled in two directions, which leads to better strain distribution. Furthermore, with an increase in passes, SiC particles were well distributed in the matrix and interfaces. The mechanical findings showed that, by increasing passes, there was a growth in the values of strengths and elongation. This behavior is believed to be related to increased work-hardening of layers, better distribution of reinforcing particles, and an enhanced bonding of interfaces at higher rolling passes. In addition, the results of thermal conductivities showed a downward trend with an increase in passes; in fact, the increased number of Al/Cu interfaces declined the heat conduction of composites.

Thermal and wear properties of Al/Cu functionally graded metal matrix composite produced by severe plastic deformation method

The past decade has witnessed a huge growth in functionally graded materials (FGM) with attractive properties. This paper is a preliminary attempt to investigate Al/Cu FGM produced by a new methodology consisting of cold roll bonding (CRB) and accumulative roll bonding (ARB) processes. The results of microstructural characterizations reveal that the volume fraction of copper changed gently across the FGM. The observed distribution of copper's pieces was achieved by using the ARB process in which the reinforcement can be well distributed in the matrix. The findings of tensile tests revealed that, with an increase in Cu content, the ultimate tensile strength of layers increased while the elongation decreased. Also, the elongation of FGMMC which was about 4.6 was the least value and its tensile strength which was around 367 MPa was as much as that of Al/80%Cu but less than that of Cu layer. The results of wear tests showed that as the volume fraction of the reinforcement rose, friction coefficient and volumetric worn loss declined; indeed, hard copper layers can be plastically deformed as much as aluminum. Then, a smaller amount of material was abraded during pin on disk interaction. Based on the results of thermal diffusivity, with an increase in copper content, the thermal conductivity increased from Al layer with 155.5 W/mK to Cu layer with 283.3 W/mK indicating the good conductance of the Al/Cu interface and copper's pieces. Further, the thermal conductivity of FGMMC with 201.67 W/mK was more than all laminated composites except Cu layer.

Feasibility study of producing Al–5Zn–1 Mg alloy by accumulative roll bonding process and subsequent heat treatment

In this research work, Al/5Zn/1Mg (wt.%) composite sheets were produced by the accumulative roll bonding (ARB) process and then converted into Al-5Zn-1 Mg (wt.%) alloy sheets by a suitable heat treatment process. Scanning electron microscopy (SEM) combined with energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) were used for structural investigations. Mechanical properties of the specimens were also examined by using tensile and microhardness measurements. SEM microstructural analyses revealed the uniform distribution of Zn layers and Mg powder particles in the Al matrix by increasing the number of ARB cycles, as well as the formation of the α phase after the seventh ARB cycle and subsequent heat treatment at 390 °C in the alloy samples. XRD results confirmed the microstructural evolution and showed only peaks related to Al for the alloy samples after the seventh cycle. Tensile results showed that by increasing the number of ARB cycles from first to seventh, tensile strength and elongation increased from 117 MPa to 370 MPa and 8 to 13 %, respectively. Microhardness measurements also depicted the progressive increase in hardness by increasing the ARB cycles up to the seventh cycle. The results confirmed that the ARB process with subsequent heat treatment is a suitable method for Al-based alloy sheets fabrication with high mechanical properties responses.