The adaption, evaluation and application of a semi-empirical bond strength model for the simulations of multi-pass hot roll bonding of aluminium alloys

Abstract Nowadays, the requirements on metallic materials have become more comprehensive, which gradually exceed the capability of monolithic metals. One of the solutions is the composite metal, where different properties of the constituents are integrated as one. In industrial practice, hot roll bonding has been frequently employed to produce laminated composite metals thanks to its high adaptivity. However, the bonding mechanism and the bond strength models have not been thoroughly investigated and parametrized. In a recent publication, a semi-empirical bond strength model has been developed, which quantitatively considers the influence of various influencing factors on the bond strength. In this paper, this new model is applied in FE simulations of lab-scale hot roll bonding of multiple passes to achieve a better understanding of the process and the bonding behaviours. Firstly, this new model is adapted for macroscopic process simulations, implemented in FE environment via Abaqus subroutines, and evaluated by the simulations of the truncated-cone experiments. Secondly, the FE setup is applied in the process simulation of hot roll bonding. Eight roll bonding passes are simulatively reproduced and good accordance with experiment is achieved. The strain distribution in thickness, evolution of temperature and bond strength, bonding status and cause of local temporary de-bonding are analysed by this simulation. Finally, the influences of the thickness ratio of metallic plates, height reduction, rolling velocity, and material combination with different bonding properties are tested in simulative studies. The process simulations provide a promising way to facilitate the design and optimization of hot roll bonding by FE simulations.