An integrated computational and experimental study of the failure mode in Mg/Al laminated composite under three-point bending

The deformation behavior of hot-roll-bonded Mg/Al laminated metal composites (LMCs) is investigated, focusing on the crack formation around the interface. The material demonstrates a positive strain rate sensitivity mainly arising from the Mg matrix. A diffusion layer was formed at the Mg/Al interface with a serrated morphology during the two-pass rolling process, which consists of the Al3Mg2 and Mg17Al12 phases. The mechanical responses of the LMCs are evaluated using uniaxial tension, interfacial debonding tests (in normal and shear modes), and microstructure characterization techniques, which clarify the interfacial heterogeneity. The fracture constants of the interface were calibrated and incorporated in the finite element models to predict the failure modes of heterogeneous Mg/Al interface under three-point bending. With the increased thickness ratio of the Mg layer, the damage accumulation rate decreases at the interface and increases in the Mg matrix. As a result, the failure mode transferred from interface failure to matrix fracture. The findings of the present work provide new insight into the failure mechanism in laminated metal composites under bending conditions and can provide theoretical guidance for the plastic forming of such materials.