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The paper has presented the results of theoretical studies and experimental tests of the plastic deformation of Mg/Al bimetallic specimens. Theoretical studies were carried out using the Forge2011® computer program. Physical modeling, on the other hand, was performed using the Gleeble3800 simulator. Bimetallic bars of an outer diameter of 22.5 mm and a cladding layer thickness of 1.7 mm were obtained by the explosive welding method. Samples for formability tests, characterized by a diameter-to-length ratio of 1, were taken from the bars. The theoretical studies and experimental tests were carried out for the temperature range from 300 to 400°C and for different strain rates. Based on the obtained investigation results it has been found that the main parameters influencing the formability of Mg/Al bimetallic bars are strain rate than the process temperature.

The paper describes an investigation of an explosively welded Mg/Al/Ti multilayer composite. Following the welding, the composite was subjected to hot-rolling in three different temperatures: 300 °C, 350 °C and 400 °C, with a total relative strain of 30%. The rolling speed was 0.2 m/s. The investigation of the composite properties involves microhardness analysis and mini-specimen tensile tests of the joints. The composite Mg/Al and Al/Ti bonds in the as-welded state and after rolling in 400 °C were subjected to microstructure analysis using scanning electron (SEM) and transmission electron microscopy (TEM). In the Al/Ti interface, the presence of melted zones with localized intermetallic precipitates has been reported in the as-welded state, and it has been stated that hot-rolling results in precipitation of intermetallic particles from the melted zone. The application of the hot-rolling process causes the formation of a continuous layer in the Mg/Al joint, consisting of two intermetallic phases, Mg2Al3 (β) and Mg17Al12 (γ).

Within the framework of this study, the 1050A/AZ31 round bimetal bars were produced by the explosive cladding method and subsequent groove rolling process. LM/SEM investigation shown that by proper selection of the explosive cladding parameters (mainly initial distance between 1050A tube and AZ31 core and detonation velocity) it is possible to produce 1050A/AZ31 feedstocks without a continuous layer of Mg–Al intermetallic phases on the interface between joined materials. The experimental tests of the groove rolling process of 1050A/AZ31 bars were supplemented with a theoretical analysis using FEM-based numerical modelling. Based on the test results obtained, it was found that the interface of the 1050A/AZ31 bar rolling at a temperature (300 °C) was characterized by the generation of a thin continuous intermetallic layer without cracks. Applying a higher rolling temperature of 400 °C, which is usually used in hot forming processes of Mg alloys, led to the production of a thicker intermetallic layer, which cracked during the rolling process as a result of deformation. Strength of the fabricated bimetal joints was high, they did not delaminate during shear tests.

Numerical modelling of the round bar rolling process, while considering the wear of the passes depending on their shape, was carried out within the present work. For the theoretical study of the rolling process, the Forge2008 R was employed, which is finite element method-relying software that enables the thermomechanical simulation of rolling processes in a triaxial strain state. The wear model implemented in the Forge2008 R permits no quantitative evaluation, but only comparative analysis of the wear of rolls. In order to use the results of simulation employing the simplified Archard model for the quantitative evaluation of roll wear, it is necessary to define the wear factor and hardness of the tool as a function of temperature. The paper present a methodology for the determination of the quantitative wear of rolls based on the results of computer simulations performed using the Forge2008 R software for a selected oval pass during rolling of round bars.Keywords: wear, rolling, round bar, FEM, Archard's model W pracy przeprowadzono numeryczne modelowanie procesu walcowania prętów okrągłych z uwzględnieniem zużycia wykrojów w zależności od ich kształtu. Do badań teoretycznych procesu walcowania zastosowano program komputerowy Forge2008 R , który oparty jest na metodzie elementów skończonych i pozwala na termomechaniczną symulację procesów walcowania w trójosiowym stanie odkształcenia. Model zużycia stosowany w programie komputerowym Forge2008 R nie pozwala na ilościową ocenę zużycia walców a jedynie na analizę porównawczą. W celu wykorzystania wyników symulacji z zastosowaniem uproszczonego modelu Archarda, do ilościowej oceny zużycia walców, konieczne jest zdefiniowanie współczynnika zużycia i twardości narzędzia w funkcji temperatury. W pracy przedstawiono metodykę wyznaczenia ilościowego zużycia walców na podstawie wyników symulacji komputerowych wykonanych za pomocą programu Forge2008 R dla wybranego przepustu owalnego podczas walcowania prętów okrągłych.