The most complex issue related to the design of high efficiency composite materials is the behavior of the reinforcing component during the bonding process. This study presents numerical and experimental investigations of the shape change in the reinforcing inlay in an aluminum-steel mesh-aluminum composite during roll-bonding. A flat composite material consisting of two outer strips of an EN AW 1050 alloy and an inlay of expanded C10 steel mesh was obtained via hot roll bonding with nominal rolling reductions of 20%, 30%, 40% and 50% at a temperature of 500 °C. The experimental procedure was carried out using two separate rolling mills with diameters equal to 135 and 200 mm, respectively. A computer simulation of the roll bonding was performed using the finite element software QForm 9.0.10 by Micas Simulations Limited, Oxford, UK. The distortion of the mesh evaluated via the change in angle between its strands was described using computer tomography scanning. The dependence of the absorbed impact energy of the roll bonded composite on the parameters of the deformation zone was found. The results of the numerical simulation of the steel mesh shape change during roll bonding concur with the data from micro-CT scans of the composites. The diameter of rolls applied during the roll bonding, along with rolling reduction and temperature, have an influence on the resulting mechanical properties, i.e., the absorbed bending energy. Generally, the composites with reinforcement exhibit up to 20% higher impact energy in comparison with the non-reinforced composites.
Purpose. Comparison of deformation parameters during rolling of reinforced composites based on aluminum alloy using braided and expanded steel meshes as a reinforcing phase. Methodology. An experimental study on the effect of pressure on the deformation of the reinforcing phase during rolling of aluminum composites is carried out. A wire mesh and expanded mesh made of stainless steel was used as a reinforcing phase. The effect of deformation on the change in the lattice angle of the reinforcing phase is investigated. Findings. In this work, experimental data on the parameters of deformation of the wire mesh and expanded mesh are obtained. A comparison is made of the shape change in such grids under hot rolling conditions between two aluminum plates, which play the role of a matrix. It is found that the elongation coefficients of the lattice for the experiment with a wire mesh c is equal to 1.682.3, which is greater than the coefficient of elongation of the lattice in the expanded mesh of 1.552.2. Therefore, expanded sheets make the best reinforcing layer for aluminum-based composites produced by the roll-bonding process. Expanded mesh also reduces the risk of rupture at the intersection of wires. Originality. In the work, for the first time, a comparison of the deformation parameters during roll bonding of composites based on an aluminum alloy, reinforced with a braided and expanded steel mesh, has been given. Obtaining composite materials by means of hot roll bonding requires an understanding of the flow of composite components during deformation and their influence on each other. These peculiarities have not been studied sufficiently. Currently, there is no reliable method for predicting the behavior of the material of a solid reinforcing phase of various shapes inside a composite. Practical value. Advantages of using an expanded steel mesh for reinforcing aluminum-based composites have been confirmed. Scientific results can be used to refine calculating methods for metal flow at high hydrostatic pressure with variable components of the stress tensor and the major stresses.
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