Metal Forming-Induced Residual Stresses and Rule of Mixtures’ Prediction of Tensile Behavior of Bimetallic Wires

Abstract

The present study investigates the tensile behavior of the two bimetallic composite wires Cu-Al and Fe-Al. The purpose is to understand the deviation their tensile strengths show from the Rule of Mixtures’ prediction. To that end, an experimental-numerical approach was adopted. Following tensile testing of the above cold-drawn composite wires, the manufacturing process (wire drawing) was simulated via finite element analysis. The prominent role of processing-induced residual stresses on the yield strength of cold-drawn products is known. Therefore, a discussion based on the axial tensile residual stress profile was developed. It was concluded that the higher-magnitude-near-surface tensile residual stresses in the Fe-Al wire causes its tensile curve to show a negative deviation from the Rule of Mixtures (RoM). The Cu-Al wire, on the contrary, exhibits a slight positive deviation.