Experimental investigation of formability of Al/Mg/Al

strips fabricated via cold roll bonding process

Davood Rahmatabadi, Moslem Tayyebi, Nima Najafizadeh, Ramin Hashemi

To cite this version:

Davood Rahmatabadi, Moslem Tayyebi, Nima Najafizadeh, Ramin Hashemi. Experimental investi-
gation of formability of Al/Mg/Al strips fabricated via cold roll bonding process. Proceedings of Iran
International Aluminium Conference (IIAC2018), Apr 2018, Tehran, Iran. �hal-03086503�

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 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran

Experimental investigation of formability of Al/Mg/Al strips fabricated via

cold roll bonding process
D. Rahmatabadi*1, M. Tayyebi2, N. Najafizadeh1, R. Hashemi1
1
School of Mechanical Engineering, Iran University of Science and Technology, Tehran, 16846-13114, Iran
2
Department of Materials Engineering, Sahand University of Technology, Tabriz 51978-17169, Iran

Abstract: Cold roll bonding (CRB) process is a method for production of multi-layered sheets with same and dissimilar

0.8 inch right margin

0.8 inch left margin

materials that, in the past decade has been attracted the attention of many researchers. In the present study, for the first
time, formability of Al/Mg/Al composite which was fabricated by the CRB process was investigated by using the
Nakazima test and forming limit diagram (FLD). Also, mechanical properties were studied by carried out uniaxial tensile
test and microhardness test. Tensile fracture surfaces were demonstrated by scanning electron microscope (SEM) to
define the fracture mode. The Al/Mg/Al composite was fabricated using a rolling machine, and a thickness reduction of
%70 was applied at room temperature and without lubricant. It was observed that a good bonding between the Al/Mg
layers fabricated via CRB process and as expected, increase strength, microhardness and decrease elongation and
formability compared to the initial strip due to strain hardening and cold work. The Al/Mg/Al composite prepared via
CRB process was annealed due to decreased the work hardening and created the stronger bonding between Al and Mg
layers. Annealing and cooling were done in the furnace at 300°C for 60 min and in the air at ambient temperature,
respectively. Finally, the value of microhardness of Al and Mg layers reaches to 98.8HV and 91.6HV, respectively and
the strength value is about 1.73 and 1.84 times higher than that of the initial aluminum and magnesium sheets,
respectively. Also results of SEM demonstrated that dimples shallower and smaller than the initial sample.

Keywords: CRB, Al/Mg/Al, FLD, SEM, mechanical properties

1. Introduction bonding (CRB) process [4, 5] cold welding with

In recent years over the last layered alloys are
used in industrial applications [1]. Mg has
excellent damping capacity and low density,
normally exhibits low formability and low
strength because of its hexagonal close packed
(HCP) structure which has limited slip systems
at room temperature [2]. Also, Al alloys often
show a higher strength and a better formability
than Mg. Therefore, it is anticipated that the
Al/Mg laminated composites could mix the
features of both Al and Mg [2]. In last decade and
between the various fabrication procedure that
are available for the multilayer alloys, cold roll
bonding (CRB) process is the growth rapid
because of the unique applications
characteristics compared to other methods [3],
such as these characteristics noted are the
simplicity of this method and also its ability to
automate. CRB has been introduced by
researchers with different terms such as cold roll
applied pressure during rolling [6-10] joining
through cold rolling [11] clad sheet by rolling
[12]. CRB is the kind of solid phase bonding
process, in which joining is made by joint plastic
deformation of the metals to be bonded [13-15].
Desirable bonding is achieved when surface
expansion breaks up the oxide layers and the roll
pressure bonds the surfaces [1, 4, 13, 15-17].
This process can be perform for a wide range of
metals. This process can be applied to variety
wide of the metals, the material could be from
same or different metals, also metals that cannot
be fabricated through another manufacturing
technologies, CRB procedure can be used [1, 6].
In the early years that this method invented, it is
also considered a promising method for mass
production of sheet and foil [18-20]. In recent
years the CRB process has been broadly utilized
for fabrication in form of sheets and foils [1]. The
all of investigations about CRB will be classified
 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran
in the following categories: (1) study the various
main factors and conditions of the process for
find out the complex nature of the joining
mechanisms such as effect of reduction thickness
on the bond strength [5, 16, 17, 21-23], bonding
temperature [14, 22], effect of annealing before
and after the CRB process[23-25], rolling speed
[22, 23, 26, 27], initial thickness [22, 23], rolling
direction [23], and reinforcement particle
between sheets [28, 29] (2) and also CRB is used
to produce different materials that investigated
mechanical properties and microstructure, such
as Al [1], steel [30], copper [31], Al/Cu [32],
Al/Ti [33], Al/Mg [2].
The capability of sheet metals to be formed into
the desired shape without necking or fracture is
generally considered as sheet metal formability
[34]. There are various sheet metal forming
processes like stretch forming, forming limit
diagram, deep drawing, bending, redrawing,
ironing, flanging, trimming and piercing, that
FLD is the most popular of these process. Each
kind of sheet metal can be formed up to a specific
constraint which is usually applied by onset of
localized necking, finally causing ductile failure.
A famous way for determination this limit is
FLD, which is a curve of the major strain (ε1)
and minor strain (ε2). The FLDs is extensively
confirmed as an impressive method to evaluate
the forming of sheet metals. This method can
assist engineers and developers to forecast the
possibility of success and failure at sheet metal
forming process such as CRB. At first, meaning
of FLD presented by Backofen and Keeler in the
1960s [35] and then, Goodwin improved the
FLD.
Finally, recent applications of CRB to wide
range of metals, especially aluminum alloys and
magnesium, are required more research on the
formability to improvement the bilayer and
multilayer sheet forming for CRBed material. It
is clear that understanding of formability in
CRBed samples can be improved and developed
the potential and practical efficacy for such
applications in industry.
In this paper, for the first time, were determined
experimentally, the formability through FLDs
for Al/Mg/Al fabricated by CRB process. For
this purpose, CRB process was done at ambient
temperature. Also mechanical properties,
microhardness, and fracture mode were
investigated. Finally, the FLDs were determined
experimentally, using the Nakazima test.
2. Experimental Procedure
2.1 Research Material
According to Table 1, material used in this study included
5052 aluminum alloy with 4 mm in thickness and Mg
AZ31B with 1.5 mm in thickness and the same initial
dimensions of 125 mm in length, 75 mm in width. Before
the CRB process, to achieve the well-structure, the 5052
Al alloy were annealed. Annealing and cooling were done
in the furnace at 380°C for 90 min and in the air at ambient
temperature, respectively.
Table 1. Specifications of primary materials
Ultimat
Chemical
e tensile
Micro Primary
Material Compositio hardnes dimension
n (%)
strength
s (HV) (mm)
(MPa)
5052 Al bal., Mg 155.6 26.1 125*75*4
aluminu 2.2, Fe 0.4,
m alloy Cr 0.2, Si
0.2, Mn 0.1,
Zn 0.1, Cu
0.1
Mg Mg 95.8, Al 144.8 16.3 125*75*1.
AZ31B 3, Zn 1, Mn 5
0.2
2.2 Cold Roll Bonding process
In the present research and to investigate, the tensile
fracture surfaces, mechanical properties and formability
via FLD of Al/Mg/Al fabricated via CRB process, sheets
were prepared into 120 mm × 75 mm in length and width,
respectively. Images in Fig.1 illustrate the basic of the
CRB process used to manufacturing of Al/Mg/Al in this
investigation. The surface preparation was performed in
the multi-steps such as degreasing by acetone, drying in
air, roughening by circular stainless steel wire brush with
dimensions of 8 mm and 0.3 mm in diameter and wire
thickness, respectively. Then after surface preparation, the
two 5052 aluminum alloy as the outer surfaces and one Mg
AZ31B layer as the inner one were stack on each other and
in order to avoid sliding, the stack was clamped through
steel wires at four corner points for CRB process, and roll
bonded by a 70% reduction in thickness was applied so that
the thickness of Al/Mg/Al stack reaches 3 mm from 9.5
mm. CRB process was performed at ambient temperature
and without using lubricant by using a laboratory rolling
mill with a capacity of 20 tons and a 107 mm diameter roll
mill at a rolling speed of 14 rpm. Also to diminish
reformation of oxide layers on the surface, tried to reduce
the time between surface preparations and rolling. Due to
high cold working after rolling (70% reduction in
thickness), the Al/Mg/Al composite prepared via CRB
process was annealed. Annealing and cooling were done in
the furnace at 300°C for 60 min and in the air at ambient
temperature, respectively.
 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran

Figure 1. Schematic illustration of CRB process

2.3 Mechanical properties 31.25, 37.5, 43.5 and 50 millimeters, constant length of 50
Mechanical properties of unprocessed samples (Al 5052 mm and thickness of 2 millimeters were prepared for the
and Mg AZ31B) and Al/Mg/Al composite produced by the forming limit test. The experimental equipment and steps
CRB process were studied through uniaxial tensile tests for determination of FLD is illustrated in Fig. 4.
and microhardness measurements. The uniaxial tensile test
samples were prepared for the unprocessed and CRB
processed sheets oriented along the rolling direction (RD)
according to the ASTME8/E8M-9 standard. The uniaxial
tensile tests were performed at a nominal initial strain rate
of 1×10−4 s−1 at room temperature using SANTAM
tensile testing machine. The Vickers microhardness tests
were done for initial, and CRBed samples using JENUS
apparatus under a load of 200 gr applied for 10 s.
Microhardness tests had been implemented to the intial and
CRBed samples at ten different points randomly on the Figure 2. Schematic of hemispherical-head punch test
cross-sections perpendicular to the rolling direction. Then, setup.
for each samples the minimum and maximum hardness
were disregarded. Also, in order to evaluate the rupture
mode, failure surfaces of the tensile samples were
investigated by a VEGA TESCAN scanning electron
microscope (SEM).
2.3 Forming Limit Diagram
Sheet metal forming is one of the most important
manufacturing processes, The ability to determine forming
limit of a sheet metal with respect to necking is critical to
the analysis of the sheet metal forming process [36].
Forming limit diagram (FLD) developed by Keeler [37]
and Goodwin[35], is used as one of the most well-known
methods in sheet metal forming analysis. The FLD is
divided into two sections separated by forming limit curve,
as long as the principal strains are below the curve it means
that the sheet is in safe strain states while above the curve
indicates failure strain states. In this study, FLD of
Al/Mg/Al sheet was investigated using hemispherical-
head punch test. Therefore, the determination of FLD of Figure 3. Dimensions of specimens (mm).
the experimental method involves the preparation of A common method for measuring the principal strains is
samples and Nakazima test, measured strain is applied and gridding the samples with circular pattern. As shown in
finally the plot that each step is briefly described. The Fig. 5 electrochemical etching was used for gridding the
Nakazima deep drawing test is used to carry out the biaxial samples, the circles’ diameter is 2.5 mm and they are
stretch-forming tests to obtain FLDs [38]. Fig. 2 illustrates tangent to each other. After the test was conducted, the
the schematic of hemispherical-head punch test setup. The etched circles turned into ellipses and the major and minor
diameter of the hemispherical-head punch is 20 mm and diameters of the ellipses close to necking position were
the diameter of the die cavity is 30 mm are in accordance measured using a transparent microscope as shown in Fig.
with ISO 12004. The test was carried out on SANTAM 6. Equations (1-4) were used in order to calculate the
STM-50 universal testing machine with a punch speed of principal strains of the specimens [39].
2 mm/min at room temperature. As shown in Fig. 3, a total 𝑎−𝑑
𝜀𝑀𝑎𝑗𝑜𝑟 = × 100 (1)
of five Al/Mg/Al samples with different widths of 20, 𝑑
 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran

𝑏−𝑑
𝜀𝑀𝑖𝑛𝑜𝑟 = × 100 (2)
𝑑
𝑒𝑀𝑎𝑗𝑜𝑟 = ln(1 + 𝜀𝑀𝑎𝑗𝑜𝑟 ) (3)
𝑒𝑀𝑖𝑛𝑜𝑟 = ln(1 + 𝜀𝑀𝑖𝑛𝑜𝑟 ) (4)
Where 𝑎, 𝑏 and 𝑑 are the major and minor diameters of the
ellipse and initial diameter of circle respectively. FLD of
Al/Mg/Al sheet was constructed using the principal strains
measured by transparent microscope.

Figure 4. Unprocessed material

Figure 6. Experimental FLD step [34]

Figure 5. Transparent microscope used for measuring
principal strains of specimens.
3. Results and Discussion
3.1 Mechanical properties
Engineering stress-strain curves for unprocessed samples
(Al and Mg) and Al/Mg/Al fabricated by CRB before and
after annealing is demonstrated in Fig. 7. Table 2 shows
the results of tensile strength (strength and elasticity) for
each sample. According to Fig. 7 and table 2, as it was
predicted, Al 5052 has a stronger strength and better
formability than Mg AZ31B. Al/Mg/Al composted
produced by CRB has higher strength and much lower
elongation than unprocessed samples [40]. Ultimate tensile
strength (UTS) of Al/Mg/Al reaches to 273.4. This UTS
value is about 1.76 and 1.89 times higher than that of the
initial Al 5052 and Mg AZ31B, but the elongation of
Al/Mg/Al after CRB process is less than 5% that this
amount cannot be accepted and will restrict the use of
produced composite. Also, as it is known, the composite
produced during the tensile testing doesn’t plastic region
and has a brittle fracture. This sharp changing (sharp rising
and decreasing of UTS and elongation) can be explained
by cold working and high thickness reduction (70%) as the
basic reasons. Al/Mg/Al was annealed due to achieving the
desirable formability and balancing the values of
elongation and strength. Annealing was carried out at 300
 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran

° C for 1 hour, due to the achievement of optimal Table 2. Variations in the ultimate tensile test and
mechanical properties [41]. After annealing, the value of elongation
elongation enhanced from 4.6% to 11.8% and strength sample UTS (MPa) El (%)
decreased from 273.4 to 264.9. In this case, the value of Al 5052 155.6 26.1
mechanical properties are more desirable compare to Mg AZ31B 144.8 16.3
before annealing. Al/Mg/Al produced by 273.4 4.6
Table 3 shows the microhardness variation of Al 5052 and CRB
Al/Mg/Al produced by 264.9 11.8
Mg AZ31B layers individually. As shown, it is apparent CRB after annealing
that after CRB process, microhardness of both Al and Mg
layers increases, drastically. Accordingly, a sharp rise in
Table 3: variations in the averaging of microhardness
the microhardness can be attributed to the work hardening sample Initial value of Microhardness Microhardness
and dislocations density. According to table 3, the value of microhardness after CRB after annealing
microhardness of Al 5052 and Mg AZ31B layers reaches (VHN) (VHN) (VHN)
to 112.1 HV, and 96.8 HV, respectively. Also, due to Al 79.7 112.1 98.8
remove the percentage of work hardening after annealing, 5052
microhardness of both Al and Mg layers decreases and Mg 63.4 96.8 91.6
reaches to 98.8 and 91.6. AZ31B

Figure 7. The stress-strain curve obtained from the
uniaxial tensile tests for initial and CRBed samples
3.3 Fractogrphy
To evaluate the fracture mode, tensile rupture surfaces
were viewed through scanning electron microscope
(SEM). Fig. 8 illustrates the tensile fractured surfaces of
Mg and Al sheets after the uniaxial tensile testing. The
basic fracture mechanism of Al, and Mg is a ductile and
brittle fracture, respectively. The basic fracture
mechanism of the most coarse-grained metals with FCC
and HCP crystal structures are ductile and brittle fractures,
respectively. Fig. 9 shows tensile fractured surfaces of
Al/Mg/Al composite at Al and Mg layers after CRB
process. Accordingly, were observed the desirable and
good bond quality between Al and Mg at the interfaces. As
well as dimples size of Al layers after CRB process is
smaller and shallower compare to dimples of unprocessed
Al.

Figure 8. Tensile Fracture Surfaces of Mg AZ31B and Al 5052

 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran
Figure 9. Tensile Fracture Surfaces of Al/Mg/Al Produced by CRB
3.4 Forming Limit Diagram
Typical deformed specimens after Nakazima test are
shown in Figure 10 that after reading the small and large
diameters of ellipses caused by the strain applied from
Nakazima tests on the samples by traveling microscope,
large and small strains calculated by using equations 1 and
2, and then FLD of Al/Mg/Al prepared by CRB process
after annealing are drawn. The points of the FLD
determined by e1 and e2 as the major and minor
engineering strain values are expressed in percent. In this
model, in the right-hand side of FLD where e2>0 and in
the left-hand side of the FLD where e2<0 [42]. Also, the
FLD0 is the engineering failure strain in plain strain
condition where e2=0. Fig. 11, illustrates FLD of Al/Mg
Al produced by CRB process.
Figure 10. Typical deformed specimens
Figure 11. FLD of Al/Mg Al produced by CRB process
The FLD is used in order to assess the sheet metal
formability. Also, this FLD can be applied in the design
stage of tools using the finite element method as a
simulation tool which is widely used in a production
environment.
4. Conclusion
In this study, mechanical properties, fracture properties
and formability of Al/Mg/Al composite produced by CRB
process were evaluated and the following conclusion were
achieved:
 Al/Mg/Al laminate composite produced by CRB
process in the room temperature with 70%
reduction in thickness, successfully.
 Ultimate tensile strength (UTS) of Al/Mg/Al
reached to 273.4. This UTS value is about 1.76
and 1.89 times higher than that of the unprocessed
Al 5052 and Mg AZ31B.
 Microhardness of both Al and Mg layers
increases, drastically. The value of microhardness
of Al 5052 and Mg AZ31B layers reaches to
112.1 HV, and 96.8 HV, respectively.
 Elongation of Al/Mg/Al after CRB process is less
than 5% that this amount cannot be accepted and
 Proceedings of Iran International Aluminium Conference (IIAC2018)
April 24-25, 2018, Tehran, I.R. Iran
will restrict the use of produced composite. For
this reason, the CRBed composite was annealed
due to achieving the desirable formability.
Annealing was carried out at 300 ° C for 1 hour,
due to the achievement of optimal mechanical
properties.
 After annealing the value of elongation enhanced
from from 4.6% to 11.8% and strength and
microhardness very little decreased.
 After Nakazima test it was drawn the forming
limit diagram of Al/Mg/Al prepared by CRB and
the suitable region of strain for forming operation
of Al/Mg/Al was determined.
 SEM images of tensile fracture surfaces showed
the desirable and good bond quality between Al
and Mg at the interfaces. As well as dimples size
of Al layers after CRB process is smaller and
shallower compare to dimples of unprocessed Al
 The main reason for these results, is applied high
strain accompanied by cold working.
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