Advanced Techoslogy of Plasticity 1993 — Proceeding o ibe Fourth tnterastonnl Coaferene aa Techoology of Plarity ON THE ROLLING OF BIMETALLIC EXPLOSIVELY CLAODED PLATES ALG. Mamalis, N.M. Vaxevanidis and 9.1. Pantelis National Technical University of Athens, athens, Greece, ‘ABSTRACT In the present paper we report on the fabrication of binetallic Components of Al/Cu and Ag-Cd0/Cu plates by explosive cladding and subsequent rolling. Emphasis is directed towards the influence of rolling on the soundness of the resulted bimetallics. Moreover. taking into account the concept of "multi-layered ber fon the “sandwich rolling" technique a theoretical a rolling of cladded Dimetallics is proposed, The influence of the clacding/rolling parameters on the integrity of the fabricated binetallics is ‘evaluated in terms of deformation characterictics of the composite plates and the residual stress fieles induced during proccesing. NOTATION 2 width inlekress at entry of roll gio thlekaess at exit of roi gap average thiciness of 1 layer roll force maximum shear stress at 1 layer mean maximue shear stress of sand eh aaterial ermal pressure partie roughness ‘etal thickness reduction ckness reduction after pass 1 torque + yield stress fear yield saterial stress of sandwlch friction principal horizontal stress 1 principal vertical stress residual stress wrizontal, stress dy anal rel ing additional “horizontal stress vivieh rolling te conven: tn TATRODUCTION Explosive cladéing is used to directly doin a wide variety of both similar and ‘Gissimilar metals that can not be Joined by any other welding or bonding technique (1,°2}." Fellowes usually by rolling ané punching 1s ‘applied extensively in modern Eechnalogy for the fabrication of conposi- te -setal Laminates replacing solid mater fals due to the urgent need for improves component performance uncer severe working conditions (3]- The fabrication of binetallic components consisting of AL/Cu and, kg-Cé0/Cu pla by explosive cladding ‘ané subsequent. ral) ing has been Investigated and experinental regults are presented in Refs-(3) and (4) Tespectively. Inthe present paper which 1s a followup of the work outlined above exphasis 1s directed tovards the influence of rolling on the integrity and soundness of the resulted composite plates. Theore; teal’ Calculations of roll force. and torque “based on the concept of “multi: Layered body" ave proposed and. predicted values” are’ compared with “experimental seasurenents. ~oa-THE COLD ROLLING OF BINETALLICS “THEORETICAL APPROACH Since cladging techniques decane, nowdays, increasingly leportant due to the indust” tal. need for highly functional composite Sheets, a theoretical estimation of the ‘overall, strengin of fabricated binetallics {sof the upecst irgortance. & theory of the rolling of cladéed bimetallics is presented below bases {he "eulti-layered" body [5] and on the Sandwich" rolling technique which was ninally proposed for the rolling “of thin very nard strips (6). The cladded/rolled sheet is considered as achreeslayeres. body and. the situation prevailing in the roll. gap, when plane Strain rolling is considered, ts illust~ Fated in Fig.l. The outer layers (a) and {b) represent the layers of the two Initi- al materials wiilst the interseciate layer {ey represents the narrow transition zone at the interface. It is assumed that, the raterials are rigid-perfectly plastic, ‘the deformed arc of contact (roll radius R’) {s circular and the coeficient of friction 8 constant over the arc of contact [6}. Since the outer softer layers are rolled toa slightly greater elongation than the Inner hardened core [3], frictional forces are induced between the layers [6], see Fig.1. we shall take Jt that the normal pressures p, and 9, are identical (7) and for the cold rolling conditions considered hey equal the versical stress [5], 1. Bet Yielding in the three layers when the Tresca criterion is considered, results in: : aa 2k oF a ek o of, 2K The horizontal stresses 0,, (ie ay bs €) are assumed to be distributed uniformly over the corresponding vertical sections and’ each of then in the relevant layer 1s tthe ‘sum of the. stress developed due to conventional rolling, x, and of the transmitted shear stress at the relevant Anterface, y,; [6]: Therefore, oy ty, hehe a eT Equilubrium of the additional stresses due terestralnt at the interfaces, results IMM IM o The effective yield stress for “sandwich” rolling may be denoted a5 (6]: Dk eo “) By combining fons. (1) and (2) we obtain: ay ye RY TERK tke y, 6) Inserting Egns.(3) and (5) in Eqn. (4). Eqn. (6) is obtained: 2 (Khe Baye KD) zits (8) emery In tne case of ine Lairs, (2) and 0), Bren "when the intersediate, zone’ (c) 15 very small, fan. (6) simplified to: 2 ik he A) ane he o hth ‘an estimation of the roll force, F, may be cbtained folloving fef{8), by using the modified Ekelund’s formula: Fy = bye (many? x (oe LWA + 1.2 By (ey ht hy Roll flattening is taken into account and the deformed roll radius, R is obtained loying Hitchock’s ‘formula and an erative procedure (6, 7). ‘The torque required to ¢rive both rolls is 9) Fig. 1: Cold rolling of clagged binetal- Ties: stresses in roll gap./ plane-strain cols rolling a4 siven ae (7] oo 0 an)" ean pentioned fgns. (6) and (7) 4, stands for the average thickness of the layer, Le nesthye Bya)/% wbilst in Ean.(8) hy and hy refer to the overall thickness of the sandwich plate, before and after a rolling ‘pass respectively. EXPERIMENTAL, YALIOATION Explosive cladéing of Al/cu ang Ag-Ca0/cu tes was. performed using the para]}el fangenent and as explosive nediun the Paxit which isa high energy explosive in powdered forms see fets.(2. 4) for a Getaslee description of the equipnent, procedure ang explosives used for Saall-plate cladding Rolling of rectangular strins of 70 nm Jength, and width either 29 (for Al/Cu binetallies) or 21 ae (for Ag-Cd0/Cu ones) cuteoff fran the cladded bivetallic plates fas perforaes on an experisental 2-high telling mill, properly. instrunented for oll Force and ‘torque measurenents, at a barrel lengths see Sei iS} tor wetyais All rolling passes were perforned in “dry* condition” and the relling direction was the epposite to the cladding one. RelLing variables, force and torque seasurenents nd surface roughness values for all roil- ed binetallics are tabulated tn Table 2 Residual, stress profiles were determined by the “biind-hole™ drilling tectnique. A fixed” bench illing tachine, properly quipped with a WC drilling eutter and 2 Special strain rosette, were employed; the celprackens "factors land "heiress profiles were deterained using a finite- Glenent code. All residual stress measure wments were conductes in two. mutually perpendicular directions, i.e. parallel £0 Uhe rolling one and tranverse t0 1 For the evaluation of the mechanical properties of the cladded binetallics the Upsetting test was used. Upsetting tests were. performed ov 2 Schuler hudraulie press ‘connected with a data acquisition System. The velocity of the upsetting devil vas 5 m/ain ané the whole process {s fully autosated and controlles through 2° computer: the overall strain rate was estimated Lo be 0.016 sec.) Cylinders with height-to-cianeter ratio, hyDel.§, were cut-off from the composite anstant apets of s/sin between two plates," thelr height being parallel to ase 1 STS ean yield stress] F,/ouss | T,/nese a oo] oom wom” toy we wm iva) | exo. theor.| int shtor.| ayer parent i are ty 1 [ez Te |e | ee dee Be Te | se seen 028 2 irs s3[ 13 | fo be eo | su se |e oe 3 le ss | ie | He - Soe HP go | 51s ses | Oc2. O21 i ism ie | io | 0 Ho ize a | Gas Gea | clea O19 5 jee fea | st | 3 de Mee ge | ote se [Oe é ep ie | S| ee Sea ee Se | no 69 | od 0.35 BY Bis] 20] 3a Me See ais | 00 S66 | O18 0:13 ak 353 | 0 | 34a 306 128_| 1105 1086 | Lia 0:12 Trg-t40_ cu Tlem[az} zo] ?| e wm |e sai 2 fig | 3b] So] $) 2 i iat | iby and) see 3 fica | ace | ele] as | ade zee ee | age) tae a (3a | 3 | Sa] in| ie 3 ate | de 2) ioe ie $ faze [ate | ei] | ise as 2a | 222 23.3) to 107 f fete jee| es] | is io ae | Ba S| ten oleae [2% | se] ie) 2a 3 der | HY de] ge 6 2 fem] eae] m2 | a | to 3h dee | Sn de | uae ae a lem] aie | ie | a | he 3s dee | 2s dea] ie ie we [oie | Fee 1155 so | 3p See des | tos 22) UeCladding direction. The flow stress-strain Curves abtained for the bisetallics under Eonticeration a well as. the relevant stress-strain curves of the initial test materials conpressed under the sane Conditions are presented in. Fig.2. From these curves. the pean yield stress was estimated to be 30) W/m? and 230 N/an? for Al/Cu and Ap-Cag/Cu cladded composites respectively. Sinilarly, values of 320 Wont, 278 Want and 158 Nom? were festinited.as the mean yield stress for the Ai Ce and Agrcao initial test waterials. The mean yield stress of the bimetallic 8 Rogelles as rigié-perfectly pla Stic. aaterial. can be alse obtained fron the ‘two-layer sandeich” approach outlined above, since the interface zone is very Small’ (about 0.1 mJ. see Rets.(3, 4]; Aherefore, Eqn.(7) say be applied ast Wath yet ay RESULTS XO DISCUSSION Deformation characteristics (a) Ae far as the overall strength of the cladded cenposites “is concerned, fron the Fig.2 it say de concluded that. for both Conbinations of materials, a. macroscopic acceptable weld ‘wis produced since the Claceed plate is stronger, at least, than fhe weaker of the tro conponents (1) -hore= over, substitution ef the. corresponding ensured values, in fen.(11) yields 8 Tat) tre! and Es egyeet@l Na 500 "e 409 2 300 z* Sig caoreu 200 E100 ° oz oe os Stroin Fig. 2: Stress-strain curves of the test mteritis and the cladded Binetallics In the case of Aly by tallies precicred and experimentally deter ined values for the ‘pean ‘yielé stress are. aleosi the Sane, whilst. for A9-te0/ty_ bimetallics. theoretical predictions ungerestinate the experinental weasurenents by about S&: sneunifare saterial properties of the fgrcad, plates dee to the uneven Glstribution of the Cad particles (S}, may be the reason for this discrepancy. (b)_ fultiple-pass cold-rolting was sel- ected ‘as tne pest-weleing forming operei Yon for. shaping clidsed plates to. their net-shape, sanuracturing. “The bisetallic Bates, were not subyected to stress Felieving heat treatuent either defore Polling or at the intemediate stages Betieen the various passes. In general, the directional mechanical process of ‘rolling does not impart any Other inoressive surface alterations. Quantitatively, these changes are expres sed. by surface roughwess measurenents Sumarised in Table 1. vith all other Felling paraneters kept constant, only the thickness redaction war considered to Affecting surface finish: It was found That with increasing total "thickness reduction, r, the surface roughness, R, decreases. for both combinations of at rials, showing a tendency to aporoximating the roll surface roughness: see also the Similar renarki reported in Ref.(5] for the rolling of steels. The variation of roll force with total thickness reduction for 2 number of pass es is presented in Fig.2. It is shows that, for both Dinetallics, the total rel] Force increases in a sight parabolic manner with increasing total thickness eduction, however, the effect of work: hardening for. the materials under Consideration is. not evident as in the Ease of rolling of steels [5]. Fron the Sane Figure it is clearly shown thet the total roll. terqie varies. also. parabolic: Bly with total thickness reduction after 2 number of passes. The theoretical prediction of roll force, F,, and torque, T,, is based on the slao-layer sandwich? approach out ined above. For each rolling pass a nean yield Stress, Qe, is calculated fron an, (11); Sy Inserting these values, in Bans. (8) and (3) "the saghituaes” of F," and ty are obtained. Calculated yalues for all roll: ing esses performed are tabulated inlupe 4 ana piostes an ¢1g.3. 19 generes reasured and calculates values are’ in g90d agreement within a0 Fig. 3: Variation of roll force and torque with total thickness reduction, Residual stress fields (a) As expected. for a process. conbini the intense sechanicrl fapnct of explorive Shock waves with thermal and metallurgical Influences, "especssily “Yor" dissimilar etal, residual stresses of consierable fagnitice are developed due to explorive cladding. Such stresses induced. during Welding a uid steel flyer plate to an Sluninies illey “parent one ‘were found Compressive’ in goth parent. “and flyer plates [6], wiilst for welding comerci- alsy pure alueinium to steel ine measures Stresses were tensile io the steel plate and compressive in the aluminiue plate Fespectively [1] Residual stress profiles, neasured curing the present investigation for Al/cu claddea Dinetallies, are’ pleted in Figs.4(a) and (0). fron these Figures it Agvevident that, residual stresses due to cladding, arising from the suzerposition Of plastic “aefarnation with "thermal/che- ‘micel’ interaction are not. unidirectional and. futhermore, profiles for longitudinal ane tranverse’ stresses are of similar Shape. anc of the sare magnitude; compare Figs.4(a) and (b). For both materials. the Tesidusl stresses developed are tensile at The. Snterface- and within. a vone extended at least dyn from te, Interfacial Stresses are higher for the alusinium plate (2y-189 W/mn) than for the cooper (eye 65 Nae") This is related to microcracking at the copper sige ef the inertace {4}, AcLing asa ‘stress relaxation sechanisey See also sinilar coments for eOM resicual Stresses in certain grades of, steels. in Hef (6). At the cuter free surface of the aluatniin plate residual stresses develon- ea were conoressive. in both direction Mhalst, onthe contrary, at the free Surface of ihe copper plate a tensile Stress pattern was revealed. "For. the alusinium layer the masioun ‘stress. was sheasured at the interface, whilst for the Copper. Layer the peak stress was found in the interior of the plate, at a eistance about Is2 sn fron the interface. (2), order to eaiuste the Sngluence of rolling variables on the residual stresses induced, “determination of the stress state i 7 [pos cw at te LL PIN i Fig. 4: Restaual stress profiles (2) fn longitusinal a for Al/Cu cladded/rolled plates: (b) in transverse direction.was also perfe-res on vullee binetaiites Ue Beasuresents sotaines are preented. in Figs.4(a) ana (b)- for a thickness reguct ton’ of r.+58 tension prevails again at the interface, however, the stresses. at the copper sice are now clearly. higher ‘than that at the aluminiua side. For this material, “stresses at the outer free surface remain cospressive (0,2-60 Waa), Ae, sinilar to the ones resultes from cladding, whilst at the cuter. surface of the copper layer they change from tension to “compression; eifferent degree of Plastic ‘seformat ion may’ account for’ this For greater thickness reductions (rj=805), ge resioual stresses atthe aluminius Layer renain practically unaffected, dues compressive, with a value 00-100 Want” at the surface, honever, towarés the inter- fice they ate grogradsively reduces tend. ing to zero. noreover. profiles of Lengi- Widinal "ane srarverse stresues "are ginilar: compare flgs:(a) and (0). At the free ‘surface cf che capper layer rather seal] “stresses were measured: tensile (ojs12 Wan’) and congressive [o,s-28 ang in the tranverse ely. For this eaterial, strais Is tensile at tne the eranrerse’~ one 2" slong the thickness at the layer, see Fig-4(Q). note “als, Ghat the stresses inside the copper layer sa fogreite att ager Large Bagnitude, balanced by “smaller tens tLe stresses. dovelosed at” the surface layer and’ near the interface conctusions Sunmarising the sain features outlined above on vine influence ef the rolling araceters op the Integrity ofthe cladded inetallics "and taking also. into account similar remarks made in Refs.{e), and. (8) ‘the following conclusions ‘may be ¢rawn: (4), spplleation of cole rolling as Post-clacding forming operation requires a careful selection of rolling variables and roll pass schedule in order to improve the soundness of ‘the Binetallic. stripe. The Surface finish of the cladéed binetallics As inproved due to the sulti-pass rolling {Peed A8td on, te concest of, ‘rulti- layered body" and the “sandwich” rolLing technique a theoretical mosel for cole Hing of Cladded biastalics iz proposec Experimental “results pertsining” to. the overall strength of tne composite plates as well as to the roll. force ind torque eveloped are in "goed agreenent with Uheoret ical predictions feagg Ueediggtene rescue rere lds were coterained, in chndaea/rolice Aca Sirloin ™taasaed“eomos ites stresses were tensile atthe interface tone. After rolling, “reduced tensile stresses were ‘again. predominant at the Interface, whilst, ‘compressive patterns, in general, ‘were revealed near the outer free surfaces of the binetallic strips: REFERENCES! [1] Crossland, 8.: Explosive Welding of Hetals and its Applications, Claren- n Press, 1962. [2]. Patterson, R.A: Eeplosive bondies, Welding: ‘Theory and Practice, Elsevi- er, 1980, 265. (3) Mamalis, A. 6.. Vasevanigis, (NM. Gioftsidis G.N.'and Szalay, A: Fab! ication ef Aluniniun/Cooper Binetal- Lies by Explosive Clagding and Roll ng, Proc. 1. Mech. Eng... (in press) Lis, 4.6, Prohaszka, 0. Vaxeva- ‘aad Szalay. "8." on the ng of AgCobyCu. Singtel - Lies by Explosive Cladzing and Rell- ing, Proc. 1, Mech. Eng. {in press) 5] Mamalis, 4.6. WK. and Karafillis, ", Integrity id Forsability of Steel sheet, VO! Verlag, 1990. [6] Alexander, (JK. and Brewer, Rt. Manufacturing’ Properties of “Hatari als, 8. van Nostrand, 1963. I7] usatowski, 2.2 Fundamentals of Roll- ing, Oxford, Perganon Press, 1969. [8] Pruemmer, R.A.; Metallurgical, Micro- radiographic "and X-ray fesidual Stress. Investigation of Explosively Welded Aluniniua-steel, Proc.» 3rd Int. Conf of the Centre for High Energy Forming, (1971), 3.5.1. ro) ~are~