Deformation and fracture of polymer/metal composites subjected to cold rolling

Abstract Cold rolling of a sandwich composite with a metallic strip inclusion in a polymeric matrix can produce a range of outcomes, including deformation and fracture of the inclusion. Using different material combinations under the same processing parameters, the results ranged from minor deformation, to folding and/or loss of adhesion, and fracture of the inclusion, with fracture particles varying in size and shape. Comparisons are made between the resulting structures after cold rolling of the polymer/metal composite to geological formations. In particular, the fracture particles obtained resemble rock structures known as boudins. The phenomena of boudinage and folding encountered in the cold rolling of polymer/metal composites is similar to that seen in geology formations although the time and size scale of these events are several orders of magnitude apart. The experimental results reported show that cold rolling applied to a polymer/metal sandwiched composite induces deformation and fracture behaviors that depend on the mechanical properties of the constituents, deformation behavior of the polymeric matrices, interfacial adhesion, and process parameters such as rollers speed and nip-gap.