Isothermal hot compression deformation behavior and interfacial bonding criteria of Al/Mg dissimilar materials
Source abstract
Abstract
Based on the analysis of the interfacial bonding state of industrially hot-rolled 1060 Al/AZ31 Mg laminated composites, isothermal hot-compression experiments were designed to simulate the rolling bonding process of Al/Mg and to investigate the interfacial bonding criteria for dissimilar metals. A thermo–mechanical coupled finite element method was employed to analyze the upsetting hot deformation behavior of Al/Mg composites under different processing parameters. By integrating the experimental results with numerical simulations, a novel interfacial bonding criterion for Al/Mg composites based on the coupled response of stress and strain was proposed. The results indicate that increasing temperature and deformation promotes interfacial bonding and improves overall deformation uniformity. Complete interfacial bonding was achieved at 250 °C/60%, 300 °C/50%, 350 °C/50%, and 400 °C/30%. At 400 °C, oxide phases Al₂O₃ and MgO formed at the interface. The strain dispersion coefficients reached 0.485 and 0.457 at 350 °C/70% and 400 °C/50%, respectively, indicating improved deformation uniformity. Stress–strain state analysis at typical locations during Al/Mg upsetting deformation was conducted, and four characteristic deformation regions were defined. Interfacial bonding criterion coefficients （、）based on strain and stress fields were established and validated through hot-compression experiments, providing a new approach for studying interfacial bonding criteria in dissimilar layered metals.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Aluminum Alloys Composites Properties · Microstructure and mechanical properties · Metal Forming Simulation Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (46)
Show source-provided references
1. Zhang W, Xu J (2022) Advanced lightweight materials for automobiles: a review. Mater Des 221:110994. https://doi.org/10.1016/j.matdes.2022.11099410.1016/j.matdes.2022.110994 ↗
2. Trzepieciński T, Najm SM (2024) Current trends in metallic materials for body panels and structural members used in the automotive industry. Materials (Basel, Switzerland) 17:59010.3390/ma17030590 ↗
3. Joost WJ, Krajewski PE (2017) Towards magnesium alloys for high-volume automotive applications. Scr Mater 128:107–112. https://doi.org/10.1016/j.scriptamat.2016.07.03510.1016/j.scriptamat.2016.07.035 ↗
4. Chen MC, Hsieh HC, Wu W (2006) The evolution of microstructures and mechanical properties during accumulative roll bonding of Al/Mg composite. J Alloys Compd 416:169–172. https://doi.org/10.1016/j.jallcom.2005.09.01710.1016/j.jallcom.2005.09.017 ↗
5. Czerwinski F (2021) Current trends in automotive lightweighting strategies and materials. Materials (Basel, Switzerland) 14:663110.3390/ma14216631 ↗
6. Song J, She J, Chen D, Pan F (2020) Latest research advances on magnesium and magnesium alloys worldwide. J Magnesium Alloys 8:1–41. https://doi.org/10.1016/j.jma.2020.02.00310.1016/j.jma.2020.02.003 ↗
7. Mei R, Chen L, Bao L, Pei S, Ma Y, Zhang X (2023) Influence of reduction and annealing temperature on the interface characteristics of Al/Cu laminated composite plates in RHR. JOM 75:3771–3780. https://doi.org/10.1007/s11837-023-05954-910.1007/s11837-023-05954-9 ↗
8. Liu T, Song B, Huang G, Jiang X, Guo S, Zheng K, Pan F (2022) Preparation, structure and properties of Mg/Al laminated metal composites fabricated by roll bonding: a review. J Magnesium Alloys 10:2062–2093. https://doi.org/10.1016/j.jma.2022.08.00110.1016/j.jma.2022.08.001 ↗
9. Lei J, Ma L, Jia W, Cai Z, Liu P, Yuan Y, Pan H, Xie H (2023) Effect of differential temperature on the interfacial microstructure evolution and mechanical properties of asymmetrically rolled Mg/Al composite plates. J Mater Res Technol 24:1281–1292. https://doi.org/10.1016/j.jmrt.2023.03.09810.1016/j.jmrt.2023.03.098 ↗
10. Zhang JS, Li DH, Zhang DX, Tian Y, Xiao HY, Jia J (2012) Prediction of edgewise compressive and side tensile elastic modulus of core materials of ripple structure sandwich composites. Appl Mech Mater 117–119:1501–1505. https://doi.org/10.4028/www.scientific.net/AMM.117-119.150110.4028/www.scientific.net/AMM.117-119.1501 ↗
11. Yoo MS, Shin KS, Kim NJ (2004) Effect of Mg2Si particles on the elevated temperature tensile properties of squeeze-cast Mg–Al alloys. Metall Mater Trans A 35:1629–1632. https://doi.org/10.1007/s11661-004-0268-410.1007/s11661-004-0268-4 ↗
12. Guo L, Wang J, Yun X, Chen Z (2021) Fabrication of aluminum–magnesium clad composites by continuous extrusion. Mater Sci Eng A 802:140670. https://doi.org/10.1016/j.msea.2020.14067010.1016/j.msea.2020.140670 ↗
13. Chen Z, Wang D, Cao X, Yang W, Wang W (2018) Influence of multi-pass rolling and subsequent annealing on the interface microstructure and mechanical properties of explosive-welded Mg/Al composite plates. Mater Sci Eng A 723:97–108. https://doi.org/10.1016/j.msea.2018.03.04210.1016/j.msea.2018.03.042 ↗
14. Zeng XY, Wang YX, Li XQ, Li XJ, Zhao TJ (2019) Effect of inert gas shielding on the interface and mechanical properties of Mg/Al explosive welding composite plate. J Manuf Process 45:166–175. https://doi.org/10.1016/j.jmapro.2019.07.00710.1016/j.jmapro.2019.07.007 ↗
15. Ding Z, Li Z, Li H, Chen Y (2020) Microstructure of Mg solid solution layer during multi-pass FSP of Mg/Al composite plates. Vacuum 172:109078. https://doi.org/10.1016/j.vacuum.2019.10907810.1016/j.vacuum.2019.109078 ↗
16. Macwan A, Patel VK, Jiang XQ, Li C, Bhole SD, Chen DL (2014) Ultrasonic spot welding of Al/Mg/Al tri-layered clad sheets. Mater Des 62:344–351. https://doi.org/10.1016/j.matdes.2014.05.03510.1016/j.matdes.2014.05.035 ↗
17. Yang N, Jiang X, Zhang R, Li J, Zheng K, Pan F (2025) The effects of Cu powder on the interface microstructure evolution of hot-rolled Al6061/MgM21/Al6061 composite plates during annealing. Materials (Basel, Switzerland) 18:65510.3390/ma18030655 ↗
18. Wang T, Wang Y, Bian L, Huang Q (2019) Microstructural evolution and mechanical behavior of Mg/Al laminated composite sheet by novel corrugated rolling and flat rolling. Mater Sci Eng A 765:138318. https://doi.org/10.1016/j.msea.2019.13831810.1016/j.msea.2019.138318 ↗
19. Yang X, Feng C, Jie C, Xiao N, Qiang X (2017) Effects of high-temperature annealing on microstructure and mechanical property of SiO2f/SiO2 composites. Vacuum 144:1–7. https://doi.org/10.1016/j.vacuum.2017.07.00510.1016/j.vacuum.2017.07.005 ↗
20. Sun R, Li G, Xu G, Fang M, Li J, Liu L, Liu W, Zhang M (2023) Evolution and formation mechanism of interface structure in rolled Mg–Al clad sheet. J Mater Eng Perform 32:7248–7259. https://doi.org/10.1007/s11665-022-07629-z10.1007/s11665-022-07629-z ↗
21. Nie H, Liang W, Chen H, Zheng L, Chi C, Li X (2018) Effect of annealing on the microstructures and mechanical properties of Al/Mg/Al laminates. Mater Sci Eng A 732:6–13. https://doi.org/10.1016/j.msea.2018.06.06510.1016/j.msea.2018.06.065 ↗
22. Lee KS, Lee YS, Kwon YN (2014) Influence of secondary warm rolling on the interface microstructure and mechanical properties of a roll-bonded three-ply Al/Mg/Al sheet. Mater Sci Eng A 606:205–213. https://doi.org/10.1016/j.msea.2014.03.08210.1016/j.msea.2014.03.082 ↗
23. Tian Y, Luo N, He W, Jiang B, Pan F (2024) Effect of Zn and Ti transition foil on the microstructure and mechanical properties of hot rolling bonded Al/Mg composite plates. Mater Sci Eng A 891:145978. https://doi.org/10.1016/j.msea.2023.14597810.1016/j.msea.2023.145978 ↗
24. Varmazyar J, Khodaei M (2019) Diffusion bonding of aluminum–magnesium using cold rolled copper interlayer. J Alloys Compd 773:838–843. https://doi.org/10.1016/j.jallcom.2018.09.32010.1016/j.jallcom.2018.09.320 ↗
25. Li J, Feng B, Feng X, Yan C, Xia Z, Chen X, Zheng K, Pan F, Jiang X (2025) Effect of pure Cu foil interlayer on the microstructure and mechanical behavior of Mg/Al composite sheet. J Alloys Compd 1010:177630. https://doi.org/10.1016/j.jallcom.2024.17763010.1016/j.jallcom.2024.177630 ↗
26. Li G, Jiang W, Guan F, Zhang Z, Wang J, Yu Y, Fan Z (2023) Preparation, interfacial regulation and strengthening of Mg/Al bimetal fabricated by compound casting: a review. J Magnesium Alloys 11:3059–3098. https://doi.org/10.1016/j.jma.2023.09.00110.1016/j.jma.2023.09.001 ↗
27. Lin ZC, Huang TG (2000) Different degree of reduction and sliding phenomenon study for three-dimensional hot rolling with sandwich flat strip. Int J Mech Sci 42:1983–2012. https://doi.org/10.1016/S0020-7403(99)00067-310.1016/S0020-7403(99)00067-3 ↗
28. Li ZX, Rezaei S, Wang T, Han JC, Shu XD, Pater Z, Huang QX (2023) Recent advances and trends in roll bonding process and bonding model: a review. Chin J Aeronaut 36:36–74. https://doi.org/10.1016/j.cja.2022.07.00410.1016/j.cja.2022.07.004 ↗
29. Rezaii A, Shafiei E, Ostovan F, Daneshmanesh H (2020) Experimental and theoretical investigation of roll bonding process of multilayer strips by finite element method. J Manuf Process 54:54–69. https://doi.org/10.1016/j.jmapro.2020.02.04410.1016/j.jmapro.2020.02.044 ↗
30. Gao YN, Xiao H, Li ZH (2010) Contact surface treatment method during rolling simulation of stainless steel clad rebars. In: Proceedings of the second symposium on production technology development and application of laminated metal composites, Beijing, China, pp 1–8
31. Kobayashi S, Oh SI, Altan T (1989) Metal forming and the finite-element method. Oxford University Press, New York10.1093/oso/9780195044027.001.0001 ↗
32. Takuda H, Morishita T, Kinoshita T, Shirakawa N (2005) Modelling of formula for flow stress of a magnesium alloy AZ31 sheet at elevated temperatures. J Mater Process Technol 164–165:1258–1262. https://doi.org/10.1016/j.jmatprotec.2005.02.03410.1016/j.jmatprotec.2005.02.034 ↗
33. Liu D, Liu Z, Wang L (2014) Simulation of rolling process of AZ31 magnesium alloy sheet. Procedia Eng 81:173–178. https://doi.org/10.1016/j.proeng.2014.09.14610.1016/j.proeng.2014.09.146 ↗
34. Ding Y, Zhu Q, Le Q, Zhang Z, Bao L, Cui J (2015) Analysis of temperature distribution in the hot plate rolling of Mg alloy by experiment and finite element method. J Mater Process Technol 225:286–294. https://doi.org/10.1016/j.jmatprotec.2015.06.01110.1016/j.jmatprotec.2015.06.011 ↗
35. Chen LQ (2019) Chemical potential and Gibbs free energy. MRS Bull 44:520–523. https://doi.org/10.1557/mrs.2019.16210.1557/mrs.2019.162 ↗
36. Pretorius R, Marais TK, Theron CC (1993) Thin film compound phase formation sequence: an effective heat of formation model. Mater Sci Rep 10:1–83. https://doi.org/10.1016/0920-2307(93)90003-W10.1016/0920-2307(93)90003-W ↗
37. Pretorius R, Vredenberg AM, Saris FW, de Reus R (1991) Prediction of phase formation sequence and phase stability in binary metal–aluminum thin-film systems using the effective heat of formation rule. J Appl Phys 70:3636–3646. https://doi.org/10.1063/1.34921110.1063/1.349211 ↗
38. Ji H, Song Q, Liu Z (2024) Micro-milling machinability prediction for crystalline materials via numerical–analytical hybrid modelling and strain rate-dependent grain-scale simulation. J Manuf Process 124:972–984. https://doi.org/10.1016/j.jmapro.2024.06.06310.1016/j.jmapro.2024.06.063 ↗
39. Zhang J, Meng F, Zhang X, Ren H, Zhang D, Chen Y, Zhang X, Zhang F, Yan Q (2026) Distinct creep behavior of martensite and ferrite in a Si-enriched heat resistance steel at 650/700 °C. Mater Sci Eng A 971:150468. https://doi.org/10.1016/j.msea.2026.15046810.1016/j.msea.2026.150468 ↗
40. Wu RH, Park H, Gao CX, Son S, Liu HW, Lee SW, Toor ZS, Li TL, Kim HS (2026) Integrated computational and experimental analysis on the incompatible plastic deformation of heterostructured Ti-based joints. Tungsten 8:149–166. https://doi.org/10.1007/s42864-025-00361-w10.1007/s42864-025-00361-w ↗
41. Kim JS, Lee KS, Kwon YN, Lee BJ, Chang YW, Lee S (2015) Improvement of interfacial bonding strength in roll-bonded Mg/Al clad sheets through annealing and secondary rolling process. Mater Sci Eng A 628:1–10. https://doi.org/10.1016/j.msea.2015.01.03510.1016/j.msea.2015.01.035 ↗
42. Brennan S, Bermudez K, Kulkarni NS, Sohn Y (2012) Interdiffusion in the Mg–Al system and intrinsic diffusion in β-Mg2Al3. Metall Mater Trans A 43:4043–4052. https://doi.org/10.1007/s11661-012-1248-810.1007/s11661-012-1248-8 ↗
43. Wang XX, Xue KM, Li P (2014) Preparation of bulk ultrafine-grained aluminum by equal-channel angular pressing and torsion process. Chin J Nonferrous Met 24:1414–1421. https://doi.org/10.19476/j.ysxb.1004.0609.2014.06.00510.19476/j.ysxb.1004.0609.2014.06.005 ↗
44. Li P, Wei XF, Nie AQ, Duan ZH, Zhou YF, Xue KM (2019) Numerical simulation and experimental investigation of closed double-channel equal-channel angular extrusion of pure tungsten. J Plast Eng 26:1–8
45. Slater RAC (2018) Sequential correspondence law between stress and strain components and its application in plastic deformation process. In: Engineering plasticity, pp 295–31610.1002/9781119237310.ch7 ↗
46. Slater RAC (1977) Stress–strain relations. In: Slater RAC (ed) Engineering plasticity: theory and application to metal forming processes. Macmillan Education UK, London, pp 90–11810.1007/978-1-349-02160-4_5 ↗