Finite Element Modeling and Experimental Verification of a New Aluminum Al-2%Cu-2%Mn Alloy Hot Cladding by Flat Rolling

The roll bonding of an experimental Al-2%Cu-2%Mn alloy with technically pure 1050A aluminum at true deformations of 0.26, 0.33 and 0.40 has been simulated using the QForm 10.3.0 FEM software. The flow stress of the Al-2%Cu-2%Mn alloy has been measured in temperature and strain rate ranges of 350–450 °C and 0.1–20 s⁻¹, respectively. The simulation results suggest that the equivalent strain in the cladding layer is more intense than that in the base layer, reaching 1.0, 1.4 and 2.0 at strains of 0.26, 0.33 and 0.40, respectively. The latter fact favors a decrease in the difference between the flow stresses of the rolled sheet layer contact surfaces by an average of 25% at the highest strain. The experimental roll bonding has achieved good layer adhesion for all the test samples. The average peeling strength of the samples produced at strains of 0.26 and 0.33 proves to be 12.6 and 18.4 N/mm, respectively, and at a strain of 0.40, it has exceeded the flow stress of the 1050A alloy cladding layer. The change in the rolling force for different rolling routes has demonstrated the best fit with the experimental data.