The effect of roll and clad sheet geometry on the necking instability
during rolling of clad sheet metals
Frank Nowicke Jr., Antonios Zavaliangos, Harry C. Rogers
Department of Materials Engineering, Drexel University, Philadelphia, PA 19104, USA
Received 23 February 2005; received in revised form 12 December 2005; accepted 31 January 2006
Available online 18 April 2006
Abstract
Experimental evidence is presented showing that the rolling strain required to produce internal necking in clad sheet depends both on
the volume fraction of each constituent in the clad and the geometry of the rolls. This result was not predicted by earlier localization
analysis that approximates the stress/strain eld in rolling with that of plane strain compression. The evolution of hardness during rolling
and complementary nite element results point to redundant shearing of the soft phase as the reason for this behavior. Such redundant
shear differentially strengthens the softer component of the clad and reduces the induced tensile stress in the harder component, delaying
the localization. Therefore, unwanted strain localization in rolling of clad sheets can be delayed signicantly by the use of small radius
rolls in congurations such as a Sendzimir mill.
r 2006 Elsevier Ltd. All rights reserved.
Keywords: Clad sheet; Instability; Necking; Rolling; Finite element analysis
1. Introduction
Clad sheets are metallic multilayer sheets that offer
attractive properties compared with monolithic sheets in
such applications as heat exchangers (lightweight aluminum/stainless steel for protection), automobile bumper
trims (stainless steel/inexpensive low carbon steel) and
cookware (copper- or aluminum-bottomed stainless steel
for heat conductivity, corrosion and wear resistance). Clad
sheets can be fabricated by two methods: (i) adhesive
bonding and (ii) roll bonding. Roll bonding creates a new
surface area via tensile strain in the rolling direction,
allowing virgin metal to be exposed through the fractured
oxide skin. The through-thickness pressure applied by the
rolls forces the two metal surfaces to approach each other
atomically closely and simultaneously prevents oxygen
from reaching the virgin metal surfaces. In places where the
proximity of one metal to the other is on the atomic scale,
the similarity of all metallic bonds allows actual bonding
between the two metals. After the clad sheet components
Corresponding author. Tel.: +1 215 895 2078; fax: +1 215 895 6760.
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(1)
2
2Y A
2Y B
A
)sA
and sBx sBy p ,
2
x sy p
3
3
where Y A and Y B is the ow stress for materials A and B.
The assumption that the magnitude of the through-thickness
compressive stress is larger than any of the longitudinal
stresses and the combination of Eqs. (1) and (2), gives:
2
B
sA
y sy p f A Y A f B Y B ,
3
(3)
2
2
B
sA
x f B p Y A Y B and sx f A p Y B Y A ,
3
3
(4)
The stronger component is in tension along the rolling
direction while the weaker component is in compression. The
presence of tension in this direction leads to neck formation
[6]. Compared to the amount of work that exists for the
necking and failure in plane stress loading of sheets (e.g., [9]),
there is very little work on the localization of sheets under
plane strain conditions loaded with one negative principal
stress component. Semiatin and Piehler applied the maximum load criterion [57] along the longitudinal direction for
the harder component of the clad that is in tension:
dsA
dY A Y B
x
sA
Y A Y B .
x )
deA
deA
x
x
Fig. 1. (a) Clad rolling geometry and (b) equivalent plane strain compression.
(5)
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870
(6)
K B =K A 4k
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Table 1
Geometry of clad sheets and mechanical properties of each component
Conguration
Total
thickness
(mm)
Knoop
hardness of
stainless
steel
10%SS
20%SS
30%SS
40%SS
80%SS
80%Al
3.10
3.11
3.29
3.28
3.23
3.14
0.36
0.69
1.08
1.34
2.63
0.36
334
339
328
330
342
350
11.6
22.2
32.8
41.0
81.5
23.1
871
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872
Fig. 4. Deformed nite element mesh. The details of the undeformed mesh are shown in the part of the sheet that has not entered the roll gap, while the
predicted necking is clearly shown in the exiting part of the sheet. Roll diameter is 152 mm and thickness is 3 mm in this simulation.
Fig. 5. (a) Internal necks revealed by dissolving the aluminum layer in NaOH, (b) ductile cutting mode in the neck, and (c) shear banding in a clad with SS
on the outside.
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Table 2
Through-thickness strain at necking and failure during rolling
10% SS
60
80% Al
Clad conguration
20% SS
50
873
152
30% SS
40
0.57 0.72
0.780.89
1.261.40
41.60
41.60
0.740.85
10%SS
20%SS
30%SS
40%SS
80%SS
80%Al
30
20
38
22
0.680.79
0.931.00
41.19b
0.770.82
40.82b
0.920.99
10
a
0.2
0.4
0.6
0.8
Rolling Strain
1.2
First and second number indicate rolling strain at necking and failure,
respectively.
b
Edge cracks caused specimen failure without necking.
c
Did not roll due to excessive bow of the rolls.
550
Knoop Hardness
80% Al
20% SS
500
30% SS
450
400
350
Stainless steel layer
300
0.2
0.4
0.6
Rolling Strain
0.8
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component. Fig. 8 shows that aluminum hardens signicantly more in the smaller roll for the same rolling strain.
This trend is consistent with the idea that in smaller rolls
there is higher redundancy of deformation (i.e., deviation
from homogeneous deformation)an idea that is well
known in the deformation of single metal strips [8]. Figs. 7
and 8 indicate that (a) there are signicant differences in
level of deformation redundancy among the various clad
and roll congurations, and (b) most of this redundancy is
present in the aluminum layer. In other words, while the
rolling strain adequately denes the level of hardness in the
stainless steel for all congurations examined, the corresponding values for aluminum depend strongly on clad
sheet and roll geometry in addition to rolling strain.
6. Discussion
The experimental data presented above are not predicted
by the simple necking analysis of Refs. [57]. A number of
potential reasons for this discrepancythe effect of strain
75
Knoop Hardness
70
Aluminum layer
65
60
55
50
152 mm
38mm
45
22mm
40
0.1
0.2
0.3
0.4
0.5
Rolling Strain
0.6
0.7
0.8
rate/temperature and the effect of the hydrostatic component of the stresscan be readily refuted. Experimental
work at different roll velocities did not result in variation of
the strain to necking [18]. This is expected because the
strain rate sensitivity of both materials at room temperature is small. No substantial temperature increase is
observed over the range of conditions used. Following
the analysis of Section 2, the hydrostatic pressure in the
harder component is given by:
YB k 2
k1
pB p
2f B
;
k
k
3
YB
where k
; with Y B 4Y A .
YA
1.10
Aluminum (0%SS)
1.00
0.90
10%SS
20%SS
0.80
0.70
0.60
0.50
0.00
0.20
0.40
0.60
0.80
1.00
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Fig. 10. Contours of equivalent plastic strain for various clad conguration at two rolling strains (one below and one above the necking strain). The
intensity of the localization depends on how much larger than the necking strain is the imposed rolling strain. Note the increasing difference between the
level of plastic strain in the two metals at higher fractions of stainless.
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2
1.8
Experiments
1.6
Rolling Strain
1.4
Fracture
1.2
1
Necking
0.8
0.6
0.4
0.2
0
0%
20%
(a)
40%
60%
Percent SS in clad
80%
100%
1.2
1.15
1.1
1.05
1
0.95
0.9
0.85
0.68
0.8
0%
(b)
10%
20%
30%
Percent SS in clad
40%
50%
FEM simulations
0.66
10SS
0.64
90Al
0.62
0.60
0.58
0.56
0.54
0.52
0.50
0
(a)
0.2
0.4
0.6
0.8
Normalized distance from centerline 2x/t
1.30
30SS
70Al
1.20
1.10
1.00
0.90
0.80
0.70
0.60
0.50
0
(b)
0.2
0.4
0.6
0.8
Normalized distance from centerline 2x/t
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