Corrugated Rolling of Metal Composite Strip for Stronger Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for rolling metal composite plates face challenges in achieving strong, stable bonding between dissimilar metals, leading to poor interface quality, low yield, and energy inefficiency, particularly due to differences in mechanical properties and the complexity of bonding surfaces.
Innovation Solution
A method involving the use of corrugated composite surfaces for rolling metal composite plates, where a metal base plate and cladding plate are laminated, rough-rolled using a two-high rolling mill with one toothed and one smooth roll, and then finish-rolled to achieve a strong bonding interface through meshing forces between corrugations, reducing energy consumption and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If explosion compositing method is used to weld dissimilar metal plates, then strong interface binding force is achieved, but the composite has smaller size, poor shape, lower yield, and causes environmental pollution
Solution Approach 1:
The patent replaces the explosion (chemical/thermal) system with a mechanical rolling system. The corrugated rolling mill uses mechanical pressure and meshing forces to bond metal plates, eliminating the need for high-energy explosion while achieving comparable or superior bonding strength with better productivity and environmental performance.
Solution Approach 2:
The patent changes the bonding mechanism from high-energy explosion to controlled mechanical pressure with corrugated meshing. By introducing corrugated surfaces with specific geometric parameters (amplitude, wavelength, profile shape), the bonding process transitions from uncontrolled high-energy impact to controlled mechanical interlocking and diffusion bonding.
2Ease of manufacture
If conventional rolling method is used for compositing dissimilar metals, then the process is simpler, but the bonding interface is more complex and produces bubbles and cracks
Solution Approach 1:
The patent introduces corrugated (curved) surfaces instead of flat surfaces for bonding. The corrugations with specific amplitudes and wavelengths create meshing forces during rolling, ensuring uniform pressure distribution and eliminating voids/bubbles that form with conventional flat surface rolling, thereby improving bonding interface quality.
Solution Approach 2:
The patent applies different surface qualities to different parts of the bonding interface. The corrugated surfaces have localized geometric features (peaks, valleys, meshing zones) that create varying pressure and contact conditions across the interface, ensuring complete bonding without defects while maintaining overall process simplicity.
3Adaptability or versatility
If dissimilar metals with great difference in mechanical properties are composited, then resource saving and cost reduction are achieved, but the bonding interface becomes more complex and difficult to control
Solution Approach 1:
The corrugated surfaces with optimized geometric parameters (amplitude 1-10mm, wavelength 10-50mm) accommodate differences in mechanical properties between dissimilar metals. The curved meshing action distributes stress uniformly and prevents cracking that would occur with flat surfaces, enabling successful bonding of materials with great property differences.
Solution Approach 2:
The patent performs preliminary surface preparation by creating corrugated patterns on the metal surfaces before bonding. This pre-shaping of surfaces ensures that during subsequent rolling, the meshing forces are uniformly distributed, accommodating differences in ductility and strength between dissimilar metals and preventing interface defects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances bonding strength, increases contact area, and improves compositing efficiency by eliminating cracking and achieving high-quality, high-yield metal composite plates with simplified processes and lower energy consumption.
Implementation Method 1
rolling the composite plate slab through a composite rough rolling mill having a corrugated roll to obtain a composite plate having a corrugated mating surface on its composite surface
Implementation Method 2
allowing the roll having toothed surface to be in contact with the cladding plate and the roll having smooth surface to be in contact with the base plate
Implementation Method 3
the distance of contact surfaces of dissimilar metals affected by deforming force during plastic deformation approaches to the thick of an atom to form a number of bonding point, so as to diffuse to form steady metallurgical bonding
Implementation Method 4
form a number of bonding point, so as to diffuse to form steady metallurgical bonding
Data Source
AI summary
The present invention discloses a method for rolling a metal composite plate/strip, comprising the following steps: 1) selecting a metal base plate and a metal cladding plate, cleaning the surfaces of the base plate and the cladding plate to be composited until the metal matrixes are exposed; 2) sequentially laminating the base plate and the cladding plate to obtain a composite plate slab; 3) rolling the composite plate slab through a composite rough rolling mill having a corrugated roll to obtain a composite plate having a corrugated mating surface on its composite surface; and 4) flattening the composite plate having a complete corrugated cladding plate by a composite finish rolling mill to a desirable thickness to obtain a composite plate/strip.