Corrugated Interface Rolling for Thick Steel-Aluminum Laminated Plates
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Solution Overview
Problem
Current methods for preparing steel-aluminum-aluminum alloy laminated composite plates face challenges such as uncoordinated deformation, interfacial oxidation, and low bonding strength, especially when the thickness exceeds 4 mm, limiting the production of high-performance heavy-gauge composite plates.
Innovation Solution
A corrugated-flat rolling composite method is employed, involving heat treatment, surface preparation, and sequential rolling with corrugated and flat rolls to create a mechanically engaged and metallurgically bonded interface, enhancing deformation coordination and bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rolling composite method is used to prepare thick steel/aluminum/aluminum alloy laminated composite plates (thickness > 4 mm), then continuous production and scale manufacturing are achieved, but interfacial oxidation, uncoordinated deformation of constituents, and low bonding strength occur
Solution Approach 1:
The invention changes the rolling parameters including temperature control (heating to 450-600°C), rolling reduction rate (not less than 40%), and multi-pass rolling to achieve coordinated deformation. It also changes the interface geometry from flat to corrugated to enhance mechanical interlocking and bonding strength while maintaining continuous production capability
Solution Approach 2:
The invention introduces corrugation (curved surface) at the steel-aluminum interface instead of a flat interface. The corrugated surface with specific amplitude and wavelength enhances mechanical interlocking between layers, improving bonding strength and enabling reliable thick composite plate production while maintaining continuous manufacturing
2Ease of manufacture
If conventional flat rolling is used for thick composite plates, then simple equipment and process are maintained, but uncoordinated deformation of constituents and small interfacial deformation occur
Solution Approach 1:
The invention replaces flat rolling with corrugated rolling, where the corrugated roll imparts a curved corrugated surface at the interface. This increases interfacial deformation and mechanical interlocking, achieving coordinated deformation of steel and aluminum constituents while maintaining a relatively simple rolling process
Solution Approach 2:
The invention optimizes rolling parameters including heating temperature (450-600°C), rolling reduction rate (≥40%), and corrugation geometry (amplitude and wavelength) to achieve coordinated deformation. These parameter changes enable precise control of deformation while maintaining ease of manufacture
3Weight of moving object
If the steel thickness exceeds 5 mm and total thickness exceeds 10 mm, then heavy-gauge composite plates are produced, but interfacial oxidation and low bonding strength increase
Solution Approach 1:
The invention controls heating temperature (450-600°C) to be below the oxidation-prone range while sufficient for metallurgical bonding. This temperature parameter change enables production of heavy-gauge plates (steel thickness >5 mm, total thickness >10 mm) while minimizing interfacial oxidation
Solution Approach 2:
The corrugated interface increases the bonding area and mechanical interlocking, compensating for any oxidation effects. The curved corrugated surface with optimized amplitude and wavelength enhances bonding strength even in thick composite plates where oxidation risk is higher
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 achieves coordinated deformation and improved bonding strength, reducing interfacial oxidation effects, and enables continuous, large-scale production of high-performance steel-aluminum-aluminum alloy laminated composite plates with enhanced mechanical properties.
Implementation Method 1
a corrugated roll and a flat roll respectively contact the steel plate and the aluminum plate
Implementation Method 2
preparing a steel/aluminum laminated composite plate with a corrugated interface, allowing the corrugated roll to be in contact with the aluminum plate and the flat roll to be in contact with the steel plate
Implementation Method 3
heat treating the steel plate and the aluminum plate respectively
Data Source
AI summary
Disclosed is a corrugated-flat rolling composite method for a steel/aluminum/aluminum alloy laminated composite plate. According to the method, a steel/aluminum laminated composite plate with a good plate shape and a firmly bonded interface is prepared, the corrugated cold rolling with a large thickness ratio is utilized to enhance the deformation of the interface to be bonded, and the deformation of constituent metals is coordinated to solve the problem that the steel-aluminum interface is not deformed. Then the deformation of constituents is coordinated by the interfacial corrugated-flat hot rolling to achieve the bonding of aluminum and aluminum alloy surfaces and prepare a high-performance steel/aluminum/aluminum alloy laminated composite plate. Taking the advantage that the interface oxidation has little effect on the bonding of aluminum and aluminum alloy, the problem of anti-oxidation in the composite process is eliminated, thereby the problem of low interfacial bonding strength is solved due to a fact that the interfacial shear becomes weak and the interfacial bonding mainly depends on the hot-press action when the steel and aluminum bonding surface approaches the neutral layer in the rolling process of a steel/aluminum/aluminum alloy laminated composite plate with a thickness more than 4 mm, and the problem of uncoordinated deformation is solved due to the large difference in the properties of steel, aluminum and aluminum alloy.