Overlap Composite Rolling With Wedge Edge for Stronger Metal Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of overlap composite materials, such as those made of copper and aluminum, faces challenges in adhesion due to the rapid formation of passivation surface layers like oxide layers, which interfere with the bonding process between metal atoms.
Innovation Solution
A method involving a first sheet with a wedge-shaped edge and a second sheet positioned on an inclined side surface of the first sheet during rolling, increasing shear and compressive stress, and causing deformation that cracks passivation layers, allowing for improved adhesion by exposing underlying metal atoms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rolling method with sheets positioned on a step is used, then the manufacturing process is simple, but the adhesion between sheets is poor due to passivation layers
Solution Approach 1:
The wedge-shaped edge is pre-formed on the first sheet before the rolling process. This preliminary geometric preparation ensures that during rolling, the second sheet is positioned on an inclined surface rather than a step, which automatically generates the necessary shear and compressive stresses to crack passivation layers and improve adhesion, eliminating the need for complex real-time control during rolling
Solution Approach 2:
The invention introduces asymmetric geometry by creating a wedge-shaped edge with a specific inclination angle on the first sheet. This asymmetric edge configuration causes non-uniform stress distribution during rolling, with higher shear and compressive stresses concentrated at the interface, which effectively cracks the passivation layers and improves metal-to-metal contact and adhesion
2Reliability
If the second sheet is positioned on a step of the first sheet, then the setup is simple, but the shear stress and compressive stress during rolling are insufficient to crack passivation layers
Solution Approach 1:
The wedge-shaped edge geometry is pre-formed on the first sheet through machining or forming operations before assembly. This preliminary action ensures that when the second sheet is positioned against the inclined surface, the rolling process automatically generates sufficient shear and compressive stresses to crack passivation layers and create strong bonds, without requiring complex positioning mechanisms
Solution Approach 2:
The invention changes the geometric parameter of the edge surface from a horizontal step to an inclined wedge surface with a specific angle. This parameter change transforms the stress distribution during rolling, increasing both shear stress and compressive stress at the interface, which enables effective cracking of passivation layers and improves bonding quality
3Reliability
If the edge region is not deformed severely during rolling, then the rolling process is gentle, but the surface area increases less and passivation layers remain intact
Solution Approach 1:
The invention applies local quality by concentrating severe deformation specifically in the edge region of the second sheet through the wedge-shaped interface. The inclined wedge surface ensures that shear and compressive stresses are localized at the interface during rolling, causing severe local deformation that cracks passivation layers and increases surface area, while the bulk material remains relatively unaffected
Solution Approach 2:
The wedge-shaped edge introduces a curved or inclined surface geometry instead of a flat step. This curved interface causes the rolling force to be applied at an angle, generating both shear and compressive stress components that concentrate deformation in the edge region, effectively cracking passivation layers and improving adhesion through increased surface area
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 the joint quality between the sheets by increasing the surface area and deforming the edge regions, leading to better contact and adhesion, compared to traditional methods where the second sheet is positioned on a step rather than an inclined surface.
Implementation Method 1
The inventive configuration of the relevant side surfaces of the sheets causes an increase in the shear stress and compressive stress between the two materials during the rolling process
Implementation Method 2
The inventive configuration of the relevant side surfaces of the sheets causes an increase in the shear stress and compressive stress between the two materials during the rolling process
Implementation Method 3
The edge region of the second sheet is plastically deformed during the rolling over the wedge-shaped edge of the first sheet
Implementation Method 4
the rolling process achieves a considerable increase in surface area and thus a cracking of oxide layers or other passivation and covering layers in the edge regions of the two sheets
Data Source
AI summary
A method for producing an overlap composite material from sheet metal is described, wherein a first sheet of a first metal and a second sheet of a second metal, which has a lower strength than the first metal, are positioned one above another in an overlapping manner in an edge region, and are then joined by rolling. The first sheet has a wedge-shaped edge in cross-section. The second sheet is to be positioned with its edge on a side surface of the first sheet formed by the wedge-shaped edge. The side surface formed by the wedge-shaped edge of the first sheet has a greater width than the side surface of the edge of the second sheet positioned on the said side surface of the first sheet, and, after positioning, the sheets are joined by rolling.