article · Alexandria Engineering Journal
Accumulative roll bonding produces composite sheets effectively, but managing its numerous operational parameters is typically costly. This research models and optimises the process for aluminium alloy AA1050 sheets reinforced with nickel and silicon carbide. Using response surface methodology, the study evaluates how rolling passes, varied between one and seven, and silicon carbide content, ranging from zero to five weight percent, dictate the resulting microstructure, phase development, hardness, and tensile strength. Fracture surfaces were also analysed using scanning electron microscopy. The modelling confirms that both the pass count and reinforcement content significantly affect mechanical performance. Numerical optimisation indicates that seven rolling passes with 3.2 weight percent silicon carbide content provide the ideal parameters, yielding a composite sheet with a tensile strength of 249.2 megapascals and a hardness of 107.8 Vickers hardness.
Accumulative roll bonding is a crucial method for manufacturing high-performance metal nanocomposites, yet exploring its processing settings experimentally is often slow and expensive. Applying statistical modelling to determine the exact mix of rolling passes and particle reinforcement helps engineers achieve high tensile strength and hardness with minimal trial and error, making the development of robust lightweight materials more efficient.
The findings could benefit advanced materials manufacturers seeking cost-effective parameter settings for producing reinforced aluminium sheets for structural components. By providing an optimised formula for accumulative roll bonding, the study reduces development expenses. However, because the results reflect laboratory-scale testing, material modelling, and microstructural analysis, the process remains at an applied testing stage and requires factory-scale validation prior to commercial deployment.
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Accumulative Roll Bonding (ARB) is one of the main techniques to manufacture nanocomposites, however, due to the large number of parameters that control this process, its application is relatively expensive. The present work considers a simple response surface methodology to study the interaction effect between the selected ARB parameters on the tensile strength and the hardness of the ARBed composite sheets. We investigated the characterization, modeling, and numerical optimization of the accumulative roll-bonded (ARBed) AA1050 composite sheets produced using a number of passes ranging from 1 to 7 and reinforced with different SiC content (0, 1, 3, and 5 wt%). The effect of the number of passes and SiC content on the microstructure, phase analysis, tensile, and hardness properties have been investigated for the ARBed sheets and their composites. Also, the fracture surface of the tensile-tested specimens was studied using SEM analysis. Numerical optimization was conducted using the developed model to determine the optimum parameters of the ARB process in the designed experiments. The modelling analysis results confirm the significance of the applied ARB parameters on the properties of the ARBed sheet composites. The numerical optimization analysis indicates the optimum ARB factors are 7 passes and 3.2 wt% of SiC content to produce an AA1050/Ni-SiC composite sheet with 249.2 MPa tensile strength and 107.8 HV hardness.
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DOI: 10.1016/j.aej.2023.06.027
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