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Interfacial quality prediction model for Al/steel sheets during friction stir–assisted double-sided incremental forming with synchronous bonding

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Abstract

The widely investigated Al/steel laminated structures are challenged with subsequent plastic deformation due to the prone generation of interfacial brittle intermetallic compound layer. To overcome this drawback, a recently proposed thermomechanical forming technology as friction stir–assisted double-sided incremental plastic forming with synchronous solid-state interfacial bonding is utilized to fabricate Al/steel laminated structures. Typical interfacial bonding-forming performances produced by a series of experiments classified as sound bonding, de-bonding, over-thinning, penetration and crack are individually assessed. Local working peak temperature and maximum forming force in loading area are recorded and evaluated during stable bonding-forming stage. Considering the heat-force coupling effect, a pressure-strain-temperature–based prediction model is modified to assess interfacial quality, which is conformed to experimental results. This work can help obtain proper process window to successfully fabricate Al/steel laminated parts and shall also inspire to build guidance of related thermomechanical joining-with-forming processes to achieve high interfacial performance.

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Funding

The authors are grateful for the financial supports of the National Natural Science Foundation of China under Grant No. 51675332 and Program of Shanghai Excellent Academic Research Leadership under Grant No. 19XD1401900.

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Authors and Affiliations

  1. Department of Plasticity Technology, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200030, China

    Renhao Wu, Meng Li, Xinmei Liu, Zhiyun Yang & Jun Chen

  2. National Engineering Research Center of Die & Mold CAD, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200030, China

    Renhao Wu, Meng Li, Xinmei Liu, Zhiyun Yang & Jun Chen

Authors
  1. Renhao Wu
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  2. Meng Li
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  3. Xinmei Liu
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  4. Zhiyun Yang
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  5. Jun Chen
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Correspondence to Jun Chen.

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Wu, R., Li, M., Liu, X. et al. Interfacial quality prediction model for Al/steel sheets during friction stir–assisted double-sided incremental forming with synchronous bonding. Int J Adv Manuf Technol 119, 733–743 (2022). https://doi.org/10.1007/s00170-021-08168-y

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