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<p>This study investigated how different steel surface treatments influence the bond strength of Al–steel composite plates and elucidated the mechanisms responsible for bond enhancement. AlSn20Cu sandwiched between layers of pure 1060 aluminum was bonded to steel plates through cold roll bonding. Results demonstrate that a 50% material reduction during cold roll bonding significantly enhances bonding for steel surfaces subjected to P80 belt grinding compared with those subjected to wire brushing, achieving a 20% lower threshold and a 46% greater bond strength. This superior performance stems from belt-treated surface’s dual bonding mechanism during cold roll bonding: mechanical interlocking combined with atomic-level bonding, which is facilitated by hardened surface layer (HSL) cracking. Film theory demonstrates that cracks induce HSL separation from the matrix at fracture locations, compromising interfacial bond strength. An optimal condition is found in this study, where high matrix strength can prevent separation even when surface cracks develop. By the time separation begins, the bond strength has already reached or surpassed that of the aluminum alloy. Under ideal conditions, cold roll bonding proceeds through four steps as thickness reduction increases: an initial (unbonded) stage, gradual strengthening, rapid bond-strength growth, and a final phase (tensile strength of aluminum alloy).</p>

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Bond Enhancement Mechanism of Aluminum–Steel Composite Plates during Cold Roll Bonding

  • 期刊论文

  • 发表日期：

    2026年3月31日

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  • Wendong Du,
  • Yanan Chen,
  • Jiayuan Chen,
  • Hulin Li,
  • YiShun Wang

摘要

This study investigated how different steel surface treatments influence the bond strength of Al–steel composite plates and elucidated the mechanisms responsible for bond enhancement. AlSn20Cu sandwiched between layers of pure 1060 aluminum was bonded to steel plates through cold roll bonding. Results demonstrate that a 50% material reduction during cold roll bonding significantly enhances bonding for steel surfaces subjected to P80 belt grinding compared with those subjected to wire brushing, achieving a 20% lower threshold and a 46% greater bond strength. This superior performance stems from belt-treated surface’s dual bonding mechanism during cold roll bonding: mechanical interlocking combined with atomic-level bonding, which is facilitated by hardened surface layer (HSL) cracking. Film theory demonstrates that cracks induce HSL separation from the matrix at fracture locations, compromising interfacial bond strength. An optimal condition is found in this study, where high matrix strength can prevent separation even when surface cracks develop. By the time separation begins, the bond strength has already reached or surpassed that of the aluminum alloy. Under ideal conditions, cold roll bonding proceeds through four steps as thickness reduction increases: an initial (unbonded) stage, gradual strengthening, rapid bond-strength growth, and a final phase (tensile strength of aluminum alloy).