applied

sciences
Review
Accumulative Roll Bonding—A Review
Seyed Mahmoud Ghalehbandi 1 , Massoud Malaki 2, * and Manoj Gupta 3, *
1 Industrial Engineering Department, University of Science and Technology of Mazandaran, Behshahr,
Mazandaran 4851878195, Iran
2 Mechanical Engineering Department, Isfahan University of Technology, Isfahan 84156-83111, Iran
3 Department of Mechanical Engineering, National University of Singapore, 9 Engineering Drive 1,
Singapore 117576, Singapore
* Correspondence: massoudmalaki@gmail.com or m.malaki@me.iut.ac.ir (M.M.); mpegm@nus.edu.sg (M.G.)




Received: 16 July 2019; Accepted: 26 August 2019; Published: 3 September 2019


Abstract: Different manufacturing processes can be utilized to fabricate light-weight high-strength

materials for their applications in a wide spectrum of industries such as aerospace, automotive and
biomedical sectors among which accumulative roll bonding (ARB) is a promising severe plastic
deformation (SPD) method capable of creating ultrafine grains (UFG) in the final microstructure.
The present review discusses recent advancements in the ARB process starting with the ARB
basics, intricacies of the underlying mechanisms and physics, different materials, surface and
rolling parameters, and finally its key effects on different properties such as strength, ductility,
fatigue, toughness, superplasticity, tribology and thermal characteristics. Moreover, results of recent
computational investigations have also been briefed towards the end. It is believed that ARB
processing is an emerging area with tremendous opportunities in the industrial sector and ample
potential in tailoring microstructures for high-performance materials.

Keywords: accumulative roll bonding; light-weight; composite; reinforced composite; ductility

1. Introduction
Nowadays, bulk materials with high strength to weight ratio are in high demand particularly in
weight-critical industrial applications. Average grain size plays a significant role in determining the
mechanical properties of almost all crystalline materials and hence ultra-fine grained (UFG) materials,
i.e., materials with the sub-micron mean grain size, are widely used owing to their superior mechanical
properties. In order to produce such UFG structures using severe plastic deformation (SPD) procedures,
exceptionally high strain value should be considered so that a high density of dislocations can be
inducted in the bulk of material resulting in re-arranged grain boundaries and new array of UFGs.
The most common SPD procedures are equal channel angular pressing (ECAP) [1], high-pressure
torsion (HPT) [2] and accumulative roll bonding (ARB). ECAP can be applied to various materials
where it employs simple shear without reducing cross-sectional area by pressing a metal billet through
an angled channel [3–6]. HPT, however, imposes torsional/compressional stresses to a relatively small
and thin metal disk [7–9], usually with no dimensional changes. Both ECAP and HPT are limited
to producing small parts, relatively expensive, poor in productivity especially in continuous mass
production, and usually require considerably large load capacities and dies. However, having an
ability to bond similar and/or dissimilar materials, ARB is emerging as a cost-effective SPD technique to
obtain large UFG sheets or multi-layered composites structures by accumulating large strains usually
by repeating the procedure. It can also be easily scaled up industrially as a continuous operation.
ARB is applicable for processing a large number of different materials including those that cannot be
bonded by traditional bonding methods.

Appl. Sci. 2019, 9, 3627; doi:10.3390/app9173627 www.mdpi.com/journal/applsci

 preparation, cutting, stacking, rolling and sometimes followed by a post-rolling heat treatment to
improve bonding quality of the stacked sheets. Figure 1a schematically shows the process where two
or more sheets are stacked together and passed through the rolls to apply plastic deformation; the
deformation must be enough to produce a solid-state bonding. ARB has a great industrial potential
due
Appl. Sci.to a high
2019, production rate and continuous procedure. For instance, a two-layer copper/aluminum
9, 3627 2 of 32
(Cu/Al) clad sheet composites manufactured by ARB can almost reduce 40% of weight, maintaining
equivalent electrical and heat conductivities like a Cu alloy.
Invented
The ARBed by Tsuji
clad et al. [10] inare
composites 1999, ARB is used
frequently a solid-state
in armored multi-stage process
cables, yoke including
coils in TV sets, surface
air-
cooling fin cutting,
preparation, and bus-bar conductor
stacking, joints
rolling [11].sometimes
and Kitazono etfollowed
al. [12] employed ARB to produce
by a post-rolling a closed- to
heat treatment
cell Albonding
improve foam wherein a reinforcing
quality of the stackedagentsheets.
is blown between
Figure the sheets. Fattahi
1a schematically showset al.
the[13] used ARB
process whereto two
fabricate composite filler metals of tungsten inert gas welding where the results
or more sheets are stacked together and passed through the rolls to apply plastic deformation; the revealed that the
yield strength
deformation must of welds was significantly
be enough to produce improved
a solid-statewhen employing
bonding. ARBAl2has
O3/TiC/TiO nanoparticle/Al
a great 2industrial potential
composite filler metals. A similar effort was made by Sabetghadam et al. [14]
due to a high production rate and continuous procedure. For instance, a two-layer copper/aluminum to produce ZrO 2/AZ31

nanocomposite fillers of gas tungsten arc welding. Using ARB, Dhib et al. [15] fabricated inexpensive
(Cu/Al) clad sheet composites manufactured by ARB can almost reduce 40% of weight, maintaining
composites commonly used as acid containers with a low-thickness stainless steel (for inner side)
equivalent electrical and heat conductivities like a Cu alloy.
stacked to a thick low-carbon metal (for outer side).

(a) (b)

Figure
Figure 1. 1.(a)
(a)Schematic
Schematic illustration
illustrationofofprinciples
principlesof the accumulative
of the roll bonding
accumulative (ARB) (ARB)
roll bonding process,process,
(b)
Schematic illustration of fracture and extrusion of surface layer during ARB.
(b) Schematic illustration of fracture and extrusion of surface layer during ARB.

TheToARBed
improvecladbonding quality,
composites contactingused
are frequently surfaces are to cables,
in armored be degreased andinwire-brushed
yoke coils to
TV sets, air-cooling
remove oxides or any other surface layers. As a result of rolling pressure, thickness reduction
fin and bus-bar conductor joints [11]. Kitazono et al. [12] employed ARB to produce a closed-cell Al and
frictions, a great amount of heat is generated wherein a synchronous presence of pressure and heat
foam wherein a reinforcing agent is blown between the sheets. Fattahi et al. [13] used ARB to fabricate
results in the bonding of cleaned surfaces. The interfacial bond is the consequence of mechanical and
composite filler metals of tungsten inert gas welding where the results revealed that the yield strength
atomic affinity of the sheets [16,17]. To improve bonding quality, ARB can be performed at elevated
of welds was significantly improved when employing Al2 O3 /TiC/TiO2 nanoparticle/Al composite filler
temperatures or below the recrystallization temperature. Annealing heat treatment may also be
metals. A similar
considered aftereffort
ARBwasin made
order by
to Sabetghadam
achieve strongetmetallurgical
al. [14] to produce ZrO
bonding 2 /AZ31or
[18–24] nanocomposite
improved
fillers of gas tungsten arc welding. Using ARB, Dhib et al. [15] fabricated inexpensive
formability [25]. The following section presents the underlying mechanisms and basic aspects. composites
commonly used as acid containers with a low-thickness stainless steel (for inner side) stacked to a
thick low-carbon
2. Basics metal (for outer side).
and Mechanisms
To improve bonding quality, contacting surfaces are to be degreased and wire-brushed to remove
oxides or any other surface layers. As a result of rolling pressure, thickness reduction and frictions,
a great amount of heat is generated wherein a synchronous presence of pressure and heat results in the
bonding of cleaned surfaces. The interfacial bond is the consequence of mechanical and atomic affinity
of the sheets [16,17]. To improve bonding quality, ARB can be performed at elevated temperatures or
below the recrystallization temperature. Annealing heat treatment may also be considered after ARB
in order to achieve strong metallurgical bonding [18–24] or improved formability [25]. The following
section presents the underlying mechanisms and basic aspects.
Appl. Sci. 2019, 9, 3627 3 of 32

2. Basics and Mechanisms

Bonding quality is significantly affected by ARB parameters and underling mechanisms. Ample
studies have been conducted to find out the bonding mechanisms during roll bonding process.
The following are four major theories proposed to explain the bonding mechanisms:

• Film theory;
• Energy barrier;
• Recrystallization
• Diffusion bonding.

Film theory proposes that if two clean metal surfaces are placed in very close contact, a bond will
create. The film theory is a dominant mechanism of low temperature ARB and bonding occurs when
metal surfaces are exposed and deformed to a sufficiently large value. The fracture of surface layers
and extrusion of virgin metals through the cracks have the main roles in a real contact.
The energy barrier theory proposes that even if the fresh surfaces are in contact firmly, no bond
creates; bonding precondition is to overcome an energy barrier. Parks concluded that the energy
barrier is recrystallization; however, Erdmann-Jesnitzer believed that energy barrier is diffusion [26].
Semenov [27] suggested that the energy barrier comes from the crystal mis-orientation at the contact
surfaces. His findings showed that bonding occurred for Al, Cu and silver (Ag) at the temperature of
liquid nitrogen, hence it cannot be attributed to diffusion or recrystallization. Vaidyanath et al. [28] and
Mohamed and Washburn [29] expressed that the film theory is the utmost mechanism during rolling at
low temperatures. An appropriate surface preparation technique removes oxides and contaminant
layers, creates a hardened layer, and increases surface roughness. It was expressed that brittle surface
layers of both metals are broken up during the rolling operation, and the underlying layers are then
exposed. The unveiled islands of metals are extruded and bonded together through opened cracks
owing to rolling pressure from both sides. This mechanism has been confirmed by optical and scanning
electron microscopies (SEM) [30,31]. Figure 1b depicts a simplified illustration of the film theory
wherein it is showed that at the outset, fracture of the brittle top layer is ongoing when the extrusion of
virgin metal has just been started through the cracks and no bonds are visible yet. Continuing the
rolling operation and increasing the pressure establishes a contact between the highest asperities of the
uncovered material of the two opposing surfaces to form a metallic bond. In the meantime, some other
areas are uncovered and innumerable bonds are created [32]. The investigations are still ongoing to
find a better understanding about the correct mechanism(s).
It should be noted that the aforesaid bonding mechanisms are metallurgical, however, it is thought
that an initial mechanical bonding is first originated due to a physical contact and afterwards a
strong metallurgical bond develops at the interface during ARB that may/may not be followed by a
heat-treatment process [33].

3. Parameters
ARB is affected by numerous parameters from which material type, surface characteristics as
well as rolling conditions are adjudged as most important. The present section identifies four distinct
parameters having both significant effects on bonding quality as well as being readily controllable in
practical conditions.

3.1. Materials Parameters

Material (i.e., type and extent) is likely the most important parameter in ARB. Sheet materials
considered in ARB can be divided into three different categories: (i) similar materials, (ii) dissimilar
materials and, (iii) similar/dissimilar materials with reinforcing agent. Based on Google Scholar,
Figure 2 represents the number of documents published in the period of 1999–2018 where it is evident
that early researches were almost all devoted to the ARB of similar materials. During the interval of
Appl. Sci. 2019, 9, 3627 4 of 32

2007–2010, a number of researchers used the ARB for bonding similar/dissimilar sheet composites.
The trend continued from 2011 to 2014, with a reduction in the bonding of similar materials and an
increase in2019,
Appl. Sci. the 9,bonding of dissimilar
x FOR PEER REVIEW materials with/without the addition of reinforcements. In recent 4 of 31
years, the number of studies devoted to ARB has grown significantly, and despite the increased
attention
attention to to
thethe bonding
bonding of of dissimilar
dissimilar materials,
materials, attention
attention to to
thethe bonding
bonding of of similar
similar materials
materials hashas
notnot
diminished. Therefore, in the coming years, researches in this field seem to be mostly
diminished. Therefore, in the coming years, researches in this field seem to be mostly concentrated on concentrated
on those
those dissimilar
dissimilar bonding
bonding or theor the reinforced
reinforced materials.
materials.

35
Similar materials
materials with reinforcement particles
30 Dissimilar materials
Quantity of published articles

25

20

15

10

0
1999-2006 2007-2010 2011-2014 2015-2018

Figure 2. Trend in material selection for ARB experiments based on Google Scholar.
Figure 2. Trend in material selection for ARB experiments based on Google Scholar.
To date, ~50% of the experiments carried out on the ARB of similar materials have been dedicated
To date,
to Al alloys; ~50%
other of theinexperiments
materials this categorycarried outcopper,
are steel, on thetitanium,
ARB of magnesium
similar materials
alloys have
and fewbeen
dedicated to Al alloys; other materials in this category are steel, copper, titanium,
researches have been made on miscellaneous metals such as Mo, Zr and Ni alloys. For bonding magnesium alloys
andreinforced
those few researches
similarhave been made
materials, the useonofmiscellaneous metals
Al/Al alloy sheets such over
reaches as Mo, ZrTo
80%. and
theNi alloys.
best of ourFor
bonding those
knowledge, reinforced
one of the sheet similar materials,
materials is alwaystheAluse
or of
its Al/Al
alloysalloy sheets
in more thanreaches
70% ofover 80%.dissimilar
ARBed To the best
of our process.
bonding knowledge, one of the sheet materials is always Al or its alloys in more than 70% of ARBed
dissimilar bonding process.
3.2. Surface Parameters
3.2.Mechanical
Surface Parameters
strength is significantly influenced by surface characteristics in both aspects of
cleanliness and roughness
Mechanical strength[34]. Metal sheets,
is significantly in two stages
influenced of production
by surface and maintenance,
characteristics in both aspects are of
affected by surface
cleanliness and contaminations
roughness [34].disturbing
Metal sheets,nearlyin all
twosurface-dependent
stages of production operations. Those thermalare
and maintenance,
treated sheets
affected by and the materials
surface produced
contaminations by hot forming
disturbing nearly processes possess surface
all surface-dependent contaminants,
operations. Those
e.g., oxides.treated
thermal Furthermore,
sheets lubricants used in sheet
and the materials metal forming
produced by hot processes are the other
forming processes sources
possess of
surface
surface contamination among which, grease, moisture and chemical compounds
contaminants, e.g., oxides. Furthermore, lubricants used in sheet metal forming processes are theusually remain on the
surface
other after the production,
sources acting as bonding
of surface contamination barriers,
among which,andgrease,
hence moisture
could seriously affect thecompounds
and chemical bonding
quality of ARBed
usually remain materials and, therefore,
on the surface after the must be removed.
production, acting Itaswould
bonding be wrong to think
barriers, that post
and hence could
forming cleaning processes will readily eliminate such contaminants and if they remain
seriously affect the bonding quality of ARBed materials and, therefore, must be removed. It would on the surface,
it would
be wrongweaken the that
to think bonding strength cleaning
post forming especially when rolling
processes at ambient
will readily temperatures
eliminate [35,36]. As and
such contaminants a
result, very
if they carefulonsurface
remain preparation
the surface, is required
it would weakenbefore the application
the bonding strengthofespecially
any solid state
whenbonding
rolling at
operation
ambient[37]. The removal
temperatures of contaminant
[35,36]. As a result,layers from
very material
careful surfaces
surface can be performed
preparation by chemical
is required before the
and/or mechanical
application of anytreatments.
solid state bonding operation [37]. The removal of contaminant layers from
Jamaatisurfaces
material and Toroghinejad [38] investigated
can be performed by chemical theand/or
effectsmechanical
of surface preparation
treatments.parameters such as
roughness, scratch-brushing
Jamaati and Toroghinejadon bonding quality. Scratch-brushing
[38] investigated parameters
the effects of surface encompass
preparation peripheral
parameters such as
speed, brushing
roughness, load and stiffness
scratch-brushing ongoverning surface Scratch-brushing
bonding quality. roughness. Shownparameters
in Figure 3a, increasingperipheral
encompass surface
speed, brushing load and stiffness governing surface roughness. Shown in Figure 3a, increasing
surface roughness leads to enhanced peeling strength, and increased brittleness of surface layers that
can consequently be broken easily providing more virgin layers for extruding and ensuing bonding.
On the other hand, scratch brushing both cleanses and roughens the surface layers. It grants more
asperities promoting localized shear deformation and breaks unavoidable oxide films during the roll
Appl. Sci. 2019, 9, 3627 5 of 32

roughness leads to enhanced peeling strength, and increased brittleness of surface layers that can
consequently be broken easily providing more virgin layers for extruding and ensuing bonding. On the
other hand, scratch brushing both cleanses and roughens the surface layers. It grants more asperities
promoting localized shear deformation and breaks unavoidable oxide films during the roll bonding
operation, therefore, contributing to better bonding of the two metal sheets [38–40].
Appl. Sci. 2019, 9, x FOR PEER REVIEW 5 of 31

(a) (b)

Figure3.3.(a)
Figure (a)Variation
Variationininaverage
averagepeel
peelstrength
strengthofofAlAlstrips
stripsvs.
vs.surface
surfaceroughness
roughness[38],
[38],(b)
(b)variations
variationsin
in average peel strength vs. delay time
average peel strength vs. delay time [38]. [38].

There exist
There exist different
different surface
surface preparation
preparation methods among among which
which degreasing
degreasing (for (for example
exampleinin
acetone)followed
acetone) followed byby scratch-brushing
scratch-brushing gives a far better bond strength.strength. ItIt has
hasalso
alsobeen
beenconcluded
concluded
thatbond
that bondstrength
strengthenhances,
enhances, with
with decreasing
decreasing the delay time between
between surface
surfacepreparation
preparationoperation
operation
and the consequent rolling.
and the consequent rolling. FigureFigure 3b indicates that if the
the rolling process is carried out withinthe
rolling process is carried out within thefirst
first
10min,
10 min,the
thebond
bondquality
quality isis not
not affected,
affected, however,
however, longer
longer delay reduces the bond bond strength.
strength. Jamaati
Jamaati
andToroghinejad
and Toroghinejad observed
observed that
that the
the bond
bond strength
strength significantly
significantly decreases
decreases after
after 15
15min
minof ofsurface
surface
preparation. Also, they identified two other important parameters in scratch-brushing, namelywire
preparation. Also, they identified two other important parameters in scratch-brushing, namely wire
diameterand
diameter andlength.
length.

3.3.Rolling
3.3. RollingParameters
Parameters

3.3.1.
3.3.1.Rolling
RollingReduction
Reduction
The
Themain
maindeterminant
determinant to to the
the bond
bond quality is the plastic
plastic strain
strain which
whichisisgoverned
governedby bythetherolling
rolling
reduction.
reduction. To note that that aa minimum
minimumvalue valueofofthickness
thicknessreduction,
reduction, named
named threshold
threshold reduction
reduction (Rt),(Rist ),
isrequired
requiredtotoachieve
achievesufficient
sufficientbonding.
bonding.TheTheamount
amountofofRRt tdecreases
decreaseswhen whenworking
workingtemperature
temperature
increases up
increases up totothe
therecrystallization
recrystallization temperature.
temperature. Higher
Higher than
than the
the recrystallization
recrystallizationtemperature,
temperature,
beneficialeffects
beneficial effectsof ofaccumulated
accumulated plastic
plastic deformation
deformation are removed.
removed. IfIf the
therolling
rollingtemperature
temperatureisislessless
thanhalf
than halfofofmelting
meltingtemperature,
temperature, an an acceptable
acceptable bonding
bonding quality
quality can
can bebe achieved
achievedby by50%
50%reduction
reduction
withoutrecrystallization
without recrystallization [41].
[41]. Qaudir et al. [42] investigated
investigated single
singlerolling
rollingof ofpure
pureAl Alatat300
300°C◦ Cand
and
foundthat
found thatincreasing
increasing RR resulted
resulted inin bonding
bonding toughness enhancement
enhancement especially
especiallyfor forthose
thosereductions
reductions
greaterthan
greater than47%.
47%. Similar
Similar findings were reported
reported forfor Al-Cu
Al-Cuby byYousefi
Yousefiet etal.
al.[36]
[36]and
andfor
forAl/brass
Al/brassby by
Naserietetal.
Naseri al.[43].
[43].
Asevidence
As evidencefor for mechanically
mechanically affected
affected bond
bond strength,
strength, microscopic
microscopicobservations
observationsofofTi/CuTi/Cupeeled
peeled
surface at different reductions by Hosseini and Manesh [44] showed that with increasing R,R,the
surface at different reductions by Hosseini and Manesh [44] showed that with increasing thesize
sizeof
of the
the surface
surface cracks
cracks increases
increases as as a consequenceofofthe
a consequence theincreased
increasedsurface
surface expansion.
expansion. ThisThissuggests
suggeststhatthat
total cracks area and the extent of extruded virgin metals increases which leads
total cracks area and the extent of extruded virgin metals increases which leads to extended welded to extended welded
areaand
area andenhanced
enhancedbond bondstrength
strength as as shown
shown inin Figure
Figure 4.
4.
Appl. Sci. 2019, 9, 3627 6 of 32
Appl. Sci. 2019, 9, x FOR PEER REVIEW 6 of 31
Appl. Sci. 2019, 9, x FOR PEER REVIEW 6 of 31

Figure 4. Optical microscope

microscope (OM)
(OM) images
imagesof ofthe
theTiTi(a–c)
(a–c)and
andCuCu(d–f)
(d–f) peeled
peeled surfaces,
surfaces, roll-bonded
roll-bonded at
Figure 4. Optical microscope (OM) images of the Ti (a–c) and Cu (d–f) peeled surfaces, roll-bonded
at
thethe different
different thickness
thickness reductions
reductions of 44%
of 44% (a,d),
(a,d), 56%
56% (b,e)
(b,e) andand
62%62%
(c,f)(c,f) [44].
[44].
at the different thickness reductions of 44% (a,d), 56% (b,e) and 62% (c,f) [44].

diffusion layer
As an evidence for chemically affected bond strength, Ma et al. [45] measured the diffusion
As an evidence for chemically affected bond strength, Ma et al. [45] measured the diffusion layer
width of ARBed Al/Ti sheets with different values of R and found that the diffusion layer width
width of ARBed Al/Ti sheets with different values of R and found that the diffusion layer width
increases as R increases, thus enhancing bond strength.
strength.
increases as R increases, thus enhancing bond strength.
3.3.2. Rolling
3.3.2. Rolling Temperature
3.3.2. Rolling Temperature
Temperature
ARB was
ARB was firstly
firstly performed at at elevated temperatures
temperatures [10], [10], however,
however, it is currently being carried
ARB was firstly performed
performed at elevated
elevated temperatures [10], however, ititisiscurrently
currentlybeing
beingcarried
carried
out
out at room temperatures as well. Bonding quality is usually affected directly by temperature, i.e.,
out at
at room
room temperatures
temperatures as as well.
well. Bonding quality is
Bonding quality is usually
usually affected
affected directly
directlyby bytemperature,
temperature,i.e., i.e.,
increasing
increasing temperature improves bond strength through increasing diffusion layer thickness across
increasing temperature
temperature improves
improves bond strength through
bond strength through increasing
increasing diffusion
diffusionlayerlayerthickness
thicknessacross
across
the
the interfaces as shown in Figure 5a for ARBed Al/Ti samples. The rolling temperature significantly
theinterfaces
interfaces as as shown
shown in in Figure
Figure 5a for ARBed
5a for ARBed Al/Ti
Al/Ti samples.
samples. The Therolling
rollingtemperature
temperaturesignificantly
significantly
affects bonding
affects bonding strength
strengthand andoverall
overall strength.
strength. Although
Although the the aim
aim is to is to increase
increase overall
overall strengthstrength
using
affects bonding strength and overall strength. Although the aim is to increase overall strength using
using temperature,
temperature, it can it can
also also
reduce reduce
the the overall
overall strength
strength by by activating
activating factors
factors such
such as
as recovery
recovery and
and
temperature, it can also reduce the overall strength by activating factors such as recovery and
recrystallization. Despite
recrystallization. Despite the fact fact that recovery
recovery is is unavoidable
unavoidable at at low
low temperatures,
temperatures, the the rolling
rolling must
must
recrystallization. Despite the the fact that
that recovery is unavoidable at low temperatures, the rolling must
be
be performed
beperformed
performed belowbelow
below the the recrystallization
the recrystallization temperature (i.e.,
temperature (i.e.,
recrystallization temperature below
(i.e.,below
belowthe the half
thehalf
halfofof melting
ofmelting point)
meltingpoint) avoiding
point)avoiding
avoiding
the
the elimination
elimination of
of beneficial
beneficial
the elimination of beneficial effects
effects of
of accumulated
accumulated plastic deformations. It should
plastic deformations. It should be kept inin
plastic deformations. It should be
be kept
kept inmind
mind
mind
that
that if the
thatififthe other
theother involving
otherinvolving parameters,
involving parameters, such as material
parameters, such as material
material andand reduction
and reduction percentage,
reductionpercentage,
percentage,cause cause a high
causeaahigh quality
highquality
quality
bonding
bonding between
bondingbetween
between the the sheets
the sheets without increasing
sheets without increasing the
the temperature,
the temperature,the
temperature, the finalstrength
thefinal
final strengthwill
strength will begreater
willbe
be greaterdue
greater due
due
to
to the
tothe reduction
reduction of
thereduction of the
of the aforementioned
the aforementioned deteriorating
aforementioned factors.
deteriorating factors.
deteriorating factors.

(a)
(a) (b)
(b)
Figure 5. Cont.
Appl. Sci. 2019, 9, 3627 7 of 32
Appl. Sci. 2019, 9, x FOR PEER REVIEW 7 of 31

(c) (d)

Figure 5.
Figure 5. (a)
(a) Variation
Variation in
in diffusion
diffusion layer
layerwidth
widthwith
withrolling
rollingtemperature
temperatureforforARBed
ARBed Al/Ti
Al/Tisheets
sheets [45],
[45],
(b) Influence
(b) Influenceofofboth
both rolling
rolling temperature
temperature andand
roll roll
speedspeed on bond
on bond toughness
toughness of Al[42],
of Al strips strips
(c) [42], (c)
Variation
Variation
of ambientoftensile
ambient tensile properties
properties of with
of 8011 alloy 8011 increasing
alloy with the
increasing the strain
equivalent equivalent strain and
in RT-ARB in RT-ARB
HT-ARB
and HT-ARB samples [46], (d) Ultimate bending strength of the ARBed Al/AZ31
samples [46], (d) Ultimate bending strength of the ARBed Al/AZ31 at different temperatures [47]. at different
temperatures [47].
Quadir et al. [42] studied the peeling behavior of ARBed Al sheets where an increase in ARB
Quadir leads
temperature et al. [42]
to anstudied
increasethe in peeling behavior
bond strength of ARBed
in term Al sheets
of toughness where5b).
(Figure an increase in ARB
They emphasized
temperature
that leadselevation
a continuous to an increase in bond
in bond strength
strength does in term
not of toughness
guarantee (Figure improvement
a continuous 5b). They emphasized
in overall
that a continuous elevation in bond strength does not guarantee a continuous improvement
strength; i.e., performing ARB at higher temperatures (especially above recrystallization temperatures) in overall
strength; i.e., performing ARB at higher temperatures (especially above
may lead to a reduction in final strength. Xing et al. [48] reported the effect of rolling temperature onrecrystallization
temperatures)
final strength ofmay leadAA8011
ARBed to a reduction
where in final
they strength.
showed thatXing
afteret al.strains
the [48] reported theroom
of ~4.8 at effecttemperature,
of rolling
temperature on final strength of ARBed AA8011 where they showed
the ultimate tensile strength (UTS) of ARBed samples started to decrease due to dynamic that after the strains ofrecovery.
~4.8 at
room temperature, the ultimate tensile strength
◦ (UTS) of ARBed samples
For HT-ARB specimens preheated at 200 C before each cycle, dynamic recrystallization and started to decrease due to
static
dynamic recovery. For HT-ARB specimens preheated at 200 °C before
and dynamic recovery may cause a reduced UTS at lower strains and also lower strength compared each cycle, dynamic
recrystallization
to those samplesand static
rolled at and dynamic
ambient recovery may
temperature. Zhan cause a reduced
et al. [46] alsoUTS at lowera strains
observed reductionand in
also
the
lower strength compared to those samples rolled at ambient temperature.
final strength of ARBed AZ31 alloy with increased rolling temperature (Figure 5c). Also, Abbasi andZhan et al. [46] also
observed a reduction in the final strength of ARBed AZ31 alloy with increased rolling temperature
Sajjadi [47] studied both aspects of the rolling temperature effects on mechanical strength wherein the
(Figure 5c). Also, Abbasi and Sajjadi [47] studied both aspects of the rolling temperature effects on
bending behavior of ARBed Al/AZ31 sheets rolled at different temperatures was examined. As shown
mechanical strength wherein the bending behavior of ARBed Al/AZ31 sheets rolled at different
in Figure 5d increasing the rolling temperature from 250 to 300 ◦ C enhanced the bending strength;
temperatures was examined. As shown in Figure 5d increasing the rolling temperature from 250 to
however, further increase to 350 and 400 ◦ C resulted in a reduction due to the recrystallization and
300 °C enhanced the bending strength; however, further increase to 350 and 400 °C resulted in a
microstructural refinement.
reduction due to the recrystallization and microstructural refinement.
3.3.3. Rolling Speed
3.3.3. Rolling Speed
Decreasing the rolling speed usually results in stronger bonding because the bonding quality is
Decreasing the rolling speed usually results in stronger bonding because the bonding quality is
greatly affected by the diffusion of adjacent materials and the time of synchronized contact-pressure.
greatly affected by the diffusion of adjacent materials and the time of synchronized contact-pressure.
Depending on material type, surface features and rolling temperature, there might therefore be a
Depending on material type, surface features and rolling temperature, there might therefore be a
threshold value of rolling speed above which an acceptable bonding is not guaranteed. As shown
threshold value of rolling speed above which an acceptable bonding is not guaranteed. As shown
before in Figure 5b, Quadir et al. [42,49] investigated the effect of roll speed on strength of Al strips at
before in Figure 5b, Quadir et al. [42,49] investigated the effect of roll speed on strength of Al strips
elevated temperatures. While scattered data was produced at high rolling temperatures, the effects
at elevated temperatures. While scattered data was produced at high rolling temperatures, the effects
of rolling speed on bond strength are undeniable, therefore, data presented so far cannot provide a
of rolling speed on bond strength are undeniable, therefore, data presented so far cannot provide a
definite relationship between strength and roll speed and it needs further investigation since it has a
definite relationship between strength and roll speed and it needs further investigation since it has a
significant influence on production time.
significant influence on production time.
3.3.4. Rolling Friction
3.3.4. Rolling Friction
Most of ARB researches have been performed without lubricants. Shown in Figure 6a Jamaati and
Most of ARB researches have been performed without lubricants. Shown in Figure 6a Jamaati
Toroghinejad [32] performed ARB at different friction coefficients with lubricant, and in dry and rough
and Toroghinejad [32] performed ARB at different friction coefficients with lubricant, and in dry and
surface conditions where the average peel strength increased when the friction coefficient increased
rough surface conditions where the average peel strength increased when the friction coefficient
Appl. Sci. 2019, 9, 3627 8 of 32
Appl. Sci. 2019, 9, x FOR PEER REVIEW 8 of 31

between thebetween
increased strips and
the rolls
stripsprobably
and rollsdue to thedue
probably increased mean contact
to the increased meanpressure betweenbetween
contact pressure the outer
layers and the rolls.
the outer layers and the rolls.

(a) (b)

Figure6.6.(a)
Figure (a)Average
Averagepeel
peelstrength
strength versus
versus the
the reduction
reduction in
in three
threefrictional
frictionalconditions,
conditions,i.e.,
i.e.,rough,
rough,dry
dry
and lubricated surface conditions [32], (b) Hardness of ARBed 4N-Cu with and without lubrication
and lubricated surface conditions [32], (b) Hardness of ARBed 4N-Cu with and without lubrication [50].
[50].
The effect of lubricant on mechanical properties of ARBed Cu was studied by Miyajima et al. [50]
where The
theyeffect of lubricant
concluded that, if on
themechanical properties
surface friction of ARBed
is reduced Cu wasthe
by lubricant, studied by Miyajima
deformation et al.
is treated as a
[50] where they concluded that, if the surface friction is reduced by lubricant, the deformation
plane strain compression, of which equivalent strain is about 0.82; nonetheless, higher frictions usually is
treated
exert as astrains
larger plane adjacent
strain compression,
to the surfaceof which equivalent
and hence enhance strain is about 0.82;evolution
microstructural nonetheless, higher
close to the
frictions usually exert larger strains adjacent to the surface and hence enhance
surface being described as an additional shear strain. The additional shear strain is mostly created microstructural
onevolution close
the surface, soto
thethe surface beingeffect
corresponding described
is moreas pronounced
an additionalatshear strain. Of
this region. Thecourse,
additional shearbe
it should
strain is mostly created on the surface, so the corresponding effect is more pronounced
noted that additional shear strain still exists inside the ARBed materials as the central points were atat this region.
Of course, it should be noted that additional shear strain still exists inside the ARBed materials as the
surface points before the last roll bonding steps; finally, grain refinement was accelerated in case no
central points were at surface points before the last roll bonding steps; finally, grain refinement was
lubricant was used due to the additional shear strain [50].
accelerated in case no lubricant was used due to the additional shear strain [50].
As shown in Figure 6b, at earlier ARB cycles, hardness value increases to ~140 Hv at surface layers
As shown in Figure 6b, at earlier ARB cycles, hardness value increases to ~140 Hv at surface
when no lubrication is consumed; the hardness of the other samples reaches to ~120 Hv. The hardness
layers when no lubrication is consumed; the hardness of the other samples reaches to ~120 Hv. The
at the surface of ARBed sample without lubrication seems to be constant, whereas for the other sections
hardness at the surface of ARBed sample without lubrication seems to be constant, whereas for the
(center and quarter) increases gradually with increasing cycle number and then saturate. The reason
other sections (center and quarter) increases gradually with increasing cycle number and then
why the hardness at surface layers is almost always higher than those of inner regions is due to the
saturate. The reason why the hardness at surface layers is almost always higher than those of inner
additional grain refinement caused by the friction between the sheets and rolls.
regions is due to the additional grain refinement caused by the friction between the sheets and rolls.
3.3.5. Number of Layers
3.3.5. Number of Layers
Regarding the number of stacked sheets, Jang et al. [51] investigated the strength of ARBed 2-
Regarding the number of stacked sheets, Jang et al. [51] investigated the strength of ARBed 2- or
or 3-layer Cu sheets wherein tensile strength is dominantly determined by applied equivalent strain
3-layer Cu sheets wherein tensile strength is dominantly determined by applied equivalent strain as
as well as the materials strength; ARBed samples followed a similar trend up to a critical point. Past
well as the materials strength; ARBed samples followed a similar trend up to a critical point. Past the
the mentioned
mentioned critical
critical point,
point, tensile
tensile strength
strength is is solely
solely determined
determined byby thedynamic
the dynamicrecovery
recoveryrate
rateunder
under
SPD
SPDconditions.
conditions. Regarding
Regarding the the number
number of of layers,
layers, Lee
Lee et
et al.
al. [52]
[52] observed
observedaasimilar
similarbehavior
behaviorfor forIFIF
steel. They also studied the effects of post ARB annealing on strength. According to
steel. They also studied the effects of post ARB annealing on strength. According to Figure 7, besides Figure 7, besides
the
thegradual
gradualdecrease
decreasein inthe
thestrength
strength during
during annealing, they stated
annealing, they statedthat
thatthe
thedecrease
decreaseininstrength
strengthwith
with
annealing is larger in six-layer stack ARBed specimen than in two-layer stack
annealing is larger in six-layer stack ARBed specimen than in two-layer stack ARBed one and ARBed one and attributed
this to the difference
attributed this to theindifference
total strainin(or stored
total strainenergy) where
(or stored the amount
energy) where theof total strain
amount was larger
of total strain in
was the
Appl. Sci.
Appl. Sci. 2019, 9, x3627
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32

larger in the six-layer stack ARB comparing to the two-layer one. Therefore, the released energy
six-layer stack ARB comparing to the two-layer one. Therefore, the released energy during annealing
during annealing would be larger in the six-layer stack ARBed sample, resulting in larger decrease
would be larger in the six-layer stack ARBed sample, resulting in larger decrease in the strength during
in the strength during annealing treatment.
annealing treatment.

Figure 7. Changes in mechanical properties with annealing temperature of IF steel processed by three
cycles of
Figure six-layer stack
7. Changes ARB compared
in mechanical to the
properties results
with of a two-layer
annealing one [52].
temperature of IF steel processed by three
cycles of six-layer stack ARB compared to the results of a two-layer one [52].
3.3.6. Reinforcement Particles
3.3.6.From
Reinforcement Particles
a perspective, the sheets produced by ARB, can be divided into monolithic, composite and
metal matrix composite (MMC) forms; the latter is usually produced with the addition of reinforcing
From a perspective, the sheets produced by ARB, can be divided into monolithic, composite and
agents. Using ARB, MMCs can be produced by uniform distribution of strengthening additives
metal matrix composite (MMC) forms; the latter is usually produced with the addition of reinforcing
between the sheets. The effect of these additives in terms of shape, geometry, size, material, and
agents. Using ARB, MMCs can be produced by uniform distribution of strengthening additives
volume fraction can be investigated. Alizadeh and Paydar [53] studied the effects of SiC particles
between the sheets. The effect of these additives in terms of shape, geometry, size, material, and
on the mechanical properties of Al strips. At first, they used a peeling test to find out the effect
volume fraction can be investigated. Alizadeh and Paydar [53] studied the effects of SiC particles on
of carbide particles on the bond strength and also to measure the minimum reduction required for
the mechanical properties of Al strips. At first, they used a peeling test to find out the effect of carbide
achieving an acceptable bond between the two strips. For one-cycle ARBed specimens, their results
particles on the bond strength and also to measure the minimum reduction required for achieving an
are presented in Figure 8a,b. The results show that SiC decreases peeling force at constant reduction
acceptable bond between the two strips. For one-cycle ARBed specimens, their results are presented
since SiC prevents the extrusion of virgin material through interfacial cracks; therefore, bonding area
in Figure 8a,b. The results show that SiC decreases peeling force at constant reduction since SiC
and consequently bond strength decreases. As a result, while using SiC, the bonding is not successful
prevents the extrusion of virgin material through interfacial cracks; therefore, bonding area and
unless thickness reduction is sufficiently high, i.e., 66% (with SiC) and 50% (without) reductions in
consequently bond strength decreases. As a result, while using SiC, the bonding is not successful
thickness are required. In addition, their results showed that reinforcement would reduce the bond
unless thickness reduction is sufficiently high, i.e., 66% (with SiC) and 50% (without) reductions in
strength in the first ARB cycle. Shown in Figure 8c,d, it was concluded that the UTS of the Al/SiC
thickness are required. In addition, their results showed that reinforcement would reduce the bondp
metal matrix composite can be improved by increasing the number of rolling cycles up to seventh
strength in the first ARB cycle. Shown in Figure 8c,d, it was concluded that the UTS of the Al/SiCp
cycle; it is then saturated for higher cycles. The microstructural evaluation indicates that by increasing
metal matrix composite can be improved by increasing the number of rolling cycles up to seventh
the number of cycles, the uniformity of SiC particles increases and porosity decreases.
cycle; it is then saturated for higher cycles. The microstructural evaluation indicates that by increasing
Another observation made by researchers was that the Al/SiC composite specimen exhibit lower
the number of cycles, the uniformity of SiC particles increases andp porosity decreases.
strength than the monolithic one before three ARB cycles, which confirms the fact that for an acceptable
composite production using ARB a minimum number of cycles is necessary to decrease the amount of
porosity and to reach a balanced distribution of particles in the metal matrix. Although SiC addition
had a positive effect on the strength of ARBed specimens, the elongation to failure decreased.
Appl. Sci. 2019, 9, 3627 10 of 32
Appl. Sci. 2019, 9, x FOR PEER REVIEW 10 of 31

(c) (d)

Figure8.8.Variation
Figure Variationofofpeeling
peelingforce
forcein
inARBed
ARBed Al-1050
Al-1050 strips,
strips, (a)
(a) in
in presence
presence and
and (b)
(b) in
in absence
absenceofofSiC
SiC
particles[53],
particles [53],(c)
(c)tensile
tensilestrength
strengthof
ofcomposite
composite and
and monolithic
monolithic samples
samples versus
versus number
numbercycles
cyclesand
and(d)
(d)
stress–straincurve
stress–strain curveofofasasreceived
receivedand
andARBed
ARBedsamples
samplesafter
after seven
seven cycles
cycles [53].
[53].

Anotherand
Rezayat observation
Akbarzadeh made
[54] by researchers
examined was of
the effect that the Al/SiC
alumina p composite
particles on the Rtspecimen
of pure Alexhibit
sheets
lower strength than the monolithic one before three ARB cycles, which confirms
(Figure 9). They indicated that Rt increases to 45% in the presence of the alumina particles compared the fact that for an
acceptable
with the Rt of composite
20% being production
needed forusing ARB a minimum
the bonding of Al sheets number
underofthecycles
sameisconditions
necessaryattributing
to decreaseit
tothe
theamount
frictionofcoefficient
porosity and to reach
reduction a balanced
and the needdistribution of particles
for longer channel in the metal
extrusion matrix.
of virgin metalAlthough
surfaces
SiC addition had a positive effect on
through the cracks in the presence of a powder layer.the strength of ARBed specimens, the elongation to failure
decreased.
Jamaati and Toroghinejad [55] investigated the effect of volume fraction on the strength of MMCs
producedRezayat
by ARBandfor
Akbarzadeh [54] examined
pure Al reinforced the effect
by different of alumina
weight particles
percentages on the Rt of
of anodized Alpure
strips.AlBesides
sheets
(Figure 9). They indicated that R t increases to 45% in the presence of the alumina particles compared
the strength enhancement provided by the SPD, mechanical strength could be significantly improved
bywith the Rt of alumina
reinforcing 20% being neededused
particles for the bonding
in the of Al sheets
host material. underbe
It should thenoted
samethat
conditions attributing
strain hardening it
and
to the friction
dislocation coefficient reduction
strengthening play a keyand rolethe
inneed for longer
strength channel extrusion
enhancement for ARBedofmonolithic
virgin metal surfaces
specimens.
through the cracks in the presence of a powder layer.
For the reinforced ARBed MMC specimens, the particles act as a barrier against dislocation movement
and crack growth. Similar result for the enhanced strength with increasing volume fraction of particles
has been reported in all researches conducted on the ARB produced composites [56–58]. Liu et al. [56]
showed that after increasing the volume fraction of tungsten by 2.8%, further increase in strength is
not realized [59].
Appl. Sci. 2019, 9, 3627 11 of 32
Appl. Sci. 2019, 9, x FOR PEER REVIEW 11 of 31

Figure 9. Average peel strength versus the thickness reduction [54].

Jamaati and Toroghinejad [55] investigated the effect of volume fraction on the strength of
MMCs produced by ARB for pure Al reinforced by different weight percentages of anodized Al
strips. Besides the strength enhancement provided by the SPD, mechanical strength could be
significantly improved by reinforcing alumina particles used in the host material. It should be noted
that strain hardening and dislocation strengthening play a key role in strength enhancement for
ARBed monolithic specimens. For the reinforced ARBed MMC specimens, the particles act as a
barrier against dislocation movement and crack growth. Similar result for the enhanced strength with
increasing volume fraction of particles has been reported in all researches conducted on the ARB
produced composites [56–58].
Figure Liu etpeel
9. Average al.strength
[56] showed thatthickness
versus the after increasing
thickness reduction the volume fraction of
reduction [54].
[54].
tungsten by 2.8%, further increase in strength is not realized [59].
Jamaati et
Jamaati andal.Toroghinejad
[60] studied the [55]influence
investigatedof particle sizeofon
the effect the properties
volume fraction on of ARBed IF steel
the strength of
composites
MMCs produced
composites using SiC
using SiCARB
by micro-
micro- and
forand
pure nano-particles.
Al reinforcedFigure
nano-particles. Figure1010
by differentdemonstrates that
weight percentages
demonstrates that thethe tensile strength
of anodized
tensile strength Al
of
of MMCs
strips.
MMCs containing
Besides
containing nanoparticles
thenanoparticles
strength is is
farfarbetter
enhancement better thanthose
provided
than those strengthened
by strengthened
the by microparticles
SPD, mechanical
by microparticles owing be
strength owing
could to
extremely higher matrix/reinforcement interfaces in nanoparticles, and hence leading
significantly improved by reinforcing alumina particles used in the host material. It should be noted to higher local
that strain density,
dislocation hardening refined
and grain size and
dislocation improved mechanical
strengthening play a keyperformance.
role in strength enhancement
Furthermore, for
particle
breaking is a damaging
ARBed monolithic factor where
specimens. For thelarger particlesARBed
reinforced tend to MMC
crack more readilythe
specimens, andparticles
composites act with
as a
microparticles
microparticles display reduced
barrier against display
dislocation movement
strength. Also, growth.
and Also,
crack hardening
hardening effects
Similar might
result
effects might be
for be important
theimportant
enhanced as the length
strength with
increasing
scale of the volume fraction of particles
stress inhomogeneities, which hasarebeen
on thereported
order ofinthe
allparticle
researches
size,conducted
is analogous ontothe ARB
typical
microstructural
produced composites lengths.[56–58]. Liu et al. [56] showed that after increasing the volume fraction of
tungsten by 2.8%, further increase in strength is not realized [59].
Jamaati et al. [60] studied the influence of particle size on the properties of ARBed IF steel
composites using SiC micro- and nano-particles. Figure 10 demonstrates that the tensile strength of
MMCs containing nanoparticles is far better than those strengthened by microparticles owing to
extremely higher matrix/reinforcement interfaces in nanoparticles, and hence leading to higher local
dislocation density, refined grain size and improved mechanical performance. Furthermore, particle
breaking is a damaging factor where larger particles tend to crack more readily and composites with
microparticles display reduced strength. Also, hardening effects might be important as the length
scale of the stress inhomogeneities, which are on the order of the particle size, is analogous to typical
microstructural lengths.

Figure 10. Tensile strength of ARBed pure IF steel, composite and nanocomposite versus number of
cycles [60].

In spite of extensive research on the aforementioned parameters, the effect of other rolling
parameters, such as rolling direction, layer thickness and roll diameter, on the properties of ARBed
sheets have not yet been fully understood and further research are required in this area.

3.3.7. Post-Heat Treatment

The formability of ARBed materials is generally poor due to limited ductility. To address this
problem, post ARB heat treatment is a viable choice. For materials deformed more than a certain
Figure 10. Tensile strength of ARBed pure IF steel, composite and nanocomposite versus number of
cycles [60].
sheets have not yet been fully understood and further research are required in this area.

3.3.7. Post-Heat Treatment

The formability of ARBed materials is generally poor due to limited ductility. To address this
Appl. Sci. 2019, 9, 3627 12 of 32
problem, post ARB heat treatment is a viable choice. For materials deformed more than a certain level
of strain, a transition in annealing behavior occurs from the conventional recrystallization (i.e.,
nucleation
level anda growth),
of strain, transitiontypically
in annealingobserved
behavior for occurs
samples fromdeformed to medium/large
the conventional strains, to
recrystallization a
(i.e.,
process of and
nucleation extended
growth), recovery,
typicallywhere a continuous
observed for samples microstructural coarsening isstrains,
deformed to medium/large observed [61,62].
to a process
Strain
of has a recovery,
extended significantwhere effectaon the recovery
continuous rate of thosecoarsening
microstructural materials deformed
is observed by[61,62].
very large values
Strain has
aofsignificant
strain. A effect
fast recovery
on the recoveryrate inratethe ofform
thoseofmaterials
structural coarsening
deformed maylarge
by very enhance
values nucleation;
of strain.
Anevertheless,
fast recovery the fastinstructural
rate the form of coarsening
structuralincoarsening
the material mayaround
enhanceany nuclei reduces
nucleation; the driving
nevertheless, the
forcestructural
fast for its growth,
coarsening i.e., in
a the
competitive effects any
material around between
nucleithe growth
reduces theofdriving
nucleiforce
and for
theits
structural
growth,
coarsening
i.e., that might
a competitive effectsbebetween
influenced by different
the growth parameters,
of nuclei e.g., processing
and the structural conditions,
coarsening that mightsolutebe
content, intermetallics, as well as annealing treatment parameters [63].
influenced by different parameters, e.g., processing conditions, solute content, intermetallics, as well as
Shengtreatment
annealing et al. [11] evaluated[63].
parameters the influence of annealing treatment on the interface of Cu/Al
composite
Sheng fabricated by one-cycle
et al. [11] evaluated cold rolling.
the influence As shown
of annealing in Figure
treatment on11,
theitinterface
is clear that an appropriate
of Cu/Al composite
heat treatment
fabricated may greatly
by one-cycle improve
cold rolling. bonding
As shown quality
in Figure 11,and high that
it is clear bond an strength
appropriatecanheat
be treatment
achieved
(annealing
may greatlyat 423 K bonding
improve for 20 h).quality
In fact,andrelatively
high bond low annealing
strength temperature
can be and shortattime
achieved (annealing 423 Kheatfor
treatment
20 significantly
h). In fact, relatively low improves
annealing thetemperature
bond strength. On time
and short the other hand, thesignificantly
heat treatment strength drastically
improves
reduces
the bond at higherOn
strength. annealing
the othertemperature
hand, the strength or longer treating
drastically timeatdue
reduces higherto annealing
the growth of brittle
temperature
intermetallic
or compounds
longer treating time due thattodeteriorates
the growth the ductility
of brittle of final products.
intermetallic compounds It wasthat
alsodeteriorates
shown in other the
research [64] that the formability of ARBed sheets are enhanced by annealing
ductility of final products. It was also shown in other research [64] that the formability of ARBed sheets to realize both
recrystallization
are enhanced by and interlayer
annealing diffusion.
to realize both recrystallization and interlayer diffusion.

Figure 11. Peeling

Figure 11. Peeling force
force of
ofCu/Al/Cu
Cu/Al/Cuclad
cladsheet
sheetwith
withdifferent
differentheat
heattreatment temperatures
treatment or or
temperatures times of
times
heat processing [11].
of heat processing [11].

Some
Some studies
studies used
used post
post ARB
ARB aging
aging process
process asas aa way
way ofof enhancing
enhancing the the strength
strength of age hardenable
of age hardenable
sheets. For example, Rezaei et al. [65] investigated the mechanical properties
sheets. For example, Rezaei et al. [65] investigated the mechanical properties and microstructural and microstructural
features
features ofofARBed
ARBed 6061 Al followed
6061 Al followedby ageing treatment
by ageing and reported
treatment that boththat
and reported the UTS
bothandtheelongation
UTS and
values increased after an ageing operation at two temperatures
elongation values increased after an ageing operation at two temperatures (337 K and (337 K and 437 K) for437
different
K) for
rolling cycles (i.e., 0–5 cycles). The results obtained revealed the competing
different rolling cycles (i.e., 0–5 cycles). The results obtained revealed the competing effects of effects of recovery
and precipitation
recovery involvedinvolved
and precipitation during during
the ageing process,
the ageing i.e., dislocation
process, density
i.e., dislocation decreases
density decreasesduedue
to
recovery while precipitation occurs during the ageing contributing to the UTS
to recovery while precipitation occurs during the ageing contributing to the UTS enhancement and enhancement and strain
hardening. Based on
strain hardening. the results
Based on theobtained, it was shown
results obtained, thatshown
it was the contribution to strength improvement
that the contribution to strength
by precipitation is higher than the loss of strength due to recovery
improvement by precipitation is higher than the loss of strength due to recovery as both the UTS andthe
as both elongation
UTS and
values were enhanced.
elongation values were enhanced.
4. Properties
Bond strength and peeling strength are the two most important properties recognized for ARBed
samples while other characteristics such as superplasticity, damping, wear, corrosion, cyclic behavior
as well as chemical, physical and thermal behaviors have also been reported in the literature. In the
present section, mechanical behaviors of ARBed materials are discussed.
Appl. Sci. 2019, 9, 3627 13 of 32

4.1. Strength and Ductility

Measuring yield stress (YS), ultimate tensile strength (UTS) and elongation (El) are the basic
indicators of strength and ductility of ARBed materials. Since there are some differences in strengthening
mechanisms of similar, dissimilar and reinforced sheet materials during ARB, the effect of ARB on
strength and ductility is discussed in three different sections.

4.1.1. Sheets with Similar Materials

As mentioned earlier, improved strength and reduced ductility usually occurs after the ARB
process; however, Xing et al. [66] investigated ARBed AA8011 at elevated temperatures wherein the YS
and UTS only increased up to 2 cycles and then decreased; in contrast, the elongation diminished up to
2 cycles and then increased. Strengthening AA8011 alloy can be attributed to solid solution hardening,
precipitation hardening, grain refinement and strain hardening. It was reported that dynamic recovery
and static recovery easily takes place in Al–Fe alloys and the microstructural evaluations of AA8011
disclosed that the grain refinement contributes to strength enhancement only after the first cycle.
The precipitation of Si particles was found to be an effective strengthening factor for AA8011 at 200 ◦ C,
nonetheless, a reduction in the concentration of precipitates may lessen the strength after a specific
amount of precipitations probably leads to a decrease in strength with increasing ARB cycles. Having
the ability of precipitation hardening, dynamic and static recovery may be considered as weakening
factors for high cycle ARB, confirmed by these researchers later in another research work where they
scrutinized the ARB of AA8011 at room temperature and observed that increasing the number of
cycles resulted in the increased strength [48]. Hence, increasing or decreasing strength or ductility by
increasing the cycles is affected by the competing effects of the strain hardening and grain refinement
on one side and the recovery on the other side.
Similarly, with an increase in tensile strength after each ARB cycle, abrupt decreases in elongation
after the first cycle are reported for alloys like AA6061 [67,68], AA1100 [69], AA5083 [70], AA1050 [71]
and Mg alloy [72]. Similar to Al8011, however, a gradual increase in elongation after initial cycles
is reported, suggesting that the strain hardening can not solely explain the mechanical properties
variation observed for the ARBed metals and alloys; instead, it is caused by dynamic and probably
static recovery of a heavily deformed structure. In addition, the aforementioned behavior is also
reported for Cu and its alloys [73,74], AA5052 [75], AA6014 [76], AA7075 [77], AA2024 [78] and pure
Ti [79–81]. It is noteworthy that few articles have also reported simultaneous improvement in strength
and ductility. Naseri et al. [82] proposed a new strategy for the simultaneous increase in both strength
and ductility of AA2024 where after each ARB cycle, an annealed AA2024 strip is laid between the two
roll-bonded strips resulting in a composite with a bimodal microstructure consisting of coarse and
ultrafine elongated grain structures.

4.1.2. Sheets with Dissimilar Materials

Based on the search made by the authors, although Zhang and Acoff [83] first produced ARBed
dissimilar materials, the first seminal study on the mechanical properties of ARBed composite sheets
seems to be reported by Eizadju et al. [84], where the mechanical properties of multi-layered Al/Cu
composite were investigated. The main goal was to fabricate an ARBed Al/Cu composite with better
mechanical properties than those achieved from ARBed Al or ARBed Cu only. Demonstrated in
Figure 12, the strengths of both ARBed Al/Al and Al/Cu composites have a striking increase compared
to the commercial pure Cu and Al. In contrast, elongation of ARBed samples has considerably
decreased compared to pure samples. It was noted that Al/Cu composites demonstrate higher strength
than ARBed Al/Al while the elongations are almost the same.
Appl.
Appl.Sci.
Sci.2019,
2019,9,9,xxFOR
FORPEER
PEER REVIEW
REVIEW 1414ofof3131

considerably
Sci. 2019, 9,decreased
considerably
Appl. decreased
3627 compared
compared to
to pure samples. It
pure samples. It was
was noted
noted that
thatAl/Cu
Al/Cucomposites
compositesdemonstrate
demonstrate
14 of 32
higher
higherstrength
strengththan
than ARBed
ARBed Al/Al
Al/Al while the elongations
while the elongations are
are almost
almostthe
thesame.
same.

(a)
(a) (b)
(b)

Figure12.
Figure 12.(a) Yield
(a)Yield strength
Yieldstrength
strengthand
andtotal
totalelongation of Cu,
ofof
elongation Cu, Al, ARBed
Al,Al,
Cu, ARBed
ARBedAl, and
Al,Al, ARB
andandARB Al/Cu
Al/Cu
ARB composite,
composite,
Al/Cu (b)
(b)
composite,
engineering
engineering
(b) engineeringstress–strain
stress–strain curves
curves
stress–strain for for
curves ARBed Al/Cu
ARBed composite
composite
Al/Cu compositewith
with cycles
cycles
with [84].
[84].
cycles [84].

As
Asseen,
seen,the
seen, thestrength
the strength
strength varied considerably
varied
varied considerably after after
each ARB
after eachcycle
each ARBwhere
ARB cyclethe
cycle variations
where
where the are controlled
the variations
variations are
are
controlled
by two main by two main
strengthening strengthening
mechanisms; mechanisms;
i.e., strain i.e., strain
hardening hardening
by by
dislocations
controlled by two main strengthening mechanisms; i.e., strain hardening by dislocations and grain dislocations
and grain and grain
refinement.
refinement.
In In the
the early cycles,
refinement. In thework
earlyhardening
early cycles, work
cycles, work hardening
was hardening
the proponent, was the
waswhilethe proponent, while
in higher cycles,
proponent, whileUFGin
in higher cycles,
structure
higher UFG
appeared
cycles, UFG
structure
to have a appeared
dominant to have a dominant
strengthening role. strengthening
Like other role.
ARBed Like other
materials,
structure appeared to have a dominant strengthening role. Like other ARBed materials, elongation ARBed
elongationmaterials,
usuallyelongation
decreases
usuallydecreases
intensively
usually decreases
after the intensively aftertothe
first cycle due
intensively after the first
thefirst cycle
reduced due
due to to the
cycle dislocation the reduced
mobilitydislocation
reduced as well as few
dislocation mobility
shear as
mobility aswell
bands asas
well[85].
fewshear
With
few shear bands [85].
an increasing
bands [85].
numberWithof
With ancycles
an increasing number
after the
increasing of
of cycles
first cycle,
number after
after the
elongation
cycles first
firstcycle,
theincreases due
cycle, elongation
to increase
elongation increases
in bond
increases
due to
strength increase in bond strength between matrix and reinforcement,
due to increase in bond strength between matrix and reinforcement, since the Cu layersto
between matrix and reinforcement, since the Cu layers act as since the
reinforcementCu layers
due act asas
their
act
reinforcement
fracture duringdue
reinforcement due
higherto their fracture
ARBfracture
to their cycles as during higher
can behigher
during seen inARB
ARB cycles
Figure as
13. as
cycles can
A can be
similar seen in Figure
trendininFigure
be seen 13.
changing A similar
13. Astrength
similar
trend
and
trend inchanging
in changing
elongation strength
during
strength and
ARBand elongation
cycles is reported
elongation during
duringfor ARB
ARB cycles
Al/Ti is
is reported
[86], Al/Zn
cycles for
forAl/Ti
[87], Al/Ni
reported [88],[86],
Al/Ti Al/Zn
Cu/Ni
[86], [89][87],
Al/Zn and
[87],
Al/Ni [88],
AA1050/AA6061 Cu/Ni [89]
[90] and
ARBed AA1050/AA6061
composites. [90]
Al/Ni [88], Cu/Ni [89] and AA1050/AA6061 [90] ARBed composites. ARBed composites.

Figure 13. Scanning electron microscope (SEM) micrograph of ARB processed Al/Cu composite cross
Figure
Figure 13.(a)Scanning
13.
sections
electron microscope (SEM) micrograph of ARB processed Al/Cu composite cross
primary sandwich, (b) 1st cycle, (c) 2nd cycle and (d) 5th cycle [84].
sections
sections (a) primary sandwich, (b)
(a) primary sandwich, (b) 1st
1st cycle,
cycle, (c)
(c) 2nd
2nd cycle
cycle and
and (d)
(d) 5th
5th cycle
cycle [84].
[84].
Sun et al. [91] studied the ARBed Cu/Zr multi-stacks and could achieve an enhanced tensile
Sun
Sun et
et al. [91] studied the
the ARBed Cu/Zr multi-stacks and
and could achieve an enhanced tensile
strength as al.
ARB[91] studied
cycles increasedARBed
due toCu/Zr multi-stacks
microstructural couldAs
refinement. achieve
shownaninenhanced
Figure 14a,tensile
the
strength
strength as ARB cycles
as improved increased
ARB cyclesupincreased due to
due and microstructural
to microstructural refinement. As shown in Figure 14a, the
elongation to six cycles then decreased refinement.
with furtherAs shownininnumber
increase Figure of
14a,
ARBthe
elongation
elongation improved
improved up
upto six
to cycles
six and
cycles then
and decreased
then with
decreased further
with increase
further in number
increase in of
numberARBof cycles.
ARB
cycles. For those samples processed for less than six cycles, fractography revealed formation of
For those
cycles. Forsamples
those processed for less than six cycles, fractography revealed formation of successive
successive cracks samples
along theprocessed
interface for less
between than
the six
Cu cycles,
and Zr fractography
layers due torevealed formation
the inhomogeneous of
cracks along the interface between the Cu and Zr layers due to the inhomogeneous
successive cracks along the interface between the Cu and Zr layers due to the inhomogeneous microstructure and
strength differences between Cu and Zr. Zr is relatively hard and therefore only Zr layers sustain the
 Appl. Sci. 2019, 9, x FOR PEER REVIEW 15 of 31
Appl. Sci. 2019, 9, 3627 15 of 32

microstructure and strength differences between Cu and Zr. Zr is relatively hard and therefore only
Zr layers sustain the external load and thus fracture quickly after the yield point. Different
external load and thus fracture quickly after the yield point. Different deformation behaviors lead to
deformation behaviors lead to the separation of dissimilar layers; nonetheless, the mentioned
the separation of dissimilar layers; nonetheless, the mentioned mechanical difference gradually reduces
mechanical difference gradually reduces and this considerably postpones final failure. As a result,
and this considerably postpones final failure. As a result, the elongation moderately increases to reach a
the elongation moderately increases to reach a maximum value at six cycles. Similar trend has been
maximum value at six cycles. Similar trend has been reported for Al/Zn [92] and Al/Cu/Mn [93]. ARBed
reported for Al/Zn [92] and Al/Cu/Mn [93]. ARBed composites, however, still further research is
composites, however, still further research is required to investigate ARB of dissimilar materials since
required to investigate ARB of dissimilar materials since inconsistent trends are sometimes reported
inconsistent trends are sometimes reported related to the strength and elongation variation [94–96].
related to the strength and elongation variation [94–96].

(a) (b)

Figure14.
Figure 14. (a)
(a) Variation
Variation of
of stress–strain
stress–strain curves
curves of
of the
the ARBed
ARBed Cu/Zr
Cu/Zr materials
materialsversus
versusARB
ARBcycles;
cycles;
elongationincreases
elongation increasesupuptotosix
sixcycles
cycles [91],
[91], (b)
(b) engineering
engineering stress–strain
stress–straincurves
curvesfor
forstarting
startingAl,
Al,ARBed
ARBed
pureAlAlafter
pure aftersixth
sixthcycle
cycleand
andAl/Cu composite within
Al/Cupp composite within different
different cycles
cycles of
of ARB
ARBprocess
process[97].
[97].

4.1.3.
4.1.3.Sheets
Sheetswith
withReinforcements
Reinforcements
Metalmatrix
Metal matrixcomposites
composites(MMCs)(MMCs) can can be synthesized
synthesized using
using ARB
ARBmethod
methodby byplacing
placingreinforcing
reinforcing
agentbetween
agent betweenthethesheets.
sheets. Kitazono
Kitazono et al. [12] initially
initially used
used ARB
ARBto toproduce
produceAl Alfoams
foamsby bydispersing
dispersing
particlesbetween
particles betweenAlAl sheets.
sheets. Cheng
Cheng et [98]
et al. al. [98]
andand Alizade
Alizade and and Paydar
Paydar [53] used
[53] used ARB to ARB to produce
produce MMCs.
MMCs. Amirkhanlu et al. [99] produced Al/Al O cast composite and Ardakani et
Amirkhanlu et al. [99] produced Al/Al2 O3p cast composite and Ardakani et al. [100] fabricated Al/SiCp
2 3p al. [100] fabricated
Al/SiCp composite,
composite, both simultaneous
both reporting reporting simultaneous
enhancement enhancement
in strength and in strength and ductility
ductility with increasingwith
ARB
increasing ARB cycles. It should be noted that strengthening mechanisms of the
cycles. It should be noted that strengthening mechanisms of the ARBed composites are not exclusively ARBed composites
are nottoexclusively
limited limited to
those mentioned thosefor
earlier mentioned earlier
other types for other
of ARB, i.e.,types
ARBed of ARB, i.e.,orARBed
similar similar
dissimilar or
sheets;
dissimilar sheets; however, they are also attributed
however, they are also attributed to the following items: to the following items:
a. Reinforcement particles acting as barrier against dislocation movement. The first mechanism is
a. Reinforcement particles acting as barrier against dislocation movement. The first mechanism
the strengthening effect since adding reinforcements to a metal matrix significantly improve
is the strengthening effect since adding reinforcements to a metal matrix significantly improve
mechanical strength due to dislocation pile up around the particles [101,102].
b. mechanical strength due
Improved uniformity to dislocation pile
of reinforcements. up around
When the particlesdistribution
the reinforcement [101,102]. becomes more
b. Improved
uniform and uniformity of reinforcements.
homogeneous, When the reinforcement
the stress concentration distribution
sites reduces enhancing becomes
the more
mechanical
uniform and homogeneous,
response [103,104]. the stress concentration sites reduces enhancing the mechanical
c. response
Improved[103,104].
bonding quality at the matrix/particle interfaces. Regardless of volume fraction, size,
c. Improved
shape and bonding quality
the spatial at the matrix/particle
distribution, the mechanical interfaces.
propertyRegardless of volume
greatly depends upon fraction, size,
how well
shape andapplied
externally the spatial
loaddistribution,
is transferredthe mechanicalmaterials,
to reinforcing propertyi.e.,
greatly depends
stronger uponadhesion
interfacial how well
enhances load
externally transfer
applied load iscapacity leading
transferred to improved
to reinforcing mechanical
materials, performance
i.e., stronger [105].adhesion
interfacial Better
interfacial load
enhances adhesion maycapacity
transfer be obtained through
leading increasingmechanical
to improved ARB cyclesperformance
[53]. Also, porosity may
[105]. Better
have detrimental
interfacial adhesioneffects
mayonbebonding
obtained quality between
through the reinforcing
increasing ARB cycles agents
[53].and theporosity
Also, host matrix
may
where the interfacial adhesion may be lowered by porosity causing interfacial
have detrimental effects on bonding quality between the reinforcing agents and the host matrix debonding. When
pores are
where the located at the
interfacial particle-matrix
adhesion interface,
may be lowered byparticles
porosity are debonded
causing fromdebonding.
interfacial the matrix even
When
pores are located at the particle-matrix interface, particles are debonded from the matrix even
Appl. Sci. 2019, 9, 3627 16 of 32

under low stress [106]. Last but not least, porosity tends to reduce effective cross-section area
and hence adversely affect mechanical strength [107].

Using reinforcing particles in the ARB process has an ability to enhance mechanical strength.
For instance, Alizade and Talebian [97] compared ARBed Al/Cup with monolithic Al where a significant
improvement in both strength and ductility was observed (Figure 14b). Increasing ARB cycles further
enhanced strength and ductility due to increased adhesion strength between the Al matrix and Cu
particles. Moreover, the ARB process boosted the uniformity of Cu clusters and could limit the
porosity as confirmed by microstructural investigation. Similar trend was seen for the ARBed Al
5083/SiCp [108], Al-Al2 O3 /SiCp [59,109], Al-Al2 O3 /B4 Cp hybrid composite produced by anodizing [110],
coated Al–Cu–25Ni/SiCp [111], Al-Al2 O3 /ZrCp [112], Cu/Graphenep [113] and Al/Al2 O3p [114] where
significant strength improvement as well as increased ductility are simultaneously reported. According
to Rezayat et al. [115], alumina particles enhance the YS, UTS and the elastic modulus, but the elongation
falls drastically attributing mostly to plastic zone created around the reinforcing particles.

4.2. Thermal Stability

Heat treatment such as annealing process may considerably improve the mechanical properties of
ARBed materials if appropriate temperature and time are chosen, particularly for SPDed materials
with high level of stored energy. Intensive grain growth and loosing UFG structures are the results of
improper annealing.
Park et al. [116] investigated the thermal stability of ARBed 6061 Al alloy where the grain size
and microhardness were studied at different annealing temperatures. It can be seen in Figure 15 that
grain size and hardness were relatively unchanged and uniformly distributed below the annealing
temperature of 473 K. In contrast, for the samples annealed at temperatures above 473 K, bimodal
grain size was observed including coarse grains and UFG. Considering the low activation energy of
grain growth for the ARBed specimens, they emphasized that the non-equilibrium characteristics of
grain boundaries of UFG alloy leads to the existence of ill-defined grain boundaries; hence, it can be
postulated that the thermal stability of the ARB produced UFG materials depends mostly on the state
of the SPD microstructure.
Slamova et al. [117] studied the thermal stability of ARBed Al-Fe-Mn-Si sheets at elevated
temperatures (see Figure 16) using the hardness as a function of annealing temperatures. In all
specimens, the hardness remains nearly constant at annealing temperatures of <200 ◦ C, but then drops
more rapidly, especially for cold-rolled specimens. The different annealing responses of ARBed and
cold-rolled samples might be justified by discrepancies in stored deformation energy providing driving
force for recrystallization. Furthermore, the nucleation and growth of new grains are more rapid in
cold-rolled samples than that of elevated temperature ARBed ones.
For ARBed samples roll bonded at 250 ◦ C, the most pronounced reduction in hardness occurs at
250 ◦ C in the specimen with six ARB cycles, whereas in the one with two cycles, a gradual hardness
diminution is observed when the annealing temperature is raised within the range 200–350 ◦ C.
In contrast to the ARBed specimens with two cycles, the sheets roll bonded by six ARB cycles required
a considerably higher temperature of 450 ◦ C to achieve fully softened material. In the specimens roll
bonded at 350 ◦ C, the greatest drop is shifted to 350 ◦ C, therefore, softening due to the annealing
treatment of the ARBed samples depends on the strain induced by the ARB as well as the recovery
influenced by the ARB temperature. The results of the hardness measurements thus indicate that the
ARBed stacks processed at 350 ◦ C or by six cycles at 250 ◦ C are most thermally stable.
Appl. Sci. 2019, 9, x FOR PEER REVIEW 17 of 31
Appl.Sci.
Appl. Sci.2019,
2019,9,9,3627
x FOR PEER REVIEW 17of
17 of32
31

Figure 15. Grain size and microhardness of ARBed 6061 Al alloy under different annealing
Figure 15. Grain size and microhardness of ARBed 6061 Al alloy under different annealing
temperatures [116].
Figure 15. Grain
temperatures [116]. size and microhardness of ARBed 6061 Al alloy under different annealing
temperatures [116].

Hardness versus
Figure 16. Hardness versus the annealing
annealing temperature
temperature of ARBed Al-Fe-Mn-Si
Al-Fe-Mn-Si sheets with (a) two
cycles, (b) six cycles at 250 ◦ C (), 300 ◦ C (N) and 350 ◦ C (×) and in cold-rolled condition (♦) [117].
Figure 16. Hardness versus °C the
(■), annealing
°C (▲)temperature
and 350 °C (×)
of ARBed Al-Fe-Mn-Si sheets with(◊) (a) two
cycles, (b) six cycles at 250 °C (■), 300 °C (▲) and 350 °C (×) and in cold-rolled condition (◊) [117].
4.3. Superplasticity
For ARBed samples roll bonded at 250 °C, the most pronounced reduction in hardness occurs at
250 °C in ARBed
Despite
For thethespecimen
fact thatwith
samples the six
rollmainARB
bonded cycles,
property
at 250of°C, whereas
the ARB
the inmaterials
most the one with
pronouncedis thetwo cycles,inimprovement
significant
reduction a hardness
gradual hardness
in the
occurs at
diminution
static
250 °Cstrength,
in theis specimen
observed whensix
it is also expected
with theARBannealing
that the temperature
resulting
cycles, whereas UFG is one
in product
the raised
may
withwithin theimproved
exhibit
two range
cycles, 200–350 °C. In
superplastic
a gradual hardness
contrast
deformation
diminutionto the ARBed
isbehavior.
observed specimens
Inwhen
1999,the with
Tsuji ettwo
annealingal. cycles,
[118] the sheets
who
temperature is roll
invented bonded
ARB,
raised bythe
six range
published
within ARB cycles
research required
regarding
200–350 °C. In
a considerably
the superplasticity
contrast higher
to the ARBed temperature
of ARBed
specimensAl–Mg of
with 450
alloy. °C to achieve
twoConstitutive fully softened
relationship
cycles, the sheets material. In the
in superplasticity
roll bonded specimens
by six ARB cyclesindicates roll
that
required
bonded
grain at 350 °C,
refinement
a considerably the temperature
would
higher greatest
result drop ofis450
in both shifted
an°C to to
increase 350
in °C,
achieve therefore,
strain
fully rate and
softened softening due
a decrease
material. In intosuperplasticity
the the annealing
specimens roll
treatment
temperature, of the
so itARBed
can be samples
concluded depends
that on
the the
ARB strain
improves induced by
superplasticthe
bonded at 350 °C, the greatest drop is shifted to 350 °C, therefore, softening due to the annealing ARB as well
deformation as the recovery
behavior. Their
results indicated
treatment of the lowARBed temperature superplasticity
samples depends on thedue to ultra-fine
strain induced by grain
the refinement
ARB as well after ARB.
as the recovery
4.4. Damping
Having both high damping capacity and high strength is important for structural materials that
are subjected to dynamic loading conditions; nonetheless, an increase in damping is usual
Appl. Sci. 2019, 9, 3627 18 of 32
accompanied by a decrease in strength. It is evident that the SPD produces high strength metals
through producing UFG microstructures, furthermore, severely deformed materials typically contain
4.4. Damping lattice defects giving rise to internal friction or material damping. Having a high density
innumerable
of grain boundaries formed by SPD is another reason for UFGed materials to have high damping
Having both high damping capacity and high strength is important for structural materials that
properties.
are subjected to dynamic loading conditions; nonetheless, an increase in damping is usual accompanied
Koizumi et al. [119] investigated the damping capacity of ARBed UFG Al samples where a
by a decrease in strength. It is evident that the SPD produces high strength metals through producing
torsional pendulum apparatus was used to measure the internal friction values versus the strain
UFG microstructures, furthermore, severely deformed materials typically contain innumerable lattice
amplitudes. Both ARBed pure Al sheets exhibited high damping capacity as well as high strength
defects giving rise to internal friction or material damping. Having a high density of grain boundaries
attributing to the vibration of the dislocations whose ends are tightly bonded with grain boundaries
formed by SPD is another reason for UFGed materials to have high damping properties.
of the ultrafine grains and hence could attenuate vibrational energies. Emadoddin et al. [120]
Koizumi et al. [119] investigated the damping capacity of ARBed UFG Al samples where a torsional
explored the damping behavior of ARBed Al/SiCp multilayer composites and extracted the first-mode
pendulum apparatus was used to measure the internal friction values versus the strain amplitudes.
damping capacity as a function of amount of reinforcing particles(Figure 17). Increasing the amount
Both ARBed pure Al sheets exhibited high damping capacity as well as high strength attributing to
of reinforcement led to increased damping capacity and that the obtained values of the reinforced
the vibration of the dislocations whose ends are tightly bonded with grain boundaries of the ultrafine
samples were greater than monolithic Al6061 alloy specimens due to internal friction caused by SiC
grains and hence could attenuate vibrational energies. Emadoddin et al. [120] explored the damping
and its accompanying modification effects on the matrix microstructure. Based on the microstructural
behavior of ARBed Al/SiCp multilayer composites and extracted the first-mode damping capacity as a
studies, a lot of holes, detachments, weak imperfect bonding were observed at the interface between
function of amount of reinforcing particles(Figure 17). Increasing the amount of reinforcement led
the reinforcements and the host metal matrix, all contributing to damping capacity enhancement
to increased damping capacity and that the obtained values of the reinforced samples were greater
[121]. It was also found that increasing ARB cycles, the number of layers, thickness reduction ratios
than monolithic Al6061 alloy specimens due to internal friction caused by SiC and its accompanying
and temperatures leads to better damping capacity [120].
modification effects on the matrix microstructure. Based on the microstructural studies, a lot of holes,
Zheng et al. [121] studied the damping capacity of ARBed Al/LLZNOp composites at different
detachments, weak imperfect bonding were observed at the interface between the reinforcements and
temperatures where the damping capacity improved when the ARB cycles increased reaching its
the host metal matrix, all contributing to damping capacity enhancement [121]. It was also found that
highest value after 10 ARB cycles at 320 K, being 4.5 times higher than that of monolithic samples.
increasing ARB cycles, the number of layers, thickness reduction ratios and temperatures leads to
They attributed the increase in damping capacity to the uniform distribution of LLZNO particles and
better damping capacity [120].
better bonding strength between the particles and the matrix material.

(a) (b)

Figure 17. (a) First mode damping capacity of sheets with different percent of reinforcing agent [120].
(b) Damping capacity of Al/LLZNOp composites at different temperatures and ARB cycles [121].

Zheng et al. [121] studied the damping capacity of ARBed Al/LLZNOp composites at different
temperatures where the damping capacity improved when the ARB cycles increased reaching its
highest value after 10 ARB cycles at 320 K, being 4.5 times higher than that of monolithic samples.
They attributed the increase in damping capacity to the uniform distribution of LLZNO particles and
better bonding strength between the particles and the matrix material.

4.5. Fracture Toughness

UFG materials processed by ARB may not be applied in industrial applications if they exhibit
poor fracture response. Research on the fracture behavior of UFG structures reports that different
materials exhibit varied fracture behaviors, i.e., it could improve or reduce after a SPD operation.
Rahmatabadi et al. [122], for the first time, experimentally evaluated the ARB effects one the plane
stress fracture toughness of Al 1050 and showed that the values of fracture toughness improves
by increasing the number of ARB cycles. As shown in Figure 18, fracture toughness reaches to a
 4.5. Fracture Toughness
UFG materials processed by ARB may not be applied in industrial applications if they exhibit
UFG materials processed by ARB may not be applied in industrial applications if they exhibit
poor fracture response. Research on the fracture behavior of UFG structures reports that different
poor fracture response. Research on the fracture behavior of UFG structures reports that different
materials exhibit varied fracture behaviors, i.e., it could improve or reduce after a SPD operation.
materials exhibit varied fracture behaviors, i.e., it could improve or reduce after a SPD operation.
Rahmatabadi et al. [122], for the first time, experimentally evaluated the ARB effects one the plane
Rahmatabadi
Appl. et al. [122], for the first time, experimentally evaluated the ARB effects one the19plane
Sci. 2019, 9, 3627 of 32
stress fracture toughness of Al 1050 and showed that the values of fracture toughness improves by
stress fracture toughness of Al 1050 and showed that the values of fracture toughness improves by
increasing the number of ARB cycles. As shown in Figure 18, fracture toughness reaches to a
increasing the number of ARB cycles. As shown in Figure 18, fracture toughness reaches to a
maximum
maximum value
value of
of 25.4
25.4 MPa.m
MPa.m
1/2 after performing seven cycles, i.e., 155% enhancement compared to
1/2 after performing
performing seven
maximum value of 25.4 MPa.m after 1/2 seven cycles,
cycles, i.e.,
i.e., 155%
155% enhancement
enhancement compared
compared to
to
the
the annealed
annealed specimens.
specimens.
the annealed specimens.

Figure 18. Plane stress fracture toughness of the ARBed Al 1050 specimens for different cycles [122].
Figure 18.
Figure 18. Plane
Plane stress fracture toughness
stress fracture toughness of
of the
the ARBed
ARBed Al
Al 1050
1050 specimens
specimens for
for different
differentcycles
cycles[122].
[122].

Strength and ductility are the main influencing parameters on fracture toughness. In initial ARB
Strength and
Strength and ductility
ductility are
are the
the main
main influencing
influencing parameters
parameterson onfracture
fracturetoughness.
toughness. InIn initial
initial ARB
ARB
cycles, the effect of strength enhancement is more pronounced than the ductility reduction; then the
cycles, the
cycles, the effect
effect of
of strength
strength enhancement
enhancement is is more
more pronounced
pronounced than
than the
the ductility
ductility reduction;
reduction; then
then the
the
ductility reduction becomes severe. However, after an ample rise in ARB cycles, ductility values are
ductility reduction
ductility reduction becomes
becomes severe.
severe. However, after
after an
an ample
ample rise
rise in
in ARB
ARB cycles,
cycles, ductility
ductility values
values are
are
resumed again and therefore, fracture toughness re-increase [122–124].
resumed again
resumed again and
and therefore,
therefore,fracture
fracturetoughness
toughnessre-increase
re-increase[122–124].
[122–124].
4.6.
4.6. Wear
4.6. Wear
Wear
Wear
Wear properties can can be tailored using ARB process to meet the end tribological requirements.
Wear properties
properties can be be tailored
tailored using
using ARB
ARB process
process to
to meet
meet the
the end
end tribological
tribological requirements.
requirements.
Talachi
Talachi et
et al.
al. [125],
[125], observed
observed that
that thethe wear
wear rate
rate of of ARBed
ARBed pure
pure Al Al sheets
sheets increases
increases gradually
gradually with with
ARB
Talachi et al. [125], observed that the wear rate of ARBed pure Al sheets increases gradually with
ARB
cycles cycles
as shownas shown in
in Figure Figure 19.
19. The19. The
wear wear resistance was increased up to the third cycle due to
ARB cycles as shown in Figure Theresistance was increased
wear resistance up to theup
was increased third cycle
to the duecycle
third to hardness
due to
hardness
increase increase and then reduced due to poor strain hardening capability [126]. The wear rate
hardnessand then reduced
increase and then due to poordue
reduced strain
to hardening
poor straincapability
hardening[126]. The wear
capability rateThe
[126]. increment at
wear rate
increment
the first at the
cycle can first
be cycle can be
attributed to attributed to
decreasing decreasing
ductility [85].ductility [85].
increment at the first cycle can be attributed to decreasing ductility [85].

Figure 19. Variation of wear rate versus number of ARB cycles [125].
Figure 19. Variation of wear rate versus number of ARB cycles [125].
Figure 19. Variation of wear rate versus number of ARB cycles [125].
Wear observed in samples subjected to higher ARB cycles seem to occur by the mechanisms other
than those usually observed in a lower number of cycles. After the third cycle, wear rate increased
progressively due to the creation of high energy and unstable grain boundaries and high angle grain
boundaries. These boundaries were reported to have low recrystallization temperature, they can easily
rotate or coalesce when a large local strain is imposed (as in a wearing surface) leading to a rapid
growth of the recrystallized grains at the subsurface. There would be a strain mismatch between the
wearing surface with large recrystallized grains and the rest with non-equilibrium UFG structure.
This is the cause for the delamination of the deformed layers that may result in high wear rates [126].
Darmiani et al. [127] investigated the wear resistance of ARBed pure Al/SiCp nanocomposite and
 angle grain boundaries. These boundaries were reported to have low recrystallization temperature,
they can easily rotate or coalesce when a large local strain is imposed (as in a wearing surface) leading
to a rapid growth of the recrystallized grains at the subsurface. There would be a strain mismatch
between the wearing surface with large recrystallized grains and the rest with non-equilibrium UFG
structure.
Appl. Sci. 2019,This is the cause for the delamination of the deformed layers that may result in high 20
9, 3627 wear
of 32
rates [126]. Darmiani et al. [127] investigated the wear resistance of ARBed pure Al/SiCp
nanocomposite and measured weight loss and friction coefficient. According to Figure 20a, it can be
measured
seen that weight loss and
the friction frictionofcoefficient.
coefficient a monolithicAccording
Al sampleto Figure 20a,
is larger it can
than be seen
ARBed thatp composite
Al/SiC the friction
coefficient of a monolithic Al sample is larger than ARBed
and that increasing ARB cycles leads to reduced friction coefficient Al/SiC composite and that increasing ARB
p owing to the fact that SiC particles
cycles
act as leads to reduced
solid lubricant frictionthe
reducing coefficient owing
temperature to the
at the fact that
contacts SiC particles
between the wornact as solid
surface andlubricant
the test
reducing
pin. the temperature at the contacts between the worn surface and the test pin.

(a) (b)

Figure20.
Figure 20.(a)
(a)Wear
Wearbehavior
behaviorof
of ARBed Al/SiCpp nanocomposites
ARBed Al/SiC nanocompositesprocessed
processedbybydifferent
differentrolling
rollingcycles,
cycles,
(b)wear
(b) wearbehavior
behaviorofofmonolithic
monolithicmaterial
materialand
andseven-cycle
seven-cycle ARBed Al/Al22O
ARBed Al/Al O33 composite
compositeversus
versussliding
sliding
distance[127].
distance [127].

Jamaatietetal.
Jamaati al.[128]
[128]studied
studiedthe
thewear
wearbehavior
behavior of of nanostructured
nanostructured Al/Al
Al/Al22O3p3p composite
compositeproduced
produced
by an ARB process. Figure
by an ARB process. Figure 20b shows20b shows the variations of weight
weight loss versus the sliding distanceof
loss versus the sliding distance of
ARBedmonolithic
ARBed monolithic and composite
compositesamples.
samples.The The ARBARBprocess causes
process an increase
causes in weight
an increase loss ofloss
in weight bothof
monolithic
both monolithicand and
composite
compositespecimens
specimens compared
compared withwithas-received
as-received strip,
strip,hence
hencereducing
reducingwearwear
resistance. Wear resistance was also decreased with an increase in number of ARB
resistance. Wear resistance was also decreased with an increase in number of ARB cycles. Wear contains cycles. Wear
acontains a combination
combination of three mechanisms
of three mechanisms of abrasion, of adhesion
abrasion, and
adhesion and delamination;
delamination; at a higheratnumber
a higher of
number
ARB of ARB
cycles, cycles, delamination
delamination remains as remains
the mainaswearthe main wear mechanism.
mechanism. The nature Theof nature
laminatedof laminated
structure
structure
helped helped
further further delamination
delamination during the during
wear testtheandwear test
that and that the
eliminates eliminates
grain sizetheeffect
grainonsize
theeffect
wear
on the wear
resistance. resistance.
Although adhesive,Although adhesive,
abrasive and abrasive
delaminating wearand delaminating
mechanisms wear mechanisms
simultaneously happened
insimultaneously
the composite,happened in the composite,
surface damage surface
resulting from thedamage resulting from
plastic deformation ofthe plastic
ARBed deformation
composite was
of ARBed composite was more widespread than the monolithic material.
more widespread than the monolithic material. It was shown that both delamination and It was shown that both
spalling
delamination
mechanisms and spalling
occurred in themechanisms occurred
composite, while it wasin just
the composite, while itmechanism
the delamination was just the delamination
that occurred in
mechanism that occurred
the monolithic samples. in the monolithic samples.

4.7.Corrosion
4.7. Corrosion
Materialswith
Materials with high
high microstructural
microstructural defects,
defects, such
such as as those
those UFG
UFG structures
structuresproduced
producedby byARB,
ARB,
usually have low corrosion resistance, however, it is still controversial to say that UFG
usually have low corrosion resistance, however, it is still controversial to say that UFG materials materials have
a poor
have corrosion
a poor resistance
corrosion in in
resistance comparison
comparison with
with their
theirpolycrystalline
polycrystallinecounterparts.
counterparts.The
Thecorrosion
corrosion
resistance of UFG materials depends on their alloy system and corrosive medium. Wei etal.
resistance of UFG materials depends on their alloy system and corrosive medium. Wei et al.[129]
[129]
investigated the corrosion behavior of UFG Al–Mn alloy produced by an ARB operation. Theresults
investigated the corrosion behavior of UFG Al–Mn alloy produced by an ARB operation. The results
showedthat
showed that the
the size
size and
andthethenumber
numberofof
pitting corrosion
pitting corrosion sites observed
sites on the
observed onmaterial are less
the material arethan
less
those coarse grain (CG) counterparts. The corrosion potential of UFG alloy was
than those coarse grain (CG) counterparts. The corrosion potential of UFG alloy was more positivemore positive than
than that of CG samples and the current density was much lower by ~33%. Immersed in 3.5% NaCl
solution for 168 h, UFG Al alloy retained nearly unchanged tensile strength, while the degradation
of total elongation was significant. Uniform pits formation was attributed to the energy balance
between non-equilibrium grain boundaries and intragranular defects as well as reduction in particle
size. The results showed that UFG Al–Mn alloy exhibit better resistance in than CG samples in 3.5%
NaCl solution.
Darmiani et al. [130] studied the corrosion behavior of ARBed Al/SiCp nanocomposite and found
that the corrosion resistance in both the surface and cross section of samples was enhanced for higher
Appl. Sci. 2019, 9, 3627 21 of 32

number of ARB cycles. In addition, the corrosion resistance of surface samples was relatively better
than those obtained from the cross samples for a specific ARB cycle. Kadkhodaee et al. [131] evaluated
the corrosion of ARBed Al/nano-SiO2p nanocomposite sheets where the corrosion resistance strongly
weakened after the first cycle but gradually resumed when the number of ARB cycles increased.
The grain boundaries were found not to be active sites rather than grains causing the formation of
more uniform and denser passive oxide layers on the specimens. In other research conducted by
Fattah-Alhosseini et al. [132], the corrosion behavior of finely dispersed and highly uniform ARBed
Al/B4C-SiCp hybrid composite in 3.5 wt.% NaCl solution was examined and it was shown that
performing ARB leads to a lower corrosion current density of the fabricated hybrid composites as well
as ARBed un-reinforced samples. Employing the ARB also led to a higher polarization resistance in
all samples.

4.8. Fatigue
The response of materials under cyclic loading is one of the main materials selection criteria in
both engineering and biomedical applications. Investigation of fatigue response of ARBed materials is,
therefore, critical for validating their reliable use in various applications. In general, the fatigue limit
has been recognized to be half of the tensile strength in smooth specimens [133–135]. Fatigue limit
and fatigue strength usually become greater when the tensile strength improves. On the other hand,
the dependence of the fatigue limit on the tensile strength is not necessarily linear and monotonic, so
one has to prudently check the fatigue limit and strength when the tensile strength jumps markedly.
As discussed in the previous section, ARB successfully enhances the tensile behavior of metallic
materials, nonetheless, the fatigue crack resistance of the ARBed materials has rarely been investigated.
Kwan and Wang [136] investigated the cyclic deformation behavior of UFG Cu processed by ARB
and found that the conventional equiaxial grains are able to accommodate a fraction of the applied
cyclic plastic strain through the development of slip bands within them due to the composite nature
of the as-received ARBed Cu. Furthermore, grain coarsening was observed when the samples were
subjected to cyclic loading both in load controlled and strain controlled tests. It was assumed that
grain coarsening ultimately cause cyclic creep and cyclic softening behaviors observed via the increase
in volume fraction of large-sized grains with a capability of developing slip bands within them.
Figure 21 shows a S-N diagram of the ARBed AA1050A/AA5005 composites with different ARB
cycles and monolithic reference materials [137] wherein the fatigue life of the N4 composite (i.e.,
composite with 4 ARBed cycles) is very similar to the N8 composite at higher strain amplitudes.
At smaller strain amplitudes, however, the N8 sample has significantly higher fatigue lives. Fatigue
lives and damage mechanisms of both the N4 and N8 samples depend on the number and thickness of
layers and thus the number of cycles, particularly at the lower amplitudes, where a noticeable grain
coarsening of the AA1050A occurs. At higher amplitudes, the N8 sample is slightly shorter than the
N4 sample whereas the fatigue life of the N8 one is considerably higher than the N4 samples at lower
amplitudes. This can be attributed to the different crack growth behavior of the composite at different
amplitudes. The fatigue life of the N12 composite is significantly improved compared to the N4 and
N8. The samples fail at an equal number of fatigue cycles as the UFG AA5005 monomaterial sheet.
Their evaluations revealed that the microstructure and the hardness of N12 composite is rather similar
to that of the AA5005 monomaterial; thus, it is not surprising that the fatigue lives are rather similar as
well. At higher total strain, the maximum stress in the AA1050A layers increase to magnitudes more
than the yield strength of AA1050A; therefore, AA1050A experiences plastic deformation whereas the
AA5005 layers does not.
Appl. Sci. 2019, 9, x FOR PEER REVIEW 22 of 31

magnitudes more than the yield strength of AA1050A; therefore, AA1050A experiences plastic
Appl. Sci. 2019, 9, 3627 22 of 32
deformation whereas the AA5005 layers does not.

Figure 21. Total

Figure 21. Total strain
strain fatigue
fatigue life
life diagram
diagram of
of the
the composites
composites processed
processed by
by different
different numbers
numbers of
of ARB
ARB
cycles,
cycles, ARB
ARB processed
processedAA1050A
AA1050Aand andAA5005
AA5005mono-material
mono-materialsheets
sheets[137].
[137].

Besides
Besidesthe thefatigue
fatiguestrength,
strength, LinLinet al.et [138] emphasized
al. [138] emphasized on theon fatigue crack initiation
the fatigue and growth
crack initiation and
in ARBed IF steel. As the hardness increment has been empirically
growth in ARBed IF steel. As the hardness increment has been empirically understood to enhance understood to enhance fatigue
strength, they expected
fatigue strength, a positive
they expected effect of effect
a positive UFG microstructures
of UFG microstructures on the fatigueon thecrack resistance
fatigue in terms
crack resistance
of
in terms of crack closure. Plasticity-induced crack closure (PICC), roughness-induced crack (RICC),
crack closure. Plasticity-induced crack closure (PICC), roughness-induced crack closure closure
transformation-induced
(RICC), transformation-induced crack closure,
crackoxidation-induced crack closure,
closure, oxidation-induced cracketc closure,
are someetc of the
aremechanisms
some of the
of the fatigueof
mechanisms crack closure;crack
the fatigue however,
closure; thehowever,
degrees of thePICC
degreesand ofRICC
PICC changes
and RICC withchanges
UFG refinement.
with UFG
PICC occurs due to the formation of compressive residual stresses
refinement. PICC occurs due to the formation of compressive residual stresses in the plastic in the plastic wake while RICCwakeis
due
whileto RICC
the deflection
is due toof thecrack paths and
deflection is related
of crack pathstoand theismorphology
related to the of morphology
microstructures and grain sizes.
of microstructures
As demonstrated
and grain sizes. in Figure 22a, the fatigue limit for the CG and UFG steels was, respectively,
140 MPa and 300 MPa where the differences in the fatigue limit and
As demonstrated in Figure 22a, the fatigue limit for the CG and UFG steels was, respectively, life were attributed to hardness or
tensile
140 MPa strength
and 300 since
MPa the fatigue
where thelimit is governed
differences in the byfatigue
both yield
limitstress
and life andwere
workattributed
hardening. to Cycles
hardness to
failure versus stress amplitude normalized by hardness is shown in Figure
or tensile strength since the fatigue limit is governed by both yield stress and work hardening. Cycles 22b and fatigue lives of the
ARBed steel
to failure werestress
versus practically
amplitudeidentical to the CG
normalized bysteel.
hardness is shown in Figure 22b and fatigue lives of
Figure steel
the ARBed 22c shows the crack growth
were practically identical curves
to theofCGthe steel.
CG and ARBed steels, respectively, at the stress
amplitudes of 180 MPa and 400 MPa.
Figure 22c shows the crack growth curves of the CG Fatigue crack growth (FCG) rate
and ARBed steels,of respectively,
the CG steelat wasthelower
stress
compared
amplitudes to of
the180UFG in short-crack
MPa and 400 MPa. region; but, in
Fatigue the long-crack
crack growth (FCG) region, ratetheofFCG
the rate
CG of thewas
steel UFGlower
steel
was lower in whole fatigue range at both stress amplitudes. The lower
compared to the UFG in short-crack region; but, in the long-crack region, the FCG rate of the UFG FCG rate in ARBed sample in
long-crack region resulted in longer fatigue life at similar conditions
steel was lower in whole fatigue range at both stress amplitudes. The lower FCG rate in ARBed compared with the CG specimen;
the higher
sample in FCG rate of the
long-crack CG resulted
region steel was,ininlongerfact, attributed
fatigue life to the crack coalescence.
at similar conditions The lower FCG
compared withrate
the
of the CG steel in short-crack regime was attributed to RICC. Also,
CG specimen; the higher FCG rate of the CG steel was, in fact, attributed to the crack coalescence. they stated that grain refinement
might affectFCG
The lower PICC ratebehavior
of the CG because
steel in of short-crack
the change regime in crackwas tip plastic
attributed zone toconfirming
RICC. Also,the theyfactstated
that
the
thatorigin
grainofrefinement
the high FCG might rates in the
affect PICClong-crack
behavior regime
because in the CG steel
of the change is associated
in crack tip with the crack
plastic zone
coalescence,
confirming the which factisthat
the the
consequence
origin of of thelowhighresistance
FCG rates to crack
in theinitiation.
long-crack Additionally,
regime in the delamination
CG steel is
can decelerate
associated withFCG the in the coalescence,
crack UFG steel resulting which isinthe a lower FCG rateofinlow
consequence long-crack
resistance regime compared
to crack to
initiation.
the CG samples (Figure 22d).
Additionally, delamination can decelerate FCG in the UFG steel resulting in a lower FCG rate in long-
crack regime compared to the CG samples (Figure 22d).
Appl. Sci. 2019, 9, 3627 23 of 32
Appl. Sci. 2019, 9, x FOR PEER REVIEW 23 of 31

Figure22.
Figure 22.Up,
Up,(a)
(a)S-N
S-Ncurves
curvesof
ofCG
CG and
and UFG
UFG steels.
steels. (b)
(b) Number
Numberof ofcycles
cyclesto
tofailure
failureplotted
plottedagainst
against
stress amplitude normalized by hardness [138]; bottom, FCGR curves of the two steels at thesame
stress amplitude normalized by hardness [138]; bottom, FCGR curves of the two steels at the same
ratiobetween
ratio betweenstress
stressamplitude
amplitudeand
andhardness.
hardness. (c)
(c) Crack
Crack length
length versus
versusthe
thenumber
numberofofcycles.
cycles.(d)
(d)Crack
Crack
growthrate
growth rateversus
versuscrack
cracklength
length[138].
[138].

5.5.Computational
ComputationalStudies
Studies
The
TheARB
ARBprocess
processinvolves
involves many
many variables,
variables,such as,as,
such material,
material,rolling & post
rolling & postrolling treatment
rolling each
treatment
each having
having a considerable
a considerable influenceinfluence
on the final on product.
the final Hence,
product.it isHence,
desirableit is desirable
to have to have a
a computational
computational
framework framework
to simulate to simulatethe
and understand andARBunderstand
process in the ARBtoprocess
order in order toprocess
obtain optimized obtain optimized
parameters,
toprocess parameters,
avoid trial and error toexperimental
avoid trial and error experimental
setups. setups.
To date, the efforts onTothedate,
ARBedthe efforts
materialson the
have ARBed
mostly
materials have mostly been devoted to experimental investigations and few
been devoted to experimental investigations and few computational studies have been reported in this computational studies
have [139–143].
regard been reported Inoueinand
thisTsuji
regard [139–143].
[144], Inouecomputational
first correlate and Tsuji [144], firsttocorrelate
studies computational
ARB process parameters
studies
with to ARB
the aim processthe
to quantify parameters
strains inwith
eachthe aim to quantify
component thetostrains
as well as in each
estimate component
the equivalent as well
strain as
during
to estimate the equivalent strain during a rolling process using finite element (FE)
a rolling process using finite element (FE) analysis. They used an FE method considering stress–strain analysis. They used
an FE method
relationships considering
depending onstress–strain
strain rate and relationships depending
friction between rollsonand
strain rate and
sheet. The friction
rolling between
condition
ofrolls
the and
ARBsheet. The rolling
was verified condition
through of the ARB wasmethod
the embedded-pin verifiedemployed
through the embedded-pin
in their FE analysis. method
Using
employed in their FE analysis. Using ABAQUS/Explicit, the exact magnitude
ABAQUS/Explicit, the exact magnitude of the total strains in each component and the equivalent strain of the total strains in
each component and the equivalent strain during rolling were shown. According
during rolling were shown. According to Figure 23a, they showed that a considerably large equivalent to Figure 23a, they
showed
strain, that afive
almost considerably
times higher largethan
equivalent
that at strain, almost
the center, five times
appears upon higher than thatThe
the surface. at the center,
equivalent
appears upon the surface. The equivalent strain at the surface of ARBed AA1100 without lubricant
strain at the surface of ARBed AA1100 without lubricant correspond to equivalent strain of five ARB
correspond to equivalent strain of five ARB cycles of lubricated samples. These quantitative strain
cycles of lubricated samples. These quantitative strain analyses would be useful for analyzing the
analyses would be useful for analyzing the microstructural evolution of ARBed materials [145,146].
microstructural evolution of ARBed materials [145,146].
Roostaei et al. [147] applied a FE analysis to investigate the induced plastic strain during the ARB
processing of AZ31 sheets using ABAQUS/Explicit as shown in Figure 23b; the effects of temperature
and friction (between roller/sheet or sheet/sheet) on the through thickness deformation distributions
were discussed. According to their results, the equivalent plastic strain increases when the friction
coefficient is increased. As the temperature arises, the equivalent plastic strain diminishes. For
AZ31 under this condition, they found that the temperature of 300 ◦ C and friction coefficient of 0.35
Appl. Sci. 2019, 9, 3627 24 of 32

compromised ARB processing parameters to achieve the highest homogeneous strain distribution
accompanied by no significant grain growth. Similar FE investigations on the affecting parameters
on deformation behavior during roll bonding were also carried out by Hosseini et al. [148] and
Ebrahimi et al.
Appl. Sci. 2019, 9, x[149].
FOR PEER REVIEW 24 of 31

(a) (b)

Figure 23.
Figure 23. (a)
(a) equivalent
equivalent strain
strain through
throughsheet
sheetthickness
thicknessforforvaried
variedfriction
frictioncoefficients [144],
coefficients (b)(b)
[144], thethe
equivalent plastic strain contours obtained at 300 °C
◦ for different roller/sheet friction coefficients [147].
equivalent plastic strain contours obtained at 300 C for different roller/sheet friction coefficients [147].

Roostaei
As et al. [147]
it is relatively applied
difficult toadirectly
FE analysis to investigate
measure the plasticthe induced
strain and plastic strain during at
stress distributions thethe
ARB processing
interface of AZ31 composites
of the laminated sheets usinginABAQUS/Explicit
a hot-rolling process,as shown
ZhanginetFigure
al. [150] 23b;
usedthea FE
effects of
analysis
temperature and friction (between roller/sheet or sheet/sheet) on the through
(Deform 2D software program) to characterize the bonding behavior of the laminated composites. thickness deformation
distributions
Yu et al. [151] were
used discussed. According
a FE simulation to their results,
to investigate the equivalent
the interface plastic
bonding strainof
quality increases
bimetallicwhen foils
the friction coefficient is increased. As the temperature arises, the equivalent
produced by a combination of ARB and asymmetric rolling techniques. LS-DYNA software was plastic strain diminishes.
For AZ31 under
employed this condition,
to simulate they found
the deformation of that
the the temperature
bimetallic foils of
at 300 ᵒC and
various friction coefficient
experimental of
conditions
0.35 compromised ARB processing parameters to achieve the highest
wherein a particular attention was placed on the interfacial bonding between AA1050 and AA6061 homogeneous strain
distribution accompanied by no significant grain growth. Similar FE investigations on the affecting
layers. The equivalent strain at the interface of the AA1050 and AA6061 layers was checked to reach a
parameters on deformation behavior during roll bonding were also carried out by Hosseini et al.
maximum value at a roll speed ratio of ~1.2–1.3, corresponding to a high-quality interfacial bonding.
[148] and Ebrahimi et al. [149].
Prakash et al. [152] proposed a framework for multiple pass rolling using ABAQUS explicit poly-crystal
As it is relatively difficult to directly measure the plastic strain and stress distributions at the
texture model for studying visco-plastic self-consistent response to demonstrate the capabilities of this
interface of the laminated composites in a hot-rolling process, Zhang et al. [150] used a FE analysis
framework to predict the response of ARBed AA5754 alloy. Their simulations validated the solution
(Deform 2D software program) to characterize the bonding behavior of the laminated composites. Yu
framework and confirmed the development of a through thickness gradient of texture and anisotropy
et al. [151] used a FE simulation to investigate the interface bonding quality of bimetallic foils
in an ARBed sheet after two cycles. A principal challenge in FE modeling of ARB process is growing
produced by a combination of ARB and asymmetric rolling techniques. LS-DYNA software was
the number of elements by a factor of two in each ARB cycle due to a large thickness reduction during
employed to simulate the deformation of the bimetallic foils at various experimental conditions
each rolling
wherein cycle. Theattention
a particular distortion was ofplaced
the mesh is also
on the challenging
interfacial bondingand between
needs to AA1050
be fixed.and AA6061
Besides the efforts made on FE modelling of ARB process, some
layers. The equivalent strain at the interface of the AA1050 and AA6061 layers was checked other studies were focused
to reachon
predicting the mechanical properties of ARBed materials. Qiao and Starink [153]
a maximum value at a roll speed ratio of ~1.2–1.3, corresponding to a high-quality interfacial bonding. developed a grain
refinement
Prakash et and strengthening
al. [152] proposed amodel for oxide-free
framework for multipleAl alloys processed
pass rolling usingby SPD to address
ABAQUS ARBed
explicit poly-
Al alloys. Their model accurately predicted the grain refinement and
crystal texture model for studying visco-plastic self-consistent response to demonstrate the hardness of an ARBed alloy.
Milner et al. [154] simulated the evolution of material strength of an ARB-processed
capabilities of this framework to predict the response of ARBed AA5754 alloy. Their simulations titanium alloy
that was then
validated validated
the solution using experimental
framework and confirmed datatheexhibiting
developmentan acceptable
of a throughfit in whole range
thickness gradientof ARB
of
cycles. To further validate the model for a wider range of materials, five
texture and anisotropy in an ARBed sheet after two cycles. A principal challenge in FE modeling of different materials were
also
ARBinvestigated and the
process is growing theresults
number confirmed
of elements theby ability of of
a factor thetwo
proposed method
in each ARB cycleindue
predicting
to a largethe
strengthening
thickness reduction behavior
during of each
all the considered
rolling cycle. The materials.
distortionReihanian
of the meshand Naseri
is also [155] proposed
challenging and needsan
analytical
to be fixed.model for necking and fracture of the hard layer during the ARB substantiating that the
critical strain the
Besides for efforts
necking and on
made fracture increased
FE modelling ofwith
ARBincreasing
process, some ARBother
ratio,studies
strengthwerecoefficient
focused on ratio
predicting the mechanical properties of ARBed materials. Qiao and Starink [153] developed a grain
refinement and strengthening model for oxide-free Al alloys processed by SPD to address ARBed Al
alloys. Their model accurately predicted the grain refinement and hardness of an ARBed alloy. Milner
et al. [154] simulated the evolution of material strength of an ARB-processed titanium alloy that was
then validated using experimental data exhibiting an acceptable fit in whole range of ARB cycles. To
further validate the model for a wider range of materials, five different materials were also
Appl. Sci. 2019, 9, 3627 25 of 32

and work-hardening exponent of the hard phase while it decreased with increasing the work-hardening
exponent of the soft phase.

6. Concluding Remarks
Accumulative roll bonding is a severe plastic deformation process that involves rolling a stack
of materials, sectioning into two halves, piling again and rolling repeatedly to produce an ultra-fine
grain (UFG) structure. Here in this review, ARB process has been thoroughly reviewed and discussed
starting with introducing different underlying mechanisms, influencing parameters and categorizing
the ARB effects on different mechanical properties. The most influential parameters, such as those
related to materials and process variables, are discussed. It was shown that the microstructural and
surface features have a considerable effect on the final ARBed products, while the process conditions
such as temperature, thickness reduction, friction, rolling speed, the type of reinforcing agent, and
post-heat treatment parameters play key roles in determining the final performance. The effects of
ARB on strength and ductility, thermal stability, superplasticity, vibration damping, fracture toughness,
wear, corrosion, and cyclic behavior are also separately presented in this paper.
The ARB process has been simulated by a few computational methods; however, still a lot of
research is required to understand more about this process owing to the complicated nature and
synergistic effects of various processing parameters and governing underlying mechanisms. The effects
of process parameters such as rolling stresses, frictions, temperatures and thermal issues, as well as
non-linearities should be taken into investigations in future studies, leading to advanced materials and
structures with desired properties.

Funding: This research received no external funding.

Conflicts of Interest: The authors declare no conflict of interest.

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