RESEARCH PROPOSAL

TITLE: A study on bonding strength of clad steel plates and prevention of warping of clad
material during hot rolling.

LITERATURE REVIEW

It is important to study and keep increasing the bonding strength between the base steel plate and
clad material in order to increase the life of the composite material for its industrial use. Along
with this, prevention of warping of the clad material which faces exposure to atmosphere in
applications like ships, boiler surface, military equipment, pressure vessels etc. is equally
important. Hot roll bonding, which is a major production method for stainless steel clad plates
accounts for more than 90% of the clad plate production worldwide (ASM Specialty Handbook:
Stainless Steels, 06398G J.R. Davis, Davis & Associates, 1994).

GK Purohit and Kalakesh Baligar conducted a study on cladding process simulation of SA 508
material (stainless steel). In this study, the base material was kept same throughout and clad
material and its thickness was changed. Residual stress estimation and analysis of thermo
structural behavior of cladding process was done with the help of finite element method, using
the software ANSYS. The results show that maximum residual stresses are observed at the
constrained region and less at the outer surface, lower residual stresses are observed with lesser
thickness of the clad material, zirconium is the best cladding material with lowest residual
stresses in the structure and thermal expansion coefficient and youngs modulus plays an
important role in the residual stress formation.

Long Li, Fuxing Yin and Kotobu Nagai made a study on fabrication technique and evaluation on
mechanical properties of clad plates including bonding strength, which stated a review of the
applications of clad metals and the prospect of clad metals in the future.

H. Danesh Manesh and A. Karimi Taheri conducted a study on effect of annealing treatment on
mechanical properties of aluminum clad steel sheet. Effects of annealing temperature and time
on mechanical properties and bond strength of aluminum clad steel sheet were evaluated. The
results indicated that there exists an optimum annealing temperature and time for achieving a
suitable formability and bonding strength between the clad layer and base metal. At this
annealing time and temperature, the brittle intermetallic layer at the intimate interface of the
layers is minimized.

Naoya Masahashi, Koichi Komatsu, Sadao Watanabe and Shuji Hanada carried out a study on
microstructure and properties of iron aluminum alloy/CrMo steel composite prepared by hot
rolling. Three layered composite steel sheet consisting of alloy/steel/alloy was fabricated by hot
rolling at 873K and 1273K. It was concluded that composite steel thin sheet can be produced
by controlling composition of iron aluminum alloy and clad rolling condition.

T. Mori and S. Kurimoto studied press-formability of stainless steel and aluminum clad sheet in
order to find out the fundamental mechanical properties. It was concluded that aluminum has
higher ductility than that of stainless steel. Formability in stretching and deep-drawing is higher
in steel sheet than in aluminium sheet. Steel has higher local deformation. The formability in the
processes of both stretching and deep-drawing is higher when the aluminum is the clad material.
The factors related to deformation, such as wrinkling and cup height are controlled by the
stainless steel portion due to its high strength.

Yoshiwara et a1. proposed an improved method for producing a clad plate by hot rolling. He
proposed the use of a base material, a cladding material and a cover material overlaid one on
another to form a multi-layer structure. On top of that, a member for preventing warp is laid over
an outer surface of the cover material with a separating agent in between. He concluded that this
new method improved the bonding of the base material and clad material. Also, the warping of
the clad material was prevented.

D.S. Zhao, J.C. Yan, Y. Wang and S.Q. Yang studied the relative slipping of interface of
titanium alloy to stainless steel during vacuum hot roll bonding. FEM software MSC Marc was
used to carry out the simulation. Results showed that the relative slipping between different
plates is less when there are no interlayers and is increased by using copper interlayer.

Most of the research stated above involves simulation of hot rolling process using FEM
softwares, studies on mechanical properties and microstructure of clad plates. Thus, to cover all
the aspects involved in affecting the bonding strength of clad steel plates, this study is aimed at a
broad and in-depth analysis of all the factors affecting improvement of bonding strength of clad
steel plates and the prevention of surface distortion.

SCOPE

The study will focus on factors which affect the bonding strength between steel base plate and
clad plate and warping or any sort of distortion of the clad surface when it is in contact with the
roll in hot rolling process.

AIMS/OBJECTIVES

The project will aim to achieve the following objectives:

1. To study all factors affecting the bonding strength of base steel plate and clad plate.
2. To study the factors affecting the warping or distortion of clad plate surface.
3. To propose points which will improve the bonding strength of base steel plate and clad
plate.
4. To propose points which will prevent distortion of clad plate surface in contact with the
roll.

AREAS TO INVESTIGATE

An investigation conducted into the following areas will allow us to fulfill the objectives detailed
above.
1. Oxides and carbides trapped between the base material and clad material during hot
rolling.
2. Use of different cladding material with the base steel plate.
 3. Strain rate of the base steel plate and different clad material.
4. Number of roll passess and reverse pass.
5. Surface roughness between the base plate and the clad plate.
6. Surface roughness of the clad plate.
7. Force applied by roll in perpendicular and shear direction.
8. Thickness of roll bite in a single pass.
9. Hot rolling at different temperatures.
10. Subjection of clad steel plates to subzero temperatures.
11. Preparations like degreasing and brushing of clad material surface before hot rolling.
12. Effect of lubricants used at the roll bite.
13. Testing the specimen with failure in tensile shear, slide shear, peeling, tension along the
thickness, bending and punching.

IMPLICATIONS

The implications of above areas to be investigated will provide an understanding in eliminating

the undesired factors and improvement on the desired ones for increasing bonding strength of
clad steel plates and preventing distortion of the clad surface. Detection of oxides and carbides as
well as other impurities trapped between the base material and clad material; experimentation of
hot rolling on the various cladding material along with base plate; measurement of strain rate of
steel and clad plates; effect of number of roll passes and also reverse pass and surface roughness
between the base plate and clad plate are the factors which will decide the bonding strength
between clad steel plates. Surface asperities of clad plates; forces acting due to the roll; thickness
of roll bite and variations in temperature are the factors which will decide both bonding strength
between clad plates and surface roughness of clad plates. Clad plate surface preparations like
degreasing and brushing and lubrication at the roll bite will aid in finding solutions to let the
surface of clad plate remain undistorted. Various failure tests mentioned above will gauge the
bonding strength of hot rolled clad steel plates.

PROJECT PLAN

The plan for this research topic is carved out to provide a basic guidance. As the nature of
research is purely experimental, practical and industrial, it may be difficult to obtain all facilities
and information on time, which can increase the time required to complete the research. In
addition, this plan is subject to change after re-evaluation.

Stage 1

A periodical literature review of all the research carried out on bonding strength and surface
protection of hot rolled steel clad plates will be carried out which will create a platform for
further research.

Stage 2

Experimentation and observation of the above mentioned factors which are necessary for
bonding strength increment and surface distortion prevention of clad steel plates will be done
with the help of laboratory facilities and permissible industrial equipment.
Stage 3

Simulation of processes which cannot be experimentally completed. Mathematical and statistical

analysis of the experimental data collected.

Stage 4

Preparation of report for final submission.

METHODOLOGY

Relevant information about the properties of steel plates, properties of different clad plates, hot
rolling processes etc. will be acquired from industries. Roughness between the base plate and
clad plate; Oxides, carbides and other impurities present inside the clad plates will be detected
with the help of CT scan or any other source of 3D X-ray. The oxides are formed due to presence
of moisture which will be eliminated by heating the plates at or above 100C. The carbides and
other impurities will be removed by subjecting the plates to vacuum pressure. The strain rate of
all the required cladding material and steel will be obtained from literature. The experiments on
hot rolling will be carried out in the research laboratory or the industrial setup if permission is
granted. The surface profiles will be examined using a VHX-1000 digital microscope. Force
applied by the roll will be measured with the help of load cell. Testing of clad plates at subzero
temperatures will be done by keeping the samples in a refrigerating space. In case of absence of
the industrial facilities to carry out rolling of clad steel plates, Finite Element Analysis will be
done using the software MSC Marc. The bonding strength will be tested by performing all the
failure tests mentioned above.

REFERENCES
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