About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Forming and Joining of Advanced Sheet Metal Materials
|
| Presentation Title |
Finite Element Simulation of Interfacial Fracture and IMC Evolution in Al-Steel Laminates |
| Author(s) |
Chandana Ravikumar, Michaela Šlapáková, Barbora Kihoulou, Olexandr Grydin |
| On-Site Speaker (Planned) |
Chandana Ravikumar |
| Abstract Scope |
Intermetallic layer formation at aluminum-steel interfaces significantly influences the mechanical integrity of laminated composites. This study aims to numerically extend the experimental findings on Al-steel laminates fabricated via twin-roll casting and annealed to promote intermetallic compound growth, studied by in-situ tensile testing and scanning electron microscopy. Using a coupled thermo-mechanical finite element framework in COMSOL Multiphysics, we simulate diffusion-driven IMC formation (Al₅Fe₂, Al₁₃Fe₄) and mechanical deformation under tensile loading. Parabolic growth kinetics and temperature-dependent diffusion models are employed alongside crystal plasticity and cohesive zone elements to capture interface cracking behavior. Parametric studies evaluate the influence of Mg content, thermal gradients, and residual stress fields. Strategies such as localized thermal gradients and graded interlayers are proposed to minimize delamination and enhance bond strength. This modeling framework guides the process optimization for improving the reliability of aluminum-steel laminates in automotive and aerospace structural applications. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Aluminum, Modeling and Simulation, Joining |