Impact of Separating Agents on the Deformation Regime in Aluminum Roll-Cladding Processes

Abstract:

Application fields and requirements for roll-cladded cooling plates are continuously rising. Especially as part of the thermal management systems in battery electric vehicles (BEV), the share of roll-cladded cooling plates is growing. A deeper understanding of the deformation regime in the roll bite is needed to completely fulfill the high quality, performance and cost requirements of the automotive industry Whereas most cause-effect relationships in the roll-cladding process have been scientifically evaluated, the influence of separating agents on the deformation regime in partial roll-cladding has not yet been investigated. To examine this relationship, an experimental set up is created and trials are conducted on a laboratory size roll-cladding mill. Two different aluminum alloy blanks are joined together under temperature by roll-cladding without the application of strip tensions and with different separating agent patterns. The results show: Firstly, there is a correlation between the materials’ relative flow stress difference and their relative deformation. Secondly, the separating agents’ areal share over the blank width significantly impacts the deformation regime in the roll bite. Thirdly, in areas with separating agent there is a correlation between the surface elongation of the bottom blank and the elongation of the contact interface between the blanks, which governs the later cooling channel tolerances. To use the results in the industrial application, the impact of so far neglected parameters such as strip tensions have to be considered in future research.

• Periodical: Materials Science Forum (Volume 1186)
• Pages: 97-107
• DOI: https://doi.org/10.4028/p-6UdHbQ
• Online since: April 2026
• Authors: Felix Muhr*, Benedikt Höniger, Philipp Niemietz, Peter Frohn-Sörensen, Bernd Engel, Thomas Bergs
• Keywords: Aluminum, Battery Cooling, BEV, E-Mobility, Heat Exchanger, Partial Roll-Cladding

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