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<p>Using DEFORM-3D finite element software, this study simulates the rolling process of TC4/7075Al/TC4 composite sheets at temperatures ranging from 800 to 1000&#xa0;°C and reductions of 10% to 30%, aiming to optimize process parameters. Results reveal distinct deformation behaviors: in the deformation zone, the TC4 layer, especially the lower layer, experiences significant stress (up to 150&#xa0;MPa), while the middle 7075Al layer undergoes substantial strain, reaching 0.25 at 1000&#xa0;°C and 30% reduction. Increasing rolling temperature reduces the deformation resistance of 7075Al, enhancing its plasticity; strain in the 7075Al layer increases by about 40% from 800 to 1000&#xa0;°C. Conversely, TC4 exhibits irregular strain due to competition between thermal softening and work hardening. At a fixed temperature, higher reduction leads to a general decrease in TC4 stress but a gradual increase in 7075Al stress. Grain size evolution also depends on deformation and temperature: TC4 grain size decreases by up to 20% with increased deformation; above 800&#xa0;°C, 7075Al grain size increases with deformation. Elevated temperatures promote grain refinement in both alloys. Optimal microstructure uniformity and strengthening are achieved at 10% reduction and 1000&#xa0;°C, where balanced stress distribution and refined grains enhance composite performance. These findings provide quantitative guidance for differential temperature rolling of titanium-aluminum composites.</p>

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Study on the Mechanism of Microstructural Evolution in TC4/7075Al/TC4 Composite Sheets during Rolling Process

  • 期刊论文

  • 发表日期：

    2026年4月8日

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  • Xuezhao Wang,
  • Ping Zhang

摘要

Using DEFORM-3D finite element software, this study simulates the rolling process of TC4/7075Al/TC4 composite sheets at temperatures ranging from 800 to 1000 °C and reductions of 10% to 30%, aiming to optimize process parameters. Results reveal distinct deformation behaviors: in the deformation zone, the TC4 layer, especially the lower layer, experiences significant stress (up to 150 MPa), while the middle 7075Al layer undergoes substantial strain, reaching 0.25 at 1000 °C and 30% reduction. Increasing rolling temperature reduces the deformation resistance of 7075Al, enhancing its plasticity; strain in the 7075Al layer increases by about 40% from 800 to 1000 °C. Conversely, TC4 exhibits irregular strain due to competition between thermal softening and work hardening. At a fixed temperature, higher reduction leads to a general decrease in TC4 stress but a gradual increase in 7075Al stress. Grain size evolution also depends on deformation and temperature: TC4 grain size decreases by up to 20% with increased deformation; above 800 °C, 7075Al grain size increases with deformation. Elevated temperatures promote grain refinement in both alloys. Optimal microstructure uniformity and strengthening are achieved at 10% reduction and 1000 °C, where balanced stress distribution and refined grains enhance composite performance. These findings provide quantitative guidance for differential temperature rolling of titanium-aluminum composites.