Hot Cladding of Al–Cu–Mn-Based Secondary Alloy Sheets: A Computational–Experimental Investigation

This study investigates the double-sided hot cladding of an experimental Al–2%Cu–1.5%Mn–1%Zn–0.7%Mg–0.4%Fe–0.4%Si alloy with commercially pure aluminum A1050 under combined hot deformation. Finite element modeling was employed to analyze the evolution of shear strains, normal stresses, and flow stresses in the deformation zone during cladding. The results indicate that increasing the degree of reduction significantly alters the distribution and direction of shear strains: at low reductions (20–30%), shear directions in the base and cladding layers coincide, while reductions above 40% induce opposing shear directions. Temperature was identified as the dominant factor affecting normal stress and flow stress differences between layers, whereas deformation magnitude primarily influenced peak stresses at the neutral section of the deformation zone. Experimental validation was conducted over a temperature range of 300–450 °C and relative reductions of 20–60%, demonstrating successful layer bonding in all cases except at low temperatures and reductions (300–375 °C, 20–30%). Based on combined modeling and experimental data, a predictive model for estimating peel strength during hot rolling cladding was developed, offering a robust tool for optimizing process parameters and ensuring reliable interlayer bonding in investigated aluminum alloys.