Influence of Roll Bonding on Texture Evolution and Mechanical Performance of Aluminum–Magnesium Bilayers

This study investigates the effect of the roll bonding process on the crystallographic texture evolution and the mechanical response of aluminum-magnesium bilayer sheets. The bilayer composite samples were produced with a 50% thickness reduction. Using advanced characterization techniques including electron backscatter diffraction (EBSD), crystal plasticity finite element simulation (CPFEM), X-ray diffraction (XRD), SEM-EDS analysis, and mechanical testing, the relationship between deformation-induced microstructural evolution and mechanical behavior was systematically studied. The findings demonstrate that the roll-bonding process produced a well‑defined FCC rolling texture in the aluminum layer (Copper, S, Brass, and Cube) and an adequate basal texture with prismatic orientation components in the magnesium layer, as confirmed by both EBSD and CPFEM analyses. Moreover, in the Al/Mg bilayer sheet, the hardness of the aluminum and magnesium sides increased by 37.5% and 38%, respectively, relative to base sheets, while the interface hardness was 107% higher than that of the aluminum base sheet layer, indicating a balanced enhancement in strength and ductility. Finally, SEM-EDS results reveal the formation of a continuous, diffusion-controlled atomic interpenetration at the Al-Mg interface during roll-bonding, a key factor contributing to the structural integrity and favorable mechanical behavior of the composite. • Successful bonding of dissimilar crystal structures (FCC-Al and HCP-Mg) was achieved through the roll bonding process. Roll bonding (RB) effectively modified the texture and mechanical response of Al/Mg bilayer sheets. • EBSD and CPFEM analyses revealed the formation of FCC rolling textures (Copper, S, Brass, Cube) in the aluminum layer and strong basal/prismatic orientations in the magnesium layer. • The interface exhibited an intermediate hardness—107% higher than Al—demonstrating efficient load transfer and interfacial integrity. • The intermetallic compounds β–Al₀.₅₈Mg₀.₄₂ and γ–Al₁₂Mg₁₇ formed at the interface, enhancing the properties in that region. The results showed that this intermetallic layer improves interfacial strength and bonding integrity.