Daneshmand, SaeedJasim, Dheyaa J.Vini, Mohammad HeydariAlkhafaji, AliSingh, Narinderjit Singh SawaranSahramaneshi, HaniSalahshour, Soheil2026-04-212026-04-2120260020-76831879-214610.1016/j.ijsolstr.2026.113929https://hdl.handle.net/123456789/9022https://doi.org/10.1016/j.ijsolstr.2026.113929This research investigates the effects of accumulative roll bonding on the forming behavior of boron nitride (BN)reinforced aluminum matrix composites, using Al alloy 2022 as the base material. By focusing on Fracture toughness and forming limit diagrams, the research evaluates changes in mechanical properties across various accumulative roll-bonding cycles, employing a constant 50% reduction ratio in each rolling step. This work provides a systematic evaluation of fracture toughness and forming limit behavior in BN-reinforced AA2022 aluminum composites processed via accumulative roll bonding (ARB). Unlike previous studies that examined BN-reinforced composites under elevated-temperature ARB or different alloy systems, this study investigates ambient-temperature ARB processing and correlates BN dispersion, bonding evolution, and mechanical/forming behavior across ten rolling cycles. Key findings reveal that X-ray diffraction analysis confirms the successful integration of boron nitride particles into the aluminum matrix composites during accumulative roll bonding, without evidence of detrimental reactions or intermetallic compound formation, thus maintaining the composite's structural integrity. Notably, composites subjected to ten rolling passes exhibited deep, elongated dimples, indicative of maintained ductility and enhanced toughness suitable for demanding applications. Scanning electron microscope (SEM) images show that increased plastic strain after the fourth pass enhances particle distribution, improving mechanical properties. The ultimate tensile strength improved by 150% (relative increase of 62 -> 155 MPa). However, the tensile toughness initially decreases before gradually recovering, reaching 10.02 J & sdot;m-3 & times; 104 after ten passes. Additionally, the study notes an improvement in bonding strength, as indicated by increased peeling force and wider bonding areas due to high rolling pressure.eninfo:eu-repo/semantics/closedAccessProcess InnovationAl-Based CompositeAccumulative Roll BondingMechanical PropertiesForming Limit DiagramArticle