The warm roll bonding technique was adopted to fabricate Aluminum–polyurethane–Aluminum (Al–PU–Al) composites. Glass whiskers or SiC particles were added to reinforce the inner layer. The main objective of the present study is to examine experimentally the main manufacturing parameters, including interface properties and layer thicknesses, both of which control the strength and integrity of Al–PU–Al composites. For this purpose, three different tests were performed, namely the peel test, the single lap shear test, and the small punch test (SPT). A numerical study was carried out to study the effect of each parameter on the bond, the mechanical behaviors, and fracture behaviors of Al–PU–Al composites using the extended finite element method. The present results indicate that there is a critical diameter of the unbonded circle (D) beyond which the interlayer bonding strength decreases markedly for both the peel and the single lap shear tests. The critical value of D/W equals 0.2 for the peel test and 0.3 for the single lap shear test, where W is the plate width. There is no clear relation between the interlayer bonding strength measured, either from the peel test, or the single lap shear test, and the ultimate load measured from SPT. The mechanical behavior of Al–PU–Al composites measured from SPT is marginally affected by the interfacial bonding strength between the layers. The presence of clearance (0.1 mm) between the SPT specimen and the fixture decreased its ultimate load by about 10% for the bonded specimen, and 30% for the unbonded specimen.

采用热轧粘合技术来制造铝－聚氨酯－铝（Al－PU－Al）复合材料。添加玻璃晶须或SiC颗粒以增强内层。本研究的主要目的是通过实验检查主要的制造参数，包括界面特性和层厚度，这两个参数均控制Al-PU-Al复合材料的强度和完整性。为此，执行了三个不同的测试，即剥离测试，单搭接剪切测试和小冲孔测试（SPT）。进行了数值研究，使用扩展有限元方法研究了每个参数对Al–PU–Al复合材料的键合，力学行为和断裂行为的影响。目前的结果表明，未结合的圆存在一个临界直径（D），对于剥离试验和单搭接剪切试验，层间粘结强度显着降低。对于剥离试验，D / W的临界值等于0.2，对于单圈剪切试验，D / W的临界值等于0.3，其中W是板的宽度。从剥离试验或单搭接剪切试验测得的层间粘结强度与从SPT测得的极限载荷之间没有明确的关系。通过SPT测量的Al–PU–Al复合材料的机械性能在一定程度上受到层间界面粘结强度的影响。SPT样品和夹具之间存在间隙（0.1毫米），对于粘结的样品，其最终载荷降低了约10％，对于未粘结的样品，其最终载荷降低了30％。