The process of roll bonding and reaction annealing was used to process gamma-titanium aluminide sheets with a nearly fully lamellar microstructure. Cold roll bonding was employed to bond elemental Al and Ti foils. The bonded sheets were annealed at 600 °C to convert all of the Al into TiAl3. The effect of rolling strain on the reaction kinetics was studied. Accumulative roll bonding was also employed to study the effect of increased rolling strain on the microstructures resulting after annealing. After the first annealing stage, a cold rolling step resulted in a denser microstructure. A second annealing treatment at 1300 °C for 6 h resulted in a microstructure consisting of two phases, gamma and alpha2, along with Kirkendall porosity. Further densification of the sheets was carried out using hot rolling. A final heat treatment at 1400 °C for 0.3 h resulted in nearly fully lamellar microstructure. The porosity evolution was evaluated at different stages of processing. The mechanical properties of the processed sheet were determined and compared with the data available in the literature.; The process of bi-metal multi-layer roll bonding was modeled using the equilibrium force balance method (slab method). The effect of anisotropy and strain hardening was included in the model. The effect of different variables such as total reduction, coefficient of friction, roll radius and initial foil thickness ratio, on the thickness fraction of metals in the bonded composite was investigated. The model enables the estimation of the final composition of the roll bonded composite. The results of the model were compared with the experimental results, and good agreement was observed.
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