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In the present work, aluminum-3% brass composite sheets are produced by accumulative roll bonding (ARB) process up to nine passes at ambient temperature. Evolution of rolling texture is studied by texture measurement using X-ray diffraction method. The results show that ARB process leads to the formation of copper ({112} <111>) and Dillamore ({4 4 11} <11 11 8>) as the major texture components. The intensity of copper and Dillamore components enhances to values as high as 19 times that of random with increasing number of passes to 9. It is observed that the 5th pass is a transition in development of the texture components, after which the intensities undergo a drop. The textures are comparable to ARB process of high purity aluminum, indicating that the addition of 3% brass particles do not cause any significant change in the deformation behavior. Electron backscatter diffraction (EBSD) technique is used to examine the microstructure; the results reveal formation of ultrafine grains (UFG), starting in the 3rd pass and covers the entire structure after the 5th pass. The major mechanisms involved are identified as rotation of the sub-grains, as well as grain boundary migration.

Steel sheet metals are widely used in different industries due to their high strength, good weldability, availability, moderate cost, and the ability to form to complex 3D parts. The study of the formability of sheet metals is often done by means of Forming Limit Diagram (FLD) which presents the major and minor engineering strain thresholds under different deformation states. In this article, the formability parameters of three different steel sheet metals with the same thickness have been determined by uniaxial tension test and their FLDs have been produced by Hecker method: RRSt14O3, Zinc coated IF (Interstitial Free) steel and uncoated IF steel. Also the materials’ formability during the stamping process of a car door inner panel has been investigated as a case study to substitute the original design of raw material, coated IF steel, with a cheaper alternative. Among the tested materials to form the part, the uniaxial tension results showed that the formability parameters of uncoated IF steel was higher than the coated IF steel and the parameters of RRSt14O3 sheet metal was the lowest. The FLD of coated IF steel sheet was the highest (best formability). Differences among the formability parameters in uniaxial tension, the FLDs, and the stamping behavior of the part with different steel sheet metals have been explained by their surface roughnesses and the friction coefficients that affect the material flow during the FLD test as well as the stamping process.