Warm roll bonding (WRB) is a promising solid-state joining technique for producing aluminium-steel laminates with high strength-to-weight ratios and corrosion resistance. Despite growing interest in roll bonding, understanding of WRB-specific mechanisms and process-structure-property relationships remains fragmented across the literature. This review critically examines the underlying bonding mechanisms, material combinations, surface engineering methods, interfacial microstructure evolution, and the role of processing parameters in WRB. WRB operates at intermediate temperatures (200°C–350°C), promoting oxide fracture, virgin metal extrusion, and diffusion bonding while minimising excessive intermetallic compound (IMC) growth. The use of steel and AA6xxx aluminium alloys, when combined with optimised surface treatments and interlayers (Zn, Ni, Cu), yields strong and ductile joints with thin IMCs such as Fe 2 Al 5 and FeAl 3 . Key challenges include controlling IMC thickness, managing thermal stresses, and achieving uniform strain during rolling and post forming. Advanced surface activation methods, such as plasma or laser structuring, and FEM-based thermomechanical models are being developed to improve bond quality and predict failure. Applications of WRB span automotive, energy, and structural sectors, particularly for electric vehicles and lightweight infrastructure. By consolidating recent experimental findings, this review identifies key research gaps and outlines strategies for achieving scalable, defect-free WRB joints. The insights presented aim to support the future development of WRB-based multilayer materials for high-performance, multifunctional applications.
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