Experimental and numerical analysis of Cu/Al8011/Al1060 trilayered composite: a comprehensive study

This work studied the interface morphology, microstructure behavior, and mechanical properties of the fabricated trilayered Cu/Al8011/Al1060 composite. In this regard, the roll-casted Cu/Al8011 bimetal was subjected to the hot-roll-bonding process with Al1060 at a thickness reduction of 47%. As a result, the hot-roll-bonding broke the produced nonuniform continuous interface within the copper and aluminum during the roll-casting process. The corresponding interface from the copper side includes Al4Cu9, AlCu, and Al2Cu, respectively. Additionally, SEM-based in-situ tensile deformation revealed that the initiated cracks at the Cu/Al8011 interface propagated into the copper layer that led to its fracture before the aluminum. Based on the FEM results, the effective stress distribution of the Cu strip is not homogeneous at the deformation zone. Moreover, the thickness reduction of the Cu and Al layers was respectively lower and slightly higher than that of the trilayered composite, indicating that plastic deformation mainly occurred at the aluminum matrix due to its large plasticity amount.