Size Effect on Tensile Properties and Fracture Mechanism of Micro-Rolled Ultra-Thin Cu/Al Composite Sheet

In this study, a laboratory-precision four-high micro-rolling mill was employed to investigate the influence of grain size on the deformation behavior and fracture mechanism of a micro-rolled Cu/Al composite ultra-thin sheet. Analytical testing techniques including scanning electron microscopy coupled with energy-dispersive spectroscopy (SEM+EDS), X-ray diffraction (XRD), and unidirectional tensile experiments were utilized. The experimental results indicate that the grain size of the Cu/Al composite ultra-thin sheet increases with increasing annealing temperature and extended holding time while undergoing the first and second micro-rolling processes. Under identical annealing conditions, secondary micro-rolling leads to an increase in the grain size of Cu, while the growth rate of Al grains is reduced. Tensile tests and fracture surface observations reveal that as the annealing temperature increases, the grain size of the once-micro-rolled Cu/Al composite ultra-thin sheet also increases. When annealing at 400 °C for 40 min, the elongation reaches a maximum of 25.6%, with a tensile strength of 106.3 MPa. For the second micro-rolled samples, a maximum tensile strength of 114.8 MPa is achieved after annealing at a temperature of 360 °C for an 80 min holding time, although the elongation is significantly lower at 3.4%. This indicates that the fracture mode of the once-micro-rolled ultra-thin Cu/Al composite sheet is ductile fracture, whereas that of the second micro-rolled sample is brittle fracture.