Influence of layer thickness and number of alternating layers on the mechanical properties of additively manufactured Cu/Ni multilayer composites

This study demonstrates the fabrication of Cu/Ni multilayered structures using Electrolytic Additive Manufacturing (EAM) to achieve tailored mechanical properties through controlled layer architecture and interfacial design. Mechanical testing revealed a Hall-Petch-like strengthening trend, with the sixteen-layered structure reaching an ultimate tensile strength of 437 MPa, 78% higher than pure copper, while maintaining comparable ductility. Two-layered structures exhibited exceptional toughness (22.7 GJ/m³), more than double that of pure copper. SEM and EBSD analyses confirmed sharp interfaces and localised slip activity near Cu/Ni boundaries, indicating interface-driven strengthening and delayed necking. These findings establish a clear link between layer organisation, interfacial mechanics, and macroscopic performance, demonstrating the potential of EAM for scalable production of high-performance multilayered materials for structural components and thermal systems.