Modeling and investigation of fabrication parameters influencing the electrical conductivity of ARBed Al/MoS2 and Al/MoS2/WC composites

This study examines the electrical conductivity of pure Cu, pure Al, and Al-based composites reinforced with MoS2 and MoS2/WC, fabricated via the accumulative roll bonding (ARB) process for up to seven cycles. Structural characterization by X-ray diffraction revealed progressive grain refinement with increasing ARB cycles, while the addition of ceramic reinforcements further accelerated this effect. Electrical conductivity decreased with both increasing cycles and reinforcement content, with hybrid Al/MoS2/WC showing the largest reduction compared to pure Al. Post-annealing treatments partially restored conductivity by reducing lattice defects and increasing grain size. A modified predictive model, developed by incorporating grain size effects into the Maxwell-based approach, achieved excellent agreement with experimental measurements (average error <5 %). The model effectively links processing parameters, microstructural refinement, and reinforcement characteristics to conductivity outcomes. These findings not only provide a reliable predictive tool for ARBed hybrid metal matrix composites but also offer guidance for tailoring their electrical and mechanical properties in applications such as lightweight conductive components in aerospace, automotive, and electronic systems.