A novel two-step method for producing Al/Cu functionally graded metal matrix composite

In the present study, a novel method for manufacturing functionally graded metal matrix composites (FGMMC) is introduced. This method is a cutting-edge combined plastic deformation process of accumulative roll bonding (ARB) and cold roll bonding (CRB) and was used to fabricate Al/Cu functionally graded composites. Several laminated composites with different content of Cu were first fabricated by the ARB process, then they were bonded by the CRB process as the volume fraction of Cu varies from the Al side to the Cu side. With an increase in Cu content, the hardness of layers rose. Furthermore, the SEM images showed the continuous changes of Cu content from the Al side to the Cu side of the composites. In addition, based on the results of the tensile test, since Cu layers act as reinforcements in the Al matrix, the strengths gradually grew with the progressive increase in the volume fractions of Cu. • Employing a new procedure consisting of ARB and CRB for producing Al/Cu FGMMC. • Good interface bond without voids and cracks was achieved. • Hardness values of laminated composites and their constituent rose with an increase in Cu content. • The tensile and yield strengths of the composite increased, from Al side to Cu side, by increasing the volume fraction of Cu. • The size and the number of voids on fracture surfaces decreased as the content of Cu grew.