Accumulative roll bonded composites with highly uniform distribution of copper layers and wear properties

This study characterizes the wear behavior of an aluminum/copper laminated composite with a highly uniform distribution using a wear test under various sliding and loading conditions. The composite is processed through up to twelve accumulative roll bonding passes to achieve a uniform distribution. The microstructure, mechanical, and wear properties are characterized using optical microscopy, scanning electron microscopy, tensile testing, hardness testing, and wear tests. The ultimate tensile strength of 321 MPa, coupled with an elongation at a break of 9.7 %, is achieved after twelve passes. For lower loads and sliding distances, the amount of weight loss decreases due to the increase in hardness (154 % for aluminum and 174 % for copper compared to the raw sheets) in the strain‐hardened layers. However, with an increase in the applied load (from 5 N to 10 N) and sliding distance (from 500 m to 1500 m), weight loss increases, which is due to the higher contact stress between the pin and wear surfaces, resulting in greater depth of deformation and surface temperature, which accelerates the recrystallization process in the plastically deformed region. Additionally, based on the wear test results, various wear mechanisms, including adhesion, abrasion, and delamination, are observed.