Tailoring Interfacial Bonding and Tensile Properties in Cu/Al/Cu Laminated Composites by Adjusting Thickness Ratio

The design of the overall thickness and thickness ratio in multilayered composites is vital because it affects interfacial microstructures and mechanical properties. These elements are significant in the application of multilayered composites in diverse scenarios. This study systematically investigated the interfacial microstructure, mechanical properties, and fracture mechanisms of Cu/Al/Cu trilayered composites with varying overall thicknesses and copper thickness ratios. The microstructure results showed that the distribution and thickness of intermetallic compounds (IMCs) at the Cu/Al interface changed significantly with different thickness designs. As the Cu thickness ratio increased from 20% to 35%, the intermetallic layer transitioned from a continuous structure to a fragmented one in both the 1 mm and 2 mm composites. Additionally, the bonding mechanism evolved from primarily metallurgical bonding to a combination of metallurgical and mechanical bonding. In the 4 mm composite with a 35% Cu thickness ratio, the interfacial intermetallic layer comprised three sublayers identified as Al4Cu9, AlCu, and Al2Cu. Tensile results indicated that increasing the Cu thickness ratio markedly enhanced strength and ductility: the 1 mm composite showed increases of 22.3% in ultimate tensile strength and 70.9% in elongation, while the 2 mm composite exhibited increases of 32.4% and 38.7%, respectively. In contrast, increasing the overall thickness had only a limited effect. Fractography revealed ductile fracture features in both the Al and Cu layers, characterized by more compact interfaces, deeper dimples, and more pronounced tear ridges at higher Cu thickness ratios. These findings demonstrate that optimizing the Cu thickness ratio is an effective strategy for enhancing interfacial bonding strength and overall mechanical performance in Cu/Al/Cu composites.