A new approach for fabrication of bulk MMCs using Accumulative Channel-die Compression Bonding (ACCB)

A new severe plastic deformation (SPD) based technique entitled Accumulative channel-die compression bonding (ACCB) is proposed for the fabrication of high strength multi-layered Al/Cu composites for the first time. In order to primarily demonstrate the capabilities of ACCB in the fabrication of metal matrix composites (MMCs), AA 1050 and pure Cu strips were processed. The primary Al/Cu sandwich was prepared and subsequently 50% thickness reduction was applied per cycle. The experimental results reveal that thickness of Al and Cu layers decreased by increasing ACCB cycles to where the Cu layers started to neck and eventually rupture. An Al/Cu bulk composite was successfully processed with homogeneous distribution of fragmented Cu layers in the aluminum matrix after 6 ACCB cycles (correspond to effective plastic strain of 5.6). The microstructure evolution and mechanical properties of the processed specimens were evaluated at different ACCB cycles. The results show that microhardness, strength and elongation of the ACCB processed composites increase with increase in the number of cycles. The capability of ACCB in processing bulk multilayered MMCs was proved.