Mechanical properties and microstructure of explosive- welded Al/Cu/Al sheet after equal channel angular rolling process in route A and C

In contemporary times, the utilization of multilayer sheets and novel materials across diverse industries such as aerospace, nuclear, medical devices, and industrial machinery has garnered attention. The explosive welding technique has been widely adopted by researchers and artisans as a suitable method for joining similar and dissimilar metals, thereby enabling the production of a broad spectrum of materials with high circulation. Enhancing the mechanical properties and grain size of explosive weld samples can be achieved through the deformation process of the sheet using the Equal Channel Angular Rolling (ECAR) process. This study investigates the mechanical and metallurgical properties of a three-layer Al/Cu/Al sheet following the ECAR process in two distinct routes, A and C. To this end, Al/Cu/Al explosive welding sheet samples were prepared by subjecting them to varying numbers of passes (ranging from one to five passes) through the ECAR machine. The mechanical properties of the samples were assessed post-ECAR process through micro-hardness tests, uniaxial tensile tests, and residual stress tests. Furthermore, the grain size of the explosive welding samples was examined using a scanning electron microscope (SEM) after the ECAR process. The findings from the mechanical properties tests indicate a significant increase in tensile strength, hardness, and residual stress, alongside a decrease in elongation, following the ECAR process in different passes and routes (A and C). Specifically, the tensile strength and yield strength of the specimen reached their peak levels after the third pass, with values of 152.07 MPa and 126.25 MPa in route A, and 139.85 MPa and 126.76 MPa after one and two passes, respectively, in route C. Moreover, the micro-hardness increased to a maximum of 136 HV after the third pass in route C and 141.7 HV after the second pass in route A. The residual stress test revealed the highest levels at 213.83 MPa and 171.76 MPa in routes A and C, respectively, after the third pass. SEM results also demonstrated that an increase in the number of passes led to a reduction in grain size, reaching nanostructure dimensions. Specifically, the grain size decreased from 6000 nm to 29.02 nm and 30.49 nm in routes A and C, respectively, resulting in enhanced sample strength. The study concludes that the ECAR process yielded a material with specific properties, and that route A was more effective than route C for the three-layer Al/Cu/Al sheet, as was evident by the mechanical properties and microstructure.

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