In this work, a novel method based on pulsed-current-assisted vacuum sintering processes was employed to fabricate the Cu/Al laminated metal composites (LMCs) with outstanding mechanical properties. The microstructural evolution, interfacial characteristics, phase composition, mechanical properties, and fracture behavior of Cu/Al composites prepared by the melted Al spheres induced with high-frequency pulsed current were investigated. Results show that robust interfacial bonding without micropores and cracks, and the grain structure consists mainly of recrystallized and substructured grains characterized by high angular grain boundaries. Meanwhile, interfacial analysis identifies melted Al and Al2Cu phases within the transition layer, exhibiting distinctive features such as "Al+Al2Cu" corrugated interfaces and island eutectic structures. Additionally, mechanical properties demonstrate superior strength (210 ± 13 MPa) and elongation (27 % ± 0.7 %) in specimens with corrugated interfaces compared to those with flat interfaces. Finite element analysis further elucidates stress redistribution and fracture behavior, emphasizing the enhanced coordinated deformation in specimens featuring corrugated interfaces. These findings underscore the significance of interface engineering and microstructural refinement in optimizing the mechanical performance of Cu/Al composite materials, offering valuable insights for their application in diverse engineering domains.
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