金屬複合板材在電子、機械、航太等領域中具有廣泛的用途，其中Al/Cu複合板在電接觸材料，如導電排、導電接觸端子等應用具有極佳的潛力。利用軋延複合的方式可將Al、Cu兩種冶金性質迥異的金屬複合形成穩定之層狀結構。本研究以冷軋延複合技術製作Al/Cu複合板，探討不同的製程參數對於Al/Cu金屬複合板之界面結合結構與結合性的影響，並針對異質複合金屬成形性與材料異向性，探討異質複合板異向性轉變理論與機制。
研究結果顯示Al/Cu軋延複合結合機制主要是以薄膜理論為基礎，表面處理時產生之加工硬化層在軋延力作用下破裂，導致新鮮金屬由裂縫中擠出、接觸而形成初期之有效鍵結。軋延量越高，界面有效結合部分(硬化層裂縫)隨之增加，故結合強度亦隨之提升。在退火初期，擴散擴及未結合的部分使結合強度隨結合點增加而增加，隨著退火時間增加Al/Cu中間結構逐漸成長，完全成長的中間相結構由硬脆的介金屬相所組成，包括：Al2Cu (θ), AlCu (η2), Al3Cu4 (ζ2), Al4Cu9 (γ1)所組成。由於Cu原子在Al基材中的擴散速率較Al原子在Cu基材中的擴散速率高，故最初先生成的中間相為Al2Cu(tetragonal structure)，其次為Al4Cu9(Cubic structure)，再者才是AlCu與Al3Cu4。界面結構的弱化主要源於中間相結構的粗化，裂縫延伸主要沿著AlCu 與Al3Cu4兩相傳播而非沿著中間相與基材間傳遞，Kirkendall voids的生成並非是造成結合強度下降的主因。
由織構分析顯示在退火溫度300oC以下Al-side近表層顯示出明顯的R-cube，近試片中心顯現明顯β-fibre織構(Brass、Silver與Copper織構)，R-cube與β-fibre織構皆貢獻45度方向的突耳。當退火溫度升至300oC以上，Al-side近表層的R-cube織構隨退火再結晶而逐漸降低，Al-side中心部分織構轉為以Cube為主的織構，貢獻0/90度方位的突耳。Cu-side近表層與中心織構則都顯示出R-cube織構，一經退火(200oC)R-cube減弱消失而產生Cube與CT織構，隨著退火溫度上升，整體織構逐漸傾向random的分佈。
Al/Cu雙金屬複合板的突耳率則介於純Al與純Cu的之間，顯示複合板的異向性同時受到Al與Cu兩組元金屬的影響。利用複合金屬理論中的加成效應預測Al/Cu複合板之突耳行為模式，可發現在冷軋狀態下，整體突耳係數值較高，隨著退火進行則減至相當小但仍然保持負值，顯示其45度方向的塑性變形性質較強。當退火溫度高達300oC以上突耳係數轉為正值，意謂者0/90度方向的塑性變形性質較強，由45度方向轉為0/90度方向的在織構上的明顯轉變，此預測模式結果與實際Al/Cu複合板引伸成形的突耳變化關係相吻合，顯示複合板的突耳行為為個別組元金屬材質突耳行為的綜合貢獻總和。

Clad metals have become increasingly popular for industrial applications in recent years, such as Al/Cu, Cu/SUS, Cu/Ag, Al/Ni, Steel/Ti, etc. They sometimes possess enhanced mechanical properties and corrosion resistance. Metallurgical bonding Cu to Al is widely used as a transition piece in high direct-current bus systems to transmit electricity. Clad roll bonding is a well-established and widely used solid state welding process to join dissimilar metals. Compared with the other processes such as explosion welding, friction stir welding, diffusion bonding, clad roll bonding has the most economic and productive for large size flat clad metal sheets and foils, which makes it suitable to be applied on some ductile metals like Al and Cu.
In this study, Al/Cu bimetal sheets are made using cold clad roll bonding. The investigation on the development of interfacial structure is performed and identified at different sintering conditions. The relation between the interfacial development and fracture mechanism provides valuable information in controlling process parameters. The other objectives in this study are to investigate the earing behavior of Al/Cu bimetal sheet and variation of texture orientation. For this purpose, some analysis methods would be applied. Mechanical properties of Al/Cu bimetal sheet will be investigated. R-value (Lankford parameter) and the Δr-value (planar anisotropy) observed form tensile tests have long been used to judge the formability and predict earings orientation of metal sheets. The earings orientation of the as-received and annealed samples was determined by cylinder deep drawing test. Texture analysis was carried out using X-ray diffraction. The relation between the texture evolution of individual sheet and couple effects with the earing behaviour provides valuable information in deep drawing process.
The investigations show that the interfacial structure development and defects formation. The bond strength will reach to maximum value under suitable sintering condition. Interfacial structures of Al/Cu bimetal plates develop with different annealing conditions. The first reaction product Al2Cu is presumed, and then the next reaction phase is Al4Cu9. AlCu, and Al3Cu4 are next. The growth of intermetallic compounds was controlled by volume diffusion mechanism. The apparent activation energies calculated for the growth of the total intermetallic compound, Al2Cu, AlCu + Al3Cu4 and Al4Cu9 intermetallic were 97.504, 107.46, 117.52 and 107.85 kJ/mol, respectively. The development of Al/Cu interfacial structure dominates the bond strength and fracture mechanism. The formation and thickening of AlCu and Al3Cu4 brittle intermetallic compounds promotes crack propagating and then damages bond strength. The Fracture mechanism is brittle cleavage. No obvious Kirkendall void formation is observed when the bond strength of the material starts to decrease in the present study. The variation of bond strength is the compromise result between some interface reactions including the joints built at unbonded region, interfacial structure development and defects formation.
The study on the deep drawing of Al/Cu bimetal sheet shows that There are four peaks that appeared at 45o from the roll direction and they transit to 0o/90o when the annealing temperature rises up to 300oC. The earing behaviour of Cu and Al sheets shows some differences. Earings of the Cu sheet reorient from 45o to 0/90o when annealed at 200oC for 0.5 hr, whereas the earings of the Al sheet reorient from 45o to 0/90o when annealed at 300oC for 0.5 hr. The mismatch in texture orientation and mechanical properties for the Al and Cu sheets will have a great influence on Al/Cu bimetal material. The superposition assumption of the element metal layer and its texture components for earing prediction successfully explained the major behavior for earing, which is a compromised result of the growth and decline in some preferred texture components. A principle of superposition is adapted to explain the earing tendency of the Al/Cu bimetal sheet, and there is agreement with the experimental findings obtained in this study.

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