Analysis of Deformation Behaviour and Residual Stress in Rotary Swaged Cu/Al Clad Composite Wires

Both copper and aluminum are widely applicable throughout a variety of industrial and commercial branches, however, joining them in a composite provides the possibility of combining all their advantageous properties in one material. This study investigates uniquely sequenced copper–aluminum clad composite wires, fabricated via rotary swaging technology. The composites were processed at 20 °C and 250 °C to a diameter of 5 mm. Structural observations and the determination of residual stress within both elements of the swaged wires were performed via electron microscopy; the experimental results were correlated with numerical predictions. As shown in the results, both the applied swaging force and temperature affected the plastic flow, which had a direct influence on residual stress and texture development; the Al(sheath) elements exhibited ideal rolling textures, whereas the Cu(wires) elements featured ideal shear texture orientation. The grains within both the Al(sheath) elements of the 5 mm composite wire were refined down to sub-micron size. Structural restoration also had a positive influence on residual stress.