This study introduces a novel manufacturing process; called single-press channel die bonding (SPCB), for producing a laminate composite of Aluminum 2024 reinforced with copper nano-powders. The process is designed based on severe plastic deformation (SPD) by a single step pressing in a channel die (warm deformation: T < 0.5Tm) following with discontinuous post heat treatment. Microstructural analysis was conducted using optical and scanning electron microscopies, energy-dispersive x-ray spectroscopy, and electron backscattered diffraction techniques to investigate the correlations between microstructure and mechanical properties. The microstructural analysis revealed a fine grain/sub-grain structure, good bonding, and the occurrence of grain nucleation and growth on the interfaces due to continuous dynamic recrystallization (cDRX) and continuous static recrystallization (cSRX). Mechanical properties were explored through tensile testing, hardness measurements, and nano-indentation studies. The results demonstrated that the resulting reinforced composite exhibits significantly improved tensile strength and toughness, measuring 355 MPa and 72 J, respectively, which is approximately two and three times higher than the raw material and exceeds previously reported data in the same field of Al alloys. The high strength, ductility, and toughness of the composite are contributed to the microstructural refining and high strength of bonding in the interfaces which have been confirmed by EBSD and fractographic studies.
