This study examines the influence of layer thickness (0.9, 1.6, 2.4, and 4 mm) on the distribution of residual stress, microstructural evolution, and tensile properties of Cu18150/Al1060/Cu18150 multilayered composites fabricated via a combined cast-rolling and hot-rolling technique. The grain refinement, dislocation density, and residual stress gradients across the interfaces were characterized and analyzed using integrated electron backscatter diffraction and kernel average misorientation mapping. The results demonstrated that specimens with a lower layer thickness (0.9-1.6 mm) possess a significantly improved tensile strength of 351 MPa, which is mainly due to the significant grain refinement and the presence of compressive residual stresses at the region of the Al/Cu interfaces. However, tensile strength decreased to 261 MPa in specimens with thicker layers (4 mm), accompanied by improved ductility, e.g., elongation of 30%. This is associated with a reduction in the degrees of interfacial constraint and the formation of more homogeneous deformation structures that accommodate a larger strain. The intermediate layer thickness of 2.4 mm offers an optimal compromise, achieving a tensile strength of 317 MPa while maintaining balanced mechanical performance. These results emphasize the importance of layer thickness in controlling such stress profiles and optimizing the mechanical behavior of hybrid metal composites, providing useful guidance on the design and fabrication of superior structural-form materials.
