Multilayer composites fabricated by accumulative roll bonding: process design, deformation behavior, and functional properties

Abstract Accumulative roll bonding (ARB) is a severe plastic deformation (SPD) technique derived from conventional rolling, which allows for the introduction of large equivalent strains while maintaining nearly constant macroscopic dimensions, and can also provide high-density interfaces and enable the customization of microstructures. Due to these features, ARB is especially effective for the fabrication of large-scale multilayer composites. This paper reviews progress in ARB multilayer composites, focusing on three aspects: ARB principles and process development, deformation behavior, and functional properties. First, the effects of key processing parameters on interfacial bonding and microstructural evolution are discussed, and the role of process development in enhancing interfacial stability and deformation compatibility is highlighted. Second, the evolution of mechanical properties under severe plastic deformation is analyzed, with particular attention to the roles of interfacial bonding, dislocation accumulation, and heterogeneous interfaces in strengthening, plasticity retention, and crack propagation control. Finally, recent advances in the functional properties of ARB multilayer composites, including thermal stability, thermal conductivity, electrical and superconducting performance, wear resistance, and irradiation resistance, are reviewed, with a focus on how interface characteristics and layer thickness influence multifunctional synergistic optimization. On this basis, current challenges related to interfacial stability, multiscale deformation mechanisms, and engineering applications are identified, and future research directions are outlined. This paper aims to provide a comprehensive reference for the structural design, performance optimization, and engineering application of ARB multilayer composites.