Abstract:Cu/Al composites are widely utilized across various industries due to their lightweight and excellent electrical conductivity. However, the impact of different manufacturing methods on the interfacial structure and mechanical properties of these composites remains significant. In this study, Cu/Al composite plates were fabricated using rolling and underwater explosive welding techniques to systematically compare their interfacial microstructure and mechanical performance. Interface morphology, grain orientation, grain boundary characteristics, and phase distribution were analyzed through optical microscopy, scanning electron microscopy, and electron backscatter diffraction. Mechanical properties were assessed using tensile shear tests, 90° bending tests, and hardness measurements, with Vickers hardness and nanoindentation tests providing further insight into hardness distributions. The results indicate that the diffusion layer in rolled Cu/Al composites is relatively fragile, while those produced by underwater explosive welding feature a diffusion layer approximately 18 μm thick, metallurgically bonded through atomic diffusion. The tensile shear strength of these composites ranges from 64.14 to 70.84 MPa, with superior flexural performance demonstrated in the 90° three-point bending test by the underwater explosive welded samples. This study elucidates the effects of distinct manufacturing methods on the interfacial properties and mechanical performance of Cu/Al composites, offering essential insights for selection of manufacturing method and application.