Investigation of Electrically-Assisted Rolling Process of Corrugated Surface Microstructure with T2 Copper Foil

Electrically-assisted (EA) forming is a low-cost and high-efficiency method to enhance the formability of materials. In the study, EAF tensile tests are carried out to study the properties of T2 copper foil in an annealed state, and the effect of the electric current on the forming quality of corrugated foils is further studied in the EA rolling forming process. The result shows that the current reduces the flow stress and the fracture strain, which is different from the result of rolled samples. The joule heating effect on mechanical properties is significant in EA tension, and the softening effect of the surface layer can be observed at tensile strength, due to the grain size effect. Moreover, the current can weaken the grain size effect. In the rolling forming process, the influence of different electrical parameters on the forming height is remarkable, especially for the rolled T2 copper. The appropriate electrical parameters can improve the forming height, while keeping a small thickness thinning. Nevertheless, the high current density will lead to local rupture. This study proves that the current can improve the forming quality of the corrugated foils and is a promising surface texture forming process.