Microchannels on metallic substrates are essential parts of microreactors, micro heat exchangers, micro heat sinks, and fuel cell bipolar plates. Because of superior properties, such as good corrosion resistance, excellent thermal conductivity, high strength, excellent ductility and structural stability, composite metal foils are gaining popularity as substrates for microchannels. With the increasing demands of low cost, high efficiency and accuracy, novel micro forming technologies must be capable of creating intricate and precise micro features of microchannels at a low cost. An ultra-thin metal foil rolling for the fabrication of micro composite channels is proposed in this study, which can improve product function and reduce operational costs. Copper/ stainless steel 304L (SS304L) composite foils with a thickness of 0.41 mm after annealing treatment at 800 ℃ and holding for 0.5 h, 1.0 h and 2.0 h are used to fabricate microchannels under the rolling reduction of 60.9%. The hardne
Copper microchannels have been attracting more and more attention due to the increasing demands for multifunctional microcomponents in the field of micromanufacturing. In the present work, the forming of microchannels on copper foils was studied by micro rolling. Copper foils with the thickness of 0.1 mm were selected and annealed at 400, 500, 600, 700 and 800 °C for 10 min prior to micro rolling, and the formability and quality of microchannels were systematically investigated. The results show that an optimal annealing temperature of 500 °C is beneficial to the forming of microchannels with high surface quality. A series of electron backscatter diffraction (EBSD) tests were performed in order to explore the effect of annealing temperatures on the formability of copper foils during micro rolling, and the results indicate that the high forming accuracy of microchannels with copper foils annealed at 500 °C is mainly attributed to the high geometric dislocation density. Additionally,