Abstract <p>In this study, Al/Cu/Sn/Ni multilayer composite (MLC) was produced by accumulative roll bonding (ARB) process up to 6 cycles. Ni and Cu layers fragmented during the sandwich and 2nd cycles, respectively, while the Sn layer stayed continuous until the 6th cycle. X-ray diffraction pattern (XRD) analysis detected Al₃Ni₂ and AlCu intermetallic compounds in the 6th cycle. During the 3rd and 6th cycles, many grains were elongated along the rolling direction, and numerous dynamic recrystallization (DRX) grains formed in some parts of the Al matrix. Furthermore, at the 6th cycle, in addition to DRX and elongated grains, the grain growth (GG) had been formed in the Al matrix, creating the multiple grain size. The average grain size during the 3rd and 6th cycles is equal to 0.55&#xa0;µm and 0.65&#xa0;µm, respectively. The tensile strength increased up to 188 MPa after 6 cycles. During the 6th cycle, the elongation and toughness is abruptly decreased compared to the initial ones and reached 6.5% and 10 × 10⁺⁶J&#xa0;m⁻³, respectively. Furthermore, the microhardness of the individual layers increased continuously with increasing numbers of ARB cycles. Due to the low hardness during the initial cycles, the wear mechanisms include adhesive, delamination, and abrasion. In contrast, during the final cycles, the increase in hardness and the number of interfaces leads to the emergence of delamination, fatigue, and spalling wear mechanisms. Until the 3rd cycle, the fracture surface of the Al and Cu layers was ductile and the Ni and Sn layers was brittle. Finally, during the last cycle, the fracture surface of all layers was brittle.</p> Graphical abstract <p></p>