In this study, the mechanical properties and wear behavior of an Al/Cu/Sn/Ni multi-layered composite (MLC), fabricated through a two-step process—accumulative roll bonding (ARB) process followed by post heat treatment—up to the 6th cycle, were investigated. The results showed that the ultimate tensile strength (UTS) and hardness of the MLC continuously increased from the 1st to the 6th cycle. This improvement was attributed to the uniform distribution of the layers, the development of an ultrafine-grained (UFGed) structure, the formation of a multiple grain size (including recrystallized, elongated, and grown grains), and the filling of interfacial cracks with molten Sn in the microstructure. The highest UTS is related to the 6th cycle, which is equal to 145 MPa. Moreover, the hardness of the Al, Cu, and Ni layers in the final cycle reached 63 HV, 109 HV, and 133 HV, respectively. However, factors such as formation of many Kirkendall cavities and cracks due to formation of AlCu and Al 3Ni 2 intermetallic compounds, and fragmentation of the three reinforcement layers of Cu, Sn and Ni in the Al matrix, and the brittleness of the fracture surface of the layers causes that the UTS and hardness of the MLC during the final cycle has not increased significantly compared to the initial ones. It had also led to decrease the El and toughness during the final cycle in comparison to the initial ones. The El and toughness of the MLC during the 6th cycle have reached to 7.6% and 5.9 × 10 +6 J.m -3, respectively. In terms of wear mechanisms, due to the low hardness and weak interfacial bonding during the initial cycles, adhesive, abrasive, and delamination wear were dominant. However, during the final cycle, due to the increased hardness and the greater number of interfaces, delamination, spalling, and fatigue became the predominant wear mechanisms. Likewise, oxidation wear as a result of post heat treatment was occurred on the wear surface of the MLC from the 1st to 6th cycle.
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