Abstract: A tempering process for tempering an aluminum alloy coil includes a first reel-to-reel process including an anneal to solutionize the aluminum alloy followed by a quench, a second reel-to-reel process comprising rolling reduction, and a hardening anneal performed on the aluminum alloy coil. Cladding may be performed during the second reel-to-reel process; or a subsequent reel-to-reel electroplating process may be performed including an alkaline soak clean, an alkaline microetch and seed electroplating, and aqueous electroplating of a contact metal onto the seed electroplating. Electrical interconnect components may be stamped from the tempered and clad or electroplated aluminum alloy coil. The electrical interconnect components may, for example, be connectors, lead frames, or bus bars.

Abstract: A layered structure for forming charging terminals for high power applications. In some embodiments, the layered structure may include a substrate and a contact layer disposed over at least a portion of the substrate. The substrate may have a conductivity greater than 40% International Annealed Copper Standard (IACS). The contact layer may demonstrate a coefficient of friction of less than 1.4, such as from 0.1 to 1.4, as measured in accordance with American Society of Testing and Materials (ASTM) G99-17. The contact layer may include a precious-metal-based alloy, such as a silver-samarium alloy.

Abstract: A stiff, lightweight metal laminate includes a first continuous metal layer, a second continuous metal layer, and a reduced density metal core layer disposed between the first and second continuous metal layers. The reduced density metal core layer comprises a core metal and has an average density that is less than the density of the core metal. Planar metallurgical bonds secure the first and second continuous metal layers to the reduced density metal core layer. The metal laminate may be manufactured by press rolling the reduced density metal core layer sandwiched between the two continuous metal layers, after removing or overcoating the native oxide layer on each layer surface that contacts another layer in the metal laminate.

Abstract: Connectors including one or more electrical contacts and a magnetic portion are disclosed. The magnetic portion is made from a copper alloy comprising nickel, tin, manganese, and balance copper. In some embodiments, the electrical contact(s) are the magnetic portion. In other embodiments, the magnetic portion is a separate element from the electrical contact(s). Also disclosed are connectors for mating a host electronic device with an accessory which both include magnetic portions. Further described herein are methods for mating host electronic devices with an accessory using such connectors.

Abstract: A stiff, lightweight metal laminate includes a first continuous metal layer, a second continuous metal layer, and a reduced density metal core layer disposed between the first and second continuous metal layers. The reduced density metal core layer comprises a core metal and has an average density that is less than the density of the core metal. Planar metallurgical bonds secure the first and second continuous metal layers to the reduced density metal core layer. The metal laminate may be manufactured by press rolling the reduced density metal core layer sandwiched between the two continuous metal layers, after removing or overcoating the native oxide layer on each layer surface that contacts another layer in the metal laminate.

Abstract: A stiff, lightweight metal laminate includes a first continuous metal layer, a second continuous metal layer, and a reduced density metal core layer disposed between the first and second continuous metal layers. The reduced density metal core layer comprises a core metal and has an average density that is less than the density of the core metal. Planar metallurgical bonds secure the first and second continuous metal layers to the reduced density metal core layer. The metal laminate may be manufactured by press rolling the reduced density metal core layer sandwiched between the two continuous metal layers, after removing or overcoating the native oxide layer on each layer surface that contacts another layer in the metal laminate.

Abstract: A tempering process for tempering an aluminum alloy coil includes a first reel-to-reel process including an anneal to solutionize the aluminum alloy followed by a quench, a second reel-to-reel process comprising rolling reduction, and a hardening anneal performed on the aluminum alloy coil. Cladding may be performed during the second reel-to-reel process; or a subsequent reel-to-reel electroplating process may be performed including an alkaline soak clean, an alkaline microetch and seed electroplating, and aqueous electroplating of a contact metal onto the seed electroplating. Electrical interconnect components may be stamped from the tempered and clad or electroplated aluminum alloy coil. The electrical interconnect components may, for example, be connectors, lead frames, or bus bars.

Abstract: A stiff, lightweight metal laminate includes a first continuous metal layer, a second continuous metal layer, and a reduced density metal core layer disposed between the first and second continuous metal layers. The reduced density metal core layer comprises a core metal and has an average density that is less than the density of the core metal. Planar metallurgical bonds secure the first and second continuous metal layers to the reduced density metal core layer. The metal laminate may be manufactured by press rolling the reduced density metal core layer sandwiched between the two continuous metal layers, after removing or overcoating the native oxide layer on each layer surface that contacts another layer in the metal laminate.

Abstract: Methods of producing composite products formed between at least two different metal structures in a side-by-side configuration are provided. The method includes providing at least two structures made of different materials that are not compatible for welding or conventional cladding processes. A geometric profile is provided in at least one of the edges of the first structure, and a corresponding mirror image of the geometric profile is provided in a corresponding edge of the second structure. The two structures are positioned together so that the profiled edge or edges form a complimentary composite structure and are then solid-phase bonded to form a composite product. The process may be repeated with additional structure at either end of the first or second structure to achieve multiple side-by-side products. The methods and corresponding products provided herein yield edge to edge products suitable for various electrical connection type applications.

Abstract: Methods of producing composite products formed between at least two different metal structures in a side-by-side configuration are provided. The method includes providing at least two structures made of different materials that are not compatible for welding or conventional cladding processes. A geometric profile is provided in at least one of the edges of the first structure, and a corresponding mirror image of the geometric profile is provided in a corresponding edge of the second structure. The two structures are positioned together so that the profiled edge or edges form a complimentary composite structure and are then solid-phase bonded to form a composite product. The process may be repeated with additional structure at either end of the first or second structure to achieve multiple side-by-side products. The methods and corresponding products provided herein yield edge to edge products suitable for various electrical connection type applications.

Abstract: A niobium-clad bipolar plate for use in a proton exchange membrane fuel cell is disclosed, whereby the electrically conductive, corrosion resistant niobium cladding protects a highly electrically conductive base metal in a harsh environment for the purpose of communicating electrical energy from the cathode of one membrane-electrode assembly to the anode of a second membrane-electrode assembly. Alternatively, the niobium-clad bipolar plate can include a titanium interlayer, interposed between the niobium cladding and the base metal. Also disclosed is a system for producing electricity using a niobium-clad bipolar plate in combination with numerous membrane-electrode assemblies to provide electrical energy and a proton exchange membrane fuel cell comprising a niobium clad-bipolar plate.

Abstract: Methods of and devices for continuously casting molten material onto one or more surfaces of a moving substrate to provide one or more profiles on one or more surfaces are disclosed in the present invention. In a preferred embodiment, the casting method includes providing a substrate, heated reservoir of a molten material, and a casting die; moving the substrate past the casting die into which the molten material is introduced; containing the molten material against the one or more surfaces of the moving substrate; heating the casting die to prevent the molten material from solidifying prematurely; and cooling the molten material to solidify the molten material to provide one or more profiles on the one or more surfaces of the moving substrate and to bond the solidified profile(s) to the one or more surfaces.

Abstract: A process for adding calcium to a bath of molten ferrous material is disclosed in which a calcium metal-containing wire is fed through a refractory lance into the bath. Recirculatory stirring of the molten ferrous material is accomplished with an inert gas flow through the lance. The calcium-containing wire is fed at such a rate that it substantially bends towards the horizontal direction after it leaves the lance and melting of the calcium in the wire occurs primarily in or directly below a region of downwelling of the molten ferrous material. Suitable wire feeding rates will depend upon the disposition of the lance in the bath and the composition (e.g. clad or unclad) and cross-sectional dimensions of the calcium metal-containing wire.

Abstract: After measuring the bulk resistance the surface of high strength low alloy steel material is treated to form a high resistance coating on its surface. When resistance welding the material the coating permits weld formation without significant expulsion or excessive electrode force over a wide range of operating conditions.