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 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: 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: A multi-layer metal composite for microwave tubing and the like, which comprises a tubular shaped copper alloy base metal (e.g., brass or phosphorus bronze) lined with silver. A relatively thin interliner layer of a grain refiner containing copper alloy (e.g., copper-zirconium alloy (C15100), tellurium-copper (C14530), cadmium-copper (C14300), manganese-copper (C15500), alumina-copper (C157XX), beryllium-copper (C17410), or the like) is provided between the base metal and the silver, for limiting diffusion of impurities from the base metal into the silver coating and for maintaining a smooth, relatively constant cross section of silver.