Abstract: A composite structure is manufactured by joining a first material, preferably made of a magnetically permeable material and having a first joining surface in which a recess having an overhang surface is formed, to a second material, preferably made of an electrically conductive material and having a second joining surface to be joined to the first joining surface of the first material. On the second joining surface is integrally formed a protrusion having an outer configuration substantially corresponding to the inner shape of the recess. The first and second materials are firmly mechanically joined to each other by, for example, a casting method, a rolling method, a pressing method, or a method utilizing plastic flow of the second material.

Abstract: A method of producing an anchor bonded composite plate. Anchor cavities are formed in a base plate by placing a forming plate with a circular hole therethrough over the base plate at a selected anchor cavity location. A punch placed through the circular hole then applies a punching force to the base plate, thereby forming in the base plate an annular mound with a concentrically punched hole. The mound is next pressed with a leveling plate to cause the material of the mound to flow inside the punched hole forming an anchor cavity with an overhanging internally tapered surface. A cladding plate with a plurality of anchor holes is then placed on the base plate with its holes aligned with the cavities of the base plate. An anchor pin is inserted in the thus aligned openings and is plastically deformed to mechanically bond the plates together. The cladding plate and the base plate may be made of an aluminum alloy and a hard steel, respectively.

Abstract: A composite structure is manufactured by joining a first material, preferably made of a magnetically permeable material having a first joining surface in which a recess having an overhang surface is formed, to a second material, preferably made of an electrically conductive material having a second joining surface to be joined to the first joining surface of the first material. On the second joining surface is integrally formed a protrusion having an outer configuration substantially corresponding to the inner shape of the recess. The first and second materials are firmly mechanically joined to each other by, for example, a casting method, a rolling method, a pressing method, or a method utilizing plastic flow of the second material.