how can I add a 1mm coating of aluminum or copper to steel?

[kristoffon]

The coating is supposed to carry induced electrical currents better than the steel itself. Would be placed on a steel plate 20+mm thick. Due to large magnetic fields and large forces induced by magnetism this must be a mechanically strong coupling. Does anyone know of a process I could use? Thanks.

 

[btrueblood]

Brazing?

 

[DVWE]

Hot dip aluminizing - similar to hot dip galvanizing.

 

[kristoffon]

Brazing won't do because it needs to be done between close fitting fixed parts, and I need the aluminum to be a finish coat. Thanks though.

I'm looking into hot dip aluminizing and it seems promising. Can't find a commercial provider of this service though. Thanks!

 

[unclesyd]

The only way I'm familiar for pure Aluminum with any thickness is with the Wire Arc transfer process. Make sure you specify pure Al no Nickel. With all of the above information I've never had pure Aluminum deposited without some other primary metal to help with the bonding and NiAl is the primary bonding aid and I know you do want that. I assume it can be done maybe with a little trouble.

I would give both White and Brodeur a call and discuss your specific requirements.

http://www.whiteengineering.com/wirearc-pure-metal-coatings.html

http://www.brodeurmachine.com/coatings.htm

 

[Compositepro]

Explosive cladding.

 

[mfgenggear]

does the coating have to be 1 mm thick?

 

[kristoffon]

Yes, the coating thickness is calculated as a function of the skin-effect for conduction of electrical current. If it is thicker, though, it could be machined down...

 

[arunmrao]

Without knowing much about your objective,I have a few suggestions.What you are trying to replicate,in efffect is used in induction heating equipment. However,they use copper tubing with internal water flow for cooling the tubes. I see this missing in your setup. How do you plan to dissipate the heat,else in no time your cladding will give way. Just a few layman concerns

 

[DVWE]

You could also look into plasma-spray bonded coating.

 

[mfgenggear]

copper ring shrink fit on outside dia. then low temp. brazed.then machine the od to size.

 

[kristoffon]

For heat dissipation the whole setup will be immersed in water.

I'll look into all ideas, thanks everyone.

 

[ornerynorsk]

Thermal spray or elecroplating. I've seen plating (accidentally) brought up to over .020" thick, I assume 1mm is possible, as well.

 

[EdStainless]

You can buy steel plate with either Al or Cu roll bonded to it. They make cookware out of it.

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