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

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

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

(OP)
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.

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

Brazing?

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

Hot dip aluminizing - similar to hot dip galvanizing.

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

(OP)
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!

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

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
 

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

Explosive cladding.

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

does the coating have to be 1 mm thick?

 

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

(OP)
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...

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

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

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

You could also look into plasma-spray bonded coating.

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

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

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

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

I'll look into all ideas, thanks everyone.  

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

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

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

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

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