How to Obtain High Load-Bearing Al-Cu Joints by Nanoscale Sculpturing

The electrochemical formation of high-mechanical-load-bearing Al-Cu joints and their characterization is presented in this paper. These Al-Cu joints rely on the mechanical interlocking between the Al and Cu layer obtained by nanoscale sculpturing of the Al joint partner, resulting in a hierarchical surface structure. The structure consists of cubes of various sizes acting like hooks. When enclosed by Cu the cubic Al hooks establish a rigid connection between the Al and Cu joint partners. In addition, the hierarchical cubic Al structures allow for a gradual transition from Al to Cu in the Al-Cu joint. Therefore, such Al-Cu joints exhibit an extraordinary load carrying ability compared to other Al-Cu joints.