Aluminum Material With an Oxide Interlayer for High-Temperature Adhesion
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Solution Overview
Problem
Existing metal materials with a nickel coating on an aluminum base experience peeling issues in high-temperature environments due to insufficient adhesion, and there is a need for improved heat resistance and bending workability.
Innovation Solution
A metal material comprising a base material with an oxide layer of aluminum, nickel, and oxygen, where the oxide layer has a thickness between 50 nm and 250 nm, and a two-layer structure with specific atomic compositions and thicknesses, enhancing adhesion through an anchor effect and pore distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a nickel coating is applied on an aluminum base material, then adhesion is improved, but heat resistance deteriorates due to peeling in high-temperature environments
Solution Approach 1:
The coating structure is segmented into multiple layers: a base aluminum layer, an intermediate oxide layer containing aluminum and nickel oxides, and a top nickel layer. This segmentation prevents direct contact between aluminum and nickel, eliminating the source of peeling while maintaining adhesion through the oxide intermediate layer.
Solution Approach 2:
An oxide intermediate layer is introduced between the aluminum base material and the nickel coating layer. This oxide layer acts as a mediator that prevents direct diffusion between aluminum and nickel, thereby preventing peeling at high temperatures while maintaining structural integrity and adhesion.
2Reliability
If the oxide layer thickness is increased to suppress diffusion, then heat resistance is improved, but bending workability deteriorates
Solution Approach 1:
The oxide layer thickness is precisely controlled within the range of 50-250 nm. This parameter optimization ensures sufficient thickness to suppress aluminum-nickel diffusion and improve heat resistance, while remaining thin enough to maintain bending workability and flexibility of the base material.
Data Source
AI summary
A metal material comprising: a base material; an oxide layer disposed on a surface of the base material; and a metal layer disposed on a surface of the oxide layer, wherein the base material includes aluminum, the oxide layer includes aluminum, nickel, and oxygen, the metal layer includes nickel, and an average thickness of the oxide layer is no less than 50 nm and no more than 250 nm.