Clad.It. CLAD METAL: What it is. How it s made. What it can do for you.
DO WHAT YOU THOUGHT YOU COULDN T. If metals exhibited all the properties we wanted, we could design anything we could imagine without regard to limitations. All kinds of currently impractical components would suddenly become feasible. We could design what was previously unworkable, creating new and optimized solutions. Or we could tailor a metal s properties to meet the specific needs of a design. Partially bonded four component composite demonstrating continuous roll bonding. 2
But though reality assures us that there are, indeed, limitations to what can be done with metal, we at EMS would like to assure you that there are far fewer limitations than you might have supposed. Thanks to the remarkable versatility afforded us by the cold-rolled cladding of metals a process largely developed right here when we were the clad metals operation of Texas Instruments it is possible to put disparate metals together in a way that opens the doors of design to an exciting new world of possibilities. So if you ve harbored the notion that there are particular characteristics you simply cannot obtain in a single metal, we urge you to think again. As you read through this brochure, don t be surprised if that design you once thought impossible to create, suddenly seems possible after all. 3
WHY CLAD? There are myriad ways that clad can help you increase performance as well as improve your bottom line. Clad metal coils can be up to 60 in diameter and weigh up to 12,000 pounds. 4
CLAD SAVINGS AND PERFORMANCE. Clad metals, with their unique ability to match virtually any need of a specific product design, offer design engineers some highly desirable benefits. Clad not only can allow you to expand your design possibilities, but also can provide significant improvements in product performance and manufacturability, and may even yield meaningful reductions in product costs as well. Pick up a U.S. quarter and you ll be holding a shining example of clad metal economy and performance. Clad coinage. Turn it sideways and you ll see a cost-effective 3-layer sandwich of cupronickel/copper/cupronickel, developed by EMS, that replaced much more costly silver, matched its look and feel, offered exceptional durability, and provided the precise resistivity and density required by automatic coin discrimination systems. Thermostat metal is an even more pervasive application of clad metal. Based on the translation of temperature changes into physical movement using the thermal expansion characteristics of different metals, clad thermostat metals are easily the most reliable and cost-effective sensing and actuating technology available today. From thermostats to circuit breakers, appliances to fluorescent lights, you are probably at this moment within a few feet of a thermal sensing device designed around bimetal. But coinage and thermostat metals are just two examples of how economies can be realized and performance enhanced through our proprietary methods of bonding two or more metals. EMS clad metals can also save money and im prove performance in more subtle ways, which is something our engineers would be happy to discuss with Thermostat metal coils. you. They re used to thinking about materials solutions in unconventional terms and they re adept at tailoring clad characteristics to precisely match a customer s application. In virtually all cases, our customers are able to reduce their total cost of ownership and enhance performance. For example, an entire sub-assembly could be eliminated along with the attendant labor, manufacturing and overhead. A manufacturing operation might be simplified. Or you might be able to offer your customers an extended warranty that would make your product more attractive to buyers. In fact, the more you know about clad metals, the more you ll come to realize the myriad ways that clad can help you increase performance as well as improve your bottom line. 5
It is possible to put disparate metals together in a way that opens the doors of design to an exciting new world of possibilities. 1000X photomicrograph of copper (top) to cupronickel bond line. Clad Metal (klad met l) n. Two or more metals or alloys joined by a roll-bonding and thermal treatment process that produces a bond at the atomic level. 6
METALS THAT CAN BE CLAD. Aluminum (Pure) Aluminum Alloys Beryllium Alloys Bismuth Brass Bronze Cadmium Cobalt Alloys Copper Copper-Nickel Alloys Electrical Resistance Alloys Gold Iron Lead Magnesium Magnesium Alloys Monel Nickel Nickel Alloys Nickel Aluminides Niobium Niobium Alloys Palladium Platinum Rhenium Silver Silver Alloys Steel - Maraging Steel - Stainless - Austenitic Steel - Stainless - Ferritic Steel - Alloy Steel - Carbon Tantalum Tantalum Alloys Tin Tin Alloys Titanium Titanium Aluminides Uranium Vanadium Alloys Zinc Zinc Alloys Zirconium Commercial Requires development Zirconium Zinc Alloys Zinc Vanadium Alloys Uranium Titanium Aluminides Titanium Basic cladding has been around for centuries. It originally served as a way to bond decorative gold or silver surfaces onto base metals. Perhaps the most famous example of an early clad metal product is the Damascus sword crafted from layers of steel and valued for its ability to take and keep an edge. Tin Alloys Tin Tantalum Alloys Tantalum Steel - Carbon Steel - Alloy Steel - Stainless - Ferritic Steel - Stainless Austenitic - Steel - Maraging Silver Alloys Silver Rhenium Platinum Palladium Niobium Alloys Niobium Nickel Aluminides Nickel Alloys Nickel Monel Magnesium Alloys Magnesium Lead Iron Gold Electrical Resistance Alloys Copper-Nickel Alloys Copper Cobalt Alloys Cadmium Bronze Brass Bismuth Beryllium Alloys Aluminum Alloys Aluminum - Pure Today, the cladding process has been refined to the point where it s become a highly sophisticated technology. We can clad virtually any combination of ductile metals and create a remarkably broad range of characteristics to fit an extensive and expanding range of applications. At EMS, we ve bonded well over a thousand different combinations of metals and alloys, in all shapes and sizes, including some with fifteen different metal layers in a single strip. The bonding technique we ve developed is so effective, there s no need for intermediate brazing alloys or adhesives. That s the genius of clad it s simple, it s clean, and it s permanent. For centuries, cladding remained virtually unchanged until EMS revolutionized the process in the mid-1960s. Today, modern cladding machinery and highly sophisticated heat-treating, rolling, and finishing techniques produce materials that provide singular performance characteristics for hundreds of products from tiny electrical contacts to truck bumpers, from cookware to engine oil coolers, from electronic components to automobile parts, plus residential and aircraft circuit breakers as well as appliance and industrial thermal controls. 7
HOW CLAD BECOMES CLAD. Anatomy of a metallurgical bond. Clad metals are joined by a roll bonding and thermal treatment process that produces a metallurgical bond as the lattice structures of the metals are forced into conformance with each other. High pressure, producing massive deformation of the metals, causes a sharing of electrons at the interface, which produces a bond on the atomic level. No intermediate layers such as adhesives or braze metal are involved. Roll bonding starts with two or more coils of cold finished strips of different metals or alloys. The metals are cleaned chemically, then abraded by a brushing operation to eliminate oxides and other surface impurities. The cleaned metals are rolled under very high pressure, which reduces their thickness and bonds the metals together. As their surfaces are extended, typically by more than five times that of their original area, the atomic lattices of the metals merge, sharing electrons between mating surfaces. Coils of bonded strip are heat treated to relax the materials and to extend diffusion of the electrons of one material into the other at the bond interface. Impurities that become gaseous when heated diffuse into the metals; nondiffusible impurities consolidate by spheroidization. 8
There are several ways we make clad metals at EMS, chief among them a continuous roll bonding process that combines two or more strips of metal. Cleanliness is paramount, so first, the individual strips are chemically or mechanically cleaned to provide contaminant-free surfaces. The strips then pass through a highly customized rolling mill designed specifically for cladding. As they pass through the mill, the rolls exert immense pressure that reduces strip thickness and Surface abrading. creates a metallurgical bond as the atomic lattices of the different metals merge into a common structure. The resulting composite material a clad metal derives its integrity from this shared electron interface. Heat is then applied to induce diffusion, which improves bond strength and provides stress relief for cold processing. The result: a clad metal imbued with precisely the right properties for its specific application. And that is the key benefit of cladding: the ability to combine the most desirable characteristics from different metals into a unique new metal composite that lets you do things you couldn t before. The examples on the following pages highlight how different characteristics have been combined in clad metals to meet a wide range of engineering and design goals. 24 wide bonding on one of many specially constructed bonding mills designed for high volume roll-to-roll production. 9
Appearance, corrosion resistance, light weight, recyclable. Stainless steel clad aluminum has become the material of choice for bright Class 8 truck bumpers because it has turned rust into a problem of the past. In fact, stainless clad aluminum bumpers may well outlast the tractors that carry them. In addition to the mirror finish and extraordinary corrosion resistance, owners appreciate the substantial weight savings clad bumpers provide when compared to chromed or painted steel, savings that contribute to greater fuel economy or higher payloads. Thermal conductivity, light weight, durability, magnetic permeability. For many years serious cooks have appreciated the performance benefits even heat conduction, light weight and easy clean-up of stainless steel clad aluminum cookware. The EMS roll-to-roll cladding process allows cost effective production of superior cookware that is clad overall, not just on the bottom. The process is also exceptionally precise, even at high volumes, holding tolerances as tight as 0.001 in., making our stainless clad aluminum ideal for induction cookware which requires a uniform magnetic layer to avoid uneven heating. Density, appearance, resource conservation. Since its invention by EMS, clad metal coinage has found favor in countries around the world. The original need was to replace silver with a lower cost material that had a more stable supply. The replacement also had to retain the appearance of silver and its compatibility with pay phones, vending machines and other coin acceptance systems. The solution was a clad metal composed of cupronickel/ copper/cupronickel which provides both the look of silver and the same density and electrical characteristics required for automatic coin discrimination. Today, many different metal combinations are available to meet the world s needs. CUPRONICKEL ALUMINUM STAINLESS STEEL COPPER STAINLESS STEEL 1.02mm (.040") Stainless Steel/2.16mm (.085") Aluminum ALUMINUM.55mm (.022 ) Stainless Steel/1.45mm (.057 ) Aluminum.19mm (.0076 ) Cupronickel/.78mm (.0307 ) Copper/.19mm (.0076 ) Cupronickel 10
Mechanical strength, conductivity, lightning protection, corrosion resistance. Cable and wire shielding that once was made of bronze alloy or copper now is often stainless steel or alloy steel clad on both sides with copper. The copper assists in reducing crosstalk and electrically protects the cable from lightning strikes or ground faults, while the steel strength increases resistance to gnawing rodents and reduces cost by allowing thinner gauge material to be used. And newly developed material systems offer improved attenuation performance over copper based alloys at lower cost. Joinability, corrosion resistance, weight reduction, strength. Manufacturers stymied by the impossibility of successfully welding aluminum to steel are turning to EMS aluminum clad steel transition material to solve the problem. Thin inserts of this material placed between aluminum and steel allow joining with existing welding equipment because the joining interfaces are now aluminum to aluminum and steel to steel. High strength ductile welds are produced and the corrosioninducing crevices between dissimilar metals are eliminated by the clad insert. Thermal expansion and contraction, reliability. Thermostat metals are two or more metals with different coefficients of expansion that are bonded together and change curvature in reaction to temperature changes. As formed parts or snap acting disks this movement is used to make and break circuits, indicate or compensate for temperature changes, release springs, open or close valves and perform many other tasks. Production of these high performance metals and parts, and understanding their innumerable applications and the customized processing parameters critical to their performance, has been at the heart of our business since its inception. STEEL ALUMINUM COPPER STAINLESS STEEL WELD NUGGETS THERMOSTAT METAL DISC WELDING ELECTRODE CLAD TRANSITION INSERT INVAR (Low Expansion) IRON NICKEL CHROME ALLOY (Hign Expansion).02mm (.0008 ) Copper/.09mm (.0034 ) Stainless Steel/.02mm (.0008 ) Copper 10-90% Aluminum or Steel 50% Alloy B (22% Ni, 3% Cr, 75% Fe) 50% Invar (36% NI, 64% Fe) 11
Thermal flexivity and corrosion resistance. Temperature variations in automotive transmissions change the viscosity of automatic transmission fluid, causing hesitations during shifting. To eliminate this, a thermostat metal valve varies its orifice dimensions as a function of fluid temperature to control fluid flow and maintain constant pressure. Benefits include precise control of the orifice and inherent repeatability. This simple, trouble-free, cost effective sensing and actuating technology has many potential applications in hydraulic and lubrication systems, as well as in power transmission. Durability, joinability, corrosion resistance. For heat exchangers and other assembled and brazed components, self-brazing materials of copper, aluminum, carbon or stainless steel clad with copper or bronze offer numerous cost-saving advantages over the traditional shim and paste approach. The cladding layer becomes the filler metal eliminating the need for critically positioned shims and paste and the chance of accidental loss or misplacement, improving brazing reliabilty. Fewer component parts means a reduction in manufacturing, assembly and inventory costs. Additional user benefits include manufacturing productivity gains, as well as process yield, quality and product design improvements. Diffusion alloying, improved processing and alloy performance. Clad metals can sometimes solve impossible processing problems. High aluminum stainless steel for catalytic converter foil is notoriously brittle and expensive to process. EMS DuraFoil solves this problem because it is processed as ductile aluminum clad stainless steel, then diffusion alloyed in situ during catalytic converter production. The process makes possible higher aluminum content yielding ultra-thin foil with improved oxidation resistance. Clad processing flexibility has allowed development of materials designed specifically for heavy duty diesel engine and close coupled automotive applications. STAINLESS STEEL TRUFLEX P675R.09mm (.0035") Truflex P675R Thermostat Metal COPPER.41mm (.016 )Stainless Steel/.05mm (.002 ) Copper 12
In situ alloying, joinability, improved process efficiency. Clad metals that form a braze alloy in situ are used to braze structural components in the engine exhaust systems of Airbus 340-500 and 340-600 long range aircraft. Seven layer material (ni-cu-ni-ti-ni-cu-ni) diffusion brazes internal honeycomb, brackets or braces of Timetal 21S high strength oxidation resistant beta titanium to a skin of the same material. The precise tolerance control of layers in the EMS cladding process provides consistent braze alloy chemistry, and roll-to-roll bonding is inherently more cost effective than one sheet at a time processes. Precious metal conservation, thermal conductivity. In electrical switching applications, contact life (switching cycles before failure) and reliability depend heavily on the electrical conductivity of the contact surface and good heat dissipation characteristics of the total system. Silver could meet both needs but copper can perform the thermal task at a fraction of silver s cost. A clad composite of silver/copper/steel is a cost effective solution providing a weldable contact that meets the regulatory electrical standards. Environmental safety, innovative, cost effective materials design and application. Our complete knowledge of metals and cladding as well as welding, stamping and forming techniques, lets us bring innovative solutions to electrical contact and contact assembly designs. For instance, silver cadmium oxide contact toxicity concerns can be eliminated by using alternate materials such as silver tin oxide, silver tin, indium oxide or silver nickel. And techniques like toplay bonding can produce a multigauge contact component that reduces costs by eliminating expensive assembly operations. SILVER COPPER STEEL SILVER TIN INDIUM OXIDE COPPER BEFORE AFTER 70% Titanium, 15% Copper, 15% Nickel (by weight).20mm (.008 ) Fine Silver/.81mm (.032 ) Copper/.20mm (.008 ) Steel Toplay contact:.70mm (0.0275") Silver Tin Indium Oxide (88Ag 12SnO 2 In 2 O 3 ) brazed to 1.57mm (.062") Copper 13
Electrical conductivity, magnetic permeability, weight reduction, ease of application. No single conventional material can provide electromagnetic and radio frequency interference (EMI and RFI) shielding for wide frequency ranges. TI-Shield, an EMS clad composite, combines the electrical conductivity of copper with the magnetic permeability of ferromagnetic material to achieve high-energy conduction, absorption and reflection. Its high performance-to-weight ratio means that very thin sections provide more EMI protection than traditional materials, and because it attenuates both magnetic and electrical fields, it reduces system costs. Chemical compatibility, electrical properties, appearance, formability. Clad metal battery materials enable designers to tailor components to meet specific needs. Having different metals inside and outside of the same part allows optimum chemical compatibility while minimizing overall thickness. Cladding guarantees perfect contact between surfaces and uniform electrical resistance. A thickerthan-plated exterior provides a more finished appearance with reduced contact resistance. Strength and formability can be altered by changing clad layer thickness. NICKEL STAINLESS STEEL COPPER Electrical properties, strength and high temperature corrosion resistance Fuel cells offer the potential of emission-free power generation for stationary and transportation applications. Individual cathode-electrolyte-anode cells assembled with bipolar plates form the stack which is the heart of the fuel cell. Clad metals, because they can combine outstanding corrosion, electrical and mechanical properties, are ideal for PEM fuel cell plates, electrolyzers and diffusers. They offer designers unique opportunities to optimize performance while reducing weight and the cost of manufacture. REFLECTION ATTENUATED INTERFERENCE VARIOUS CLAD METALS ABSORBTION INTERFERENCE Cu FERRO MAGNETIC MATERIALS Cu STAINLESS STEEL NICKEL PEM MEMBRANE 0.07mm (0.0028") Copper/0.21mm (0.0084") 49 Permalloy/0.07mm (0.028") Copper Caps:.02mm (.0008 ) Nickel/.19mm (.0076 ) Stainless/.04mm (.0016 ) Copper Cans:.02mm (.00075 ) Nickel/.22mm (.0085 ) Stainless/.02mm (.00075 ) Nickel Possible alloys: Al, Nb, Ni, SS,Ta, Ti, Zr. 14
EMS THERMOSTAT METALS Some of the things clad thermostat metal devices do: Over 100 thermostat metals are always in stock. Wherever there s a need to sense, control or protect. Thermostat metals comprise one of the most widely applied families of clad metals. Typically processed in strip form, they are combinations of metals that are selected and joined to best take advantage of the bimetal effect movement caused by their different coefficients of expansion, as they respond to temperature changes. At work, at home, in an airplane, boat or car virtually anywhere on earth you are almost always within reach of a thermostat metal device. At Engineered Materials Solutions we are a start-to-finish resource for materials and parts made from thermostat metals. We have produced more of these materials for more different applications than anyone else in the world. And we ve done it using a greater number of component metals yielding a higher number of materials combinations offering a wider range of performance parameters. It s given us an immense amount of knowledge about all aspects of the technology, from input material selection to measuring end product performance. We invite you to take advantage of what we ve learned and put this knowledge to work to maximize the performance and minimize the cost of your products. Regulate and control temperature on clothes irons, toasters, toaster ovens, coffee makers, ovens, clothes dryers, hair dryers, deep fat fryers, electric blankets, electric frying pans and tea kettles, rice cookers, griddles, grills and waffle irons, and others Protect fluorescent light ballasts from overheating Regulate room temperature Turn automotive fans on or off Record the temperature of food in transport to assure it has not varied from the safe frozen or not frozen range Protect home, office, factory electrical circuits Protect aircraft electrical circuits Open/close vent doors on furnaces and heating systems Open/close crawl space and attic vents Regulate electric range burner temperatures Protect electric motors from overloading Protect circuitry in computer and peripheral surge protectors Provide anti-scald protection in hospital and nursing home showerheads Protect tractor trailer self-adjusting brakes from over-adjusting Compensate for ambient temperature variations in car and SUV hatch and hood struts Compensate for viscosity variations due to temperature changes in automatic transmissions Assure correct readings by gas meters Protect circuits in large transformers Protect refrigerator motors and compressors from overload 15
WE SUPPORT YOU. Corrosion test cell. We hope it s clear by now that we want you to have precisely the combination of metallurgical properties you need for your specific application. Also, that we ll work in partnership with you to get it, always asking the question Is this the best solution for the intended application? Toward that end, our material testing and characterization procedures are extensive with capabilities that range from in-depth surface analysis to complex corrosion testing. The Bulk Analysis Lab performs a variety of tests on incoming materials and inprocess or finished materials, as well as on products that you may want tested. The Surface Analytical Lab looks at surface characteristics associated with the development of new clad systems, or with maintaining the quality of on-going production. The Non-Destructive Lab develops and implements new techniques and process control instrumentation for detecting and measuring the properties of clad metal, its structure, components and assemblies. The Welding and Brazing Lab solves joining problems that involve clad metal systems, and uses Differential Thermal Analy sis and other procedures to develop new joining methods. The Corrosion Lab carries out accelerated testing, in-service tests, and field tests that include salt spray, cyclic humidity, immersion, polarization and controlled potential, and more. As you can see, we re well prepared to provide you with the support you need to get to market faster with a better product. WE SUPPORT QUALITY. Differential thermal anaysis. In today s world of intense competition and hyper-speed, going it alone is no longer an option. It s the reason we place such strong emphasis on the concept of strategic alliance. And why we work with you to create a product that perfectly matches your needs. As part of our commitment to such an alliance, we ensure that an integral part of the clad metal you ve ordered is a component called quality. We are ISO 9001:2000 certified and tightly focused on continuous improvement of our organization, performance excellence and customer satisfaction. We employ Lean Manufacturing, Total Productive Manufacturing and Six Sigma methodologies as standard procedures in our ongoing continuous improvement efforts. In addition, the training of our technical and operations specialists is state-of-the-art, as are the controls, measurement tools and equipment they use. All of which we invite you to see in person by visiting our facilities. Of course, as part of your supply chain, we recognize that none of the above means much if you don t have the product. So we make sure that in addition to quality, we deliver what you want, when you want it. As our customers have discovered, that s the EMS way. Lab sample mill. 16
HOW TO GET STARTED WITH CLAD. If you ve read this far, then you re probably wondering how you might use clad metal in your own products as a cost-effective material solution. We urge you not to limit your thinking, because no matter what design limitations you ve faced in the past, clad metals offer you the opportunity to create new products, enhance the performance of existing products, or lower your total cost of ownership by simplifying a manufacturing process. As we ve done with so many of our customers, we can help you determine your needs and the best way to go about meeting them. It s possible that one of the hundreds and hundreds of clad combinations already available may fit your requirements exactly. But it s likely you ll need a tailored system, and we re ready to work closely with you as a team member to design one that will perfectly meet your needs. You can get started now by contacting us through the information on the following page. Electrical contact tape welding. Wrought silver inlay contact material for electrical components. 17
EMS IS... AND ALWAYS HAS BEEN... THE NUMBER ONE PROVIDER OF CLAD METAL SOLUTIONS. But we don t believe in resting on our laurels. Though we re a major manufacturing facility with the industry s largest assembly of clad metal development and production equipment including rolling mills for cladding under one roof; and though our lot-to-lot consistency and quality is the best in the world, we continue to seek ways to im prove our products and our services. The industries we serve appliance, automotive, heavy truck, electrical distribution, home ventilation and air conditioning, industrial control, telecommunications and more have come to rely on our quality and expertise. And as strategic partners, we re committed to providing them with high value through our knowhow and experience as well as technology and process sharing. Our company was created almost a hundred years ago and grew to its current size as part of Texas Instruments. Throughout that period, we perfected well over a thousand metallurgical combinations, and there are more on the way. These tailored clad metal solutions, created through close working relationships with end users, give our customers a competitive edge, and in many cases, allow them Contact assembly and forming using clad metal and monometal. to trim manufacturing costs. Either way, the process is productive and the outcome is positive. We hope you ll be in touch, because we can do the same to help you. Engineered Materials Solutions Inc. 39 Perry Avenue Attleboro, MA 02703 U.S.A. Phone: 508 342-2100 Fax: 508 342-2125 E-mail: sales@emsclad.com www.cladit.com High speed stamping. 18
Clad metals can often solve unsolvable processing problems A clad U.S. quarter is durable, practical, economical, recognizable, and touches just about everyone. Timetal is a registered trademark of Titanium Metals Corporation. DuraFoil and TI-Shield are registered trademarks of Engineered Materials Solutions, Inc. 2007 Engineered Materials Solutions 19
39 Perry Avenue Attleboro, MA 02703 U.S.A. Phone: 508 342-2100 Fax: 508 342-2125 E-mail: sales@emsclad.com www.cladit.com