Stamping Parts Multi-Layer Material Combination

Multi-layer material combinations (also called clad metals or composite sheets) are innovative solutions in stamping part production, combining the advantages of different metals to create parts with enhanced properties—such as corrosion resistance, conductivity, or strength—unachievable with single-layer materials. These layered structures (e.g., aluminum-steel, copper-stainless steel, or nickel-brass) are bonded via processes like roll bonding, explosive bonding, or thermal diffusion, then stamped into parts for industries like electronics, automotive, and renewable energy.

A key benefit of multi-layer materials is property customization. For example, a copper-aluminum clad sheet (50% copper, 50% aluminum) combines copper’s high electrical conductivity (for current transfer) with aluminum’s light weight (for reducing part mass)—ideal for stamping electrical busbars in electric vehicles (EVs). The copper layer ensures efficient power transmission, while the aluminum layer cuts weight by 30% compared to a solid copper busbar, improving EV range.

Another advantage is corrosion resistance. A stainless steel-aluminum clad sheet (stainless steel outer layer, aluminum inner layer) is used for stamping automotive exhaust components: the stainless steel resists high-temperature corrosion from exhaust gases, while the aluminum reduces weight and cost. Similarly, a nickel-copper clad sheet is used for stamping marine hardware, as nickel’s resistance to saltwater corrosion protects the copper core (which provides strength).

Stamping multi-layer materials requires specialized considerations. The bond between layers must be strong enough to withstand forming forces—roll-bonded materials (with bond strengths of 15–30 MPa) are preferred for deep drawing or bending. Tooling must account for differences in material hardness: for example, stamping a brass-stainless steel clad sheet (brass HRB 50, stainless steel HRB 70) requires a punch with variable edge angles to avoid delamination. Press force must also be calibrated to the combined thickness and strength of the layers—too much force can split the layers, too little can cause incomplete forming.

Real-world applications highlight their value. In electronics, a gold-copper clad sheet is stamped into connector pins: gold’s low contact resistance ensures reliable signal transfer, while copper’s conductivity keeps costs lower than solid gold. In renewable energy, a titanium-steel clad sheet is stamped into solar panel frames: titanium resists outdoor corrosion, while steel provides structural support. By combining multiple materials, manufacturers can create stamping parts that meet complex performance requirements—balancing cost, weight, strength, and functionality—for next-generation products.

Read recommendations:

Sealing ring Precision electronic parts

Housing components for recessed downlights Precision electronic parts

Oval Magnetic Hardware Precision electronic parts

CNC Machining Dimension Accuracy

CNC processing factory - Meeting customers' strict requirements for precision