Authors

M. Pohn, J. Bauer, A. Müller, Miba Sinter Austria GmbH, Vorchdorf

Year

2026

Print Info

Production/Publication ÖVK

Summary

As charging power for electric vehicles increases, both copper and aluminium components become critical: copper is indispensable for high-current contacts due to its excellent electrical conductivity, while aluminium is ideal for thermal management solutions thanks to its low weight and high thermal conductivity. High currents generate significant heat, requiring active cooling and complex geometries. The presented Cu/Al sintering technology enables the production of precise, functionally integrated components with tool-defined tolerances and allows monoblock designs without additional joining processes. The first application example - a copper high-current contact - demonstrates advantages over solid copper: improved machinability, silver-based contact coating, low contact resistance, and stable conductivity under load. The second example - an aluminium pin-fin plate - shows that fine cooling structures and sealing functions can be realized without machining; additionally, the weldability of sintered aluminium components is confirmed. A comparison of process routes (sintering vs. fully machined copper; sintering vs. impact extruded aluminium) quantifies performance and manufacturing effort. Finally, further application fields are outlined - from charging infrastructure and power electronics to battery cooling and busbars, as well as industrial non-automotive solutions. This contribution demonstrates that the Cu/Al sintering route is a technologically and economically compelling option for highly loaded electrical and thermal functional components.

ISBN

978-3-9504969-5-6

DOI

https://doi.org/10.62626/upat-y7mn Copy link

Order Members Login