Copper-Aluminum Thermal Block

Copper conducts fast but is heavy and expensive; aluminum is light and cheaper but conducts less. The hybrid idea is to use copper only at the contact face.

How they are joined

Typically the copper insert is pressed or brazed into the aluminum body. Any void at the joint raises interface resistance, so surface roughness and joining pressure are controlled together.

Where it fits

High heat flux situations where solid copper is overkill. The structure should follow thermal simulation results — we do not recommend fixing copper thickness by rule of thumb.

Process notes

Separate machining of copper and aluminum, joint surface preparation, press or braze, flatness correction, optional nickel plating, joint sampling.

Applications

High power lasers, power modules, server cold plates, power electronics.