High throughput continuous processing of aluminum alloys for electrical interconnect components

Abstract

A tempering process for tempering an aluminum alloy coil includes a first reel-to-reel process including an anneal to solutionize the aluminum alloy followed by a quench, a second reel-to-reel process comprising rolling reduction, and a hardening anneal performed on the aluminum alloy coil. Cladding may be performed during the second reel-to-reel process; or a subsequent reel-to-reel electroplating process may be performed including an alkaline soak clean, an alkaline microetch and seed electroplating, and aqueous electroplating of a contact metal onto the seed electroplating. Electrical interconnect components may be stamped from the tempered and clad or electroplated aluminum alloy coil. The electrical interconnect components may, for example, be connectors, lead frames, or bus bars.