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Precision Rolling Lines
Rolling, slitting and dimensional control
Clad & Weld Process
Our proprietary Clad & Weld process creates metallurgically bonded bimetallic materials with superior performance characteristics.
Validation Capability
From Process Capability to Procurement Evidence
Raytron connects material selection, process control and inspection items to procurement specifications so engineering, quality and sourcing teams can align before RFQ.
| Stage | Key Checks | Evidence Buyers Should Request |
|---|---|---|
| Material and surface preparation |
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| Cladding and heat treatment |
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| Final release |
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Test Methods & Applicability
Clad & Weld Evidence Modules
The following test items can be provided per product form, purchase specification and customer agreement. Unpublished data is available upon NDA / request. No fabricated data.
Metallographic Cross-Section
- Applicable Product
- CCA, CCS, NCC clad conductors
- Test Method
- Cross-section preparation and microscopic examination of clad layer continuity and interface
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per product control plan or qualification plan
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- Continuous clad layer, no visible interface defects
- Reference Standard
- ASTM B748 / ISO 1463
- Limitations
- Sample represents a specific cross-section, not full-length evaluation
EDS Line Scan
- Applicable Product
- CCA, CCS, NCC clad conductors
- Test Method
- Energy dispersive spectroscopy line scan across bond interface
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per qualification plan
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- Composition transition consistent with clad & weld process
- Reference Standard
- ISO 22309
- Limitations
- Semi-quantitative; requires calibration against reference samples
Layer Thickness Distribution
- Applicable Product
- CCA, CCS, NCC wire and strip
- Test Method
- Multi-point measurement of clad layer thickness uniformity on cross-section
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per product control plan
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- Per product specification and customer agreement
- Reference Standard
- ASTM B748 / ISO 1463
- Limitations
- Thickness may vary around circumference; reported as statistical range
Peel / Shear Test
- Applicable Product
- CCA, CCS, NCC clad conductors
- Test Method
- Peel or shear test of clad bond interface
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per product control plan or qualification
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- Per product specification and customer agreement
- Reference Standard
- Per product specification and customer agreement
- Limitations
- Test method and specimen geometry must be agreed
Bending Test
- Applicable Product
- CCA, CCS, NCC wire and strip
- Test Method
- Repeated bending or wrap test to assess interface integrity
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per product control plan
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- No delamination or cracking at interface
- Reference Standard
- ISO 7801 (where applicable)
- Limitations
- Bend radius and cycle count must match application condition
Thermal Cycling
- Applicable Product
- CCA, CCS, NCC clad conductors
- Test Method
- Thermal cycling across specified temperature range
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per qualification plan
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- No delamination, cracking, or resistance increase beyond limit
- Reference Standard
- IEC 60068-2-14
- Limitations
- Test profile must be agreed based on application environment
Electrical Resistivity Test
- Applicable Product
- CCA, CCS, NCC clad conductors
- Test Method
- DC resistance or conductivity measurement
- Equipment
- Available upon NDA / request
- Sampling Frequency
- Per product control plan
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- Per product specification (e.g., CCA 62–70% IACS)
- Reference Standard
- ASTM B193
- Limitations
- Measurement temperature and method must be specified
Inspection Report Sample
- Applicable Product
- All clad & weld products
- Test Method
- Combined inspection report per order
- Equipment
- N/A
- Sampling Frequency
- Per shipment or lot
- Typical Result
- Available upon NDA / request
- Acceptance Criterion
- Per purchase specification
- Reference Standard
- Per customer agreement
- Limitations
- Report content and format customizable; samples require NDA
Key Process Characteristics
Solid-State Bonding
- • No melting of base metals during the bonding process
- • Preserves the original properties of both metals
- • Creates a true metallurgical bond at the interface
Bond Integrity
- • Bond integrity verified per product control plan
- • Solid-state cladding, not electroplated
- • Interface inspected per applicable inspection method
Material Combinations
Copper Clad Aluminum (CCA)
Copper cladding ratio: 60%-90%
Lightweight, excellent conductivity
Copper Clad Steel (CCS)
Copper cladding ratio: 10%-40%
High strength for demanding applications
Nickel Clad Copper (NCC)
Various nickel ratios available
Corrosion resistance for harsh environments
Silver Clad Copper (SCC)
High-conductivity applications
Premium performance for precision applications
Process Declaration
All our bimetallic products are manufactured using the Clad & Weld process with metallurgical bonding, not electroplated. Bond integrity is verified per the product control plan.
Bond Integrity (per control plan)
Process Visualization
Schematic Diagram
01. Cleaning
Removes oxides and impurities from raw material surfaces to ensure a clean bonding interface.
02. Bonding
Physically presses two metals together under high pressure to form an initial mechanical bond.
03. Diffusion
High-temperature annealing causes atoms to diffuse across the interface, forming a metallurgical bond.
Key Technical Parameters
| Parameter | Range | Note |
|---|---|---|
| Diffusion Temp | 800°C - 1000°C | Depends on material combo |
| Bonding Pressure | > 100 MPa | Ensures gap-free contact |
| Thickness Tolerance | ± 0.005 mm | High precision control |
FAQ
How does Clad & Weld differ from Electroplating?
Electroplating is a surface deposition process. Clad & Weld uses pressure, heat and diffusion control to form a bonded interface. Reliability should be confirmed by cross-section, peel or bond-strength testing.
Does this process affect conductivity?
The process is designed to maintain a stable conductive path, but conductivity and contact resistance should be confirmed by product form, layer ratio and customer test method.
Products Utilizing This Technology
