Structure and method of bonding copper and aluminum

1. A method of bonding a first metallic workpiece and a second metallic workpiece having different melting points and thermal conductivities, the method comprising:

applying a first coating to at least a portion of the first metallic workpiece, the first coating being made of a material having a lower melting point than the material of the first metallic workpiece;

applying a second coating to the first metallic workpiece at substantially the same location as the first coating, prior to applying the first coating, wherein the second coating is made of a material having a higher melting point than the material of the first metallic workpiece;

positioning the first metallic workpiece and the second metallic workpiece with respect to each other to form at least one joint where the first and second metallic workpieces are to be bonded; and

welding the first metallic workpiece to the second metallic workpiece along the at least one joint via an arc welding process including a welding wire such that the first metallic workpiece is wetted and brazed, and the second metallic workpiece is melted and fused along the at least one joint; and

wherein the arc welding process involves a cyclic alternating of a first stage, in which an electric current is supplied to the welding wire as the welding wire is moved toward the first and second metallic workpieces, and a second stage, in which the electric current is reduced and the welding wire is moved away from the first and second metallic workpieces, to generate and detach a plurality of molten droplets along the at least one joint, the molten droplets being formed from the welding wire in the first stage.

2. The method of claim 1 wherein the materials of the first metallic workpiece and the second metallic workpiece are copper and aluminum, respectively.

3. The method of claim 1 wherein the material of the first coating is zinc.

4. The method of claim 1 wherein the material of the welding wire is an aluminum alloy.

5. The method of claim 1 wherein the material of the second coating is nickel.

6. The method of claim 1 wherein the first coating is applied via an electrolytic plating process.

7. A method of bonding an aluminum workpiece to a copper workpiece via an arc welding process including a welding wire, the method comprising:

applying a first coating to at least a portion of the copper workpiece, the first coating being made of a material having a lower melting point than copper;

applying a second coating to the copper workpiece at the same location as the first coating, prior to applying the first coating, wherein the second coating is made of a material having a higher melting point than copper;

positioning the copper workpiece and the aluminum workpiece with respect to each other to form at least one joint where the copper and aluminum workpieces are to be bonded;

welding the aluminum workpiece to the copper workpiece along the at least one joint via the arc welding process such that the aluminum workpiece is melted and fused, and the copper workpiece is wetted and brazed along the at least one joint; and

wherein the arc welding process involves a cyclic alternating of a first stage, in which an electric current is supplied to the welding wire as the welding wire is moved toward the copper and aluminum workpieces, and a second stage, in which the electric current is reduced and the welding wire is moved away from the copper and aluminum workpieces, to generate and detach a plurality of molten droplets along the at least one joint, the molten droplets being formed from the welding wire in the first stage.

8. The method of claim 7 wherein the material of the first coating is zinc.

9. The method of claim 7 wherein the material of the welding wire is an aluminum alloy.

10. The method of claim 7 wherein the material of the second coating is nickel.

11. The method of claim 7 wherein the first coating is applied via an electrolytic plating process.

12. A bonded structure of copper and aluminum, the structure comprising:

a first metallic workpiece made of copper;

a first coating applied to at least a portion of the first metallic workpiece, the first coating being made of a material having a lower melting point than copper;

a second coating applied to the first metallic workpiece beneath the first coating, the second coating being made of a material having a higher melting point than copper;

a second metallic workpiece made of aluminum, the second metallic workpiece being positioned with respect to the first metallic workpiece to form at least one joint where the first and second metallic workpieces are bonded;

wherein the first metallic workpiece and the second metallic workpiece are bonded via an arc welding process including a welding wire such that the first metallic workpiece is wetted and brazed, and the second metallic workpiece is melted and fused along the joint; and

wherein the arc welding process involves a cyclic alternating of a first stage, in which an electric current is supplied to the welding wire as the welding wire is moved toward the first and second metallic workpieces, and a second stage, in which the electric current is reduced and the welding wire is moved away from the first and second metallic workpieces, to generate and detach a plurality of molten droplets along the at least one joint, the molten droplets being formed from the welding wire in the first stage.

13. The bonded structure of claim 12 wherein the material of the first coating is zinc.

14. The bonded structure of claim 12 wherein the material of the welding wire is an aluminum alloy.

15. The bonded structure claim 12 wherein the material of the second coating is nickel.