Conference Tools for 2026 TMS Annual Meeting & Exhibition

Login

Register as a New User

Help

Submit An Abstract

Propose A Symposium

Presenter/Author Tools

Organizer/Editor Tools

About this Abstract

Meeting

2026 TMS Annual Meeting & Exhibition

Symposium

Late News Poster Session

Presentation Title

J-15: Diffusion Bonding of Ultra-Conductive Composites for Electric Motor Windings: Interfacial Mechanisms and Microstructural Evolution

Author(s)

Hossein Abbasi, Lei Chen

On-Site Speaker (Planned)

Hossein Abbasi

Abstract Scope

Electric vehicle (EV) motors require conductors with low resistive losses and high efficiency. Conventional copper–aluminum joints are limited by interfacial degradation and poor diffusion control during bonding, reducing electrical and mechanical performance. This study investigates diffusion bonding of aluminum and copper under controlled temperature, pressure, and time conditions to enhance joint reliability. Microstructural analyses reveal the evolution of interfacial layers, diffusion zones, and intermetallic compound formation. Complementary modeling captures diffusion behavior and its influence on electrical contact performance. Optimized bonding parameters reduced intermetallic layer thickness to below ~2 痠 while maintaining near-stoichiometric Al₂Cu stability. These improvements decreased interfacial resistance by ~30–40% and increased joint strength by ~25% compared to baseline conditions. The results establish processing–structure–property relationships essential for scalable manufacturing of high-conductivity, durable Al–Cu joints in next-generation EV traction motors.

Proceedings Inclusion?

Undecided

Keywords

Energy Conversion and Storage, Thin Films and Interfaces, Computational Materials Science & Engineering

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A-20: Structure-Tuning of GelMA Hydrogels by Physical Gelation Induction as a Strategy for the Development of Drug Delivery Systems

A-22: Antibacterial Properties of Plant Mediated Gum Arabic Stabilized Fe-Ag-V Oxide Ternary NPs

Adsorbent Materials as a Platform for Accelerating the Identification of Trace Contaminants

B-33: Mimosa-Inspired Tribo-Electromagnetic Nanogenerator for Adaptive Wind Energy Harvesting and Intelligent Wind Monitoring

B-34: Porous Metal Hydride–Polymer Composites for Hydrogen Storage – From Fundamental Questions to Application

C-28: Computational Modelling of Mg Alloy Corrosion at the Microstructural Level

C-29: Sensitivity Analysis for Corrosion of Carbon Steel Relevant to Long-Term Repository Conditions

C-30: Thermal Degradation Mechanisms of Nanometric Metallic Multilayers

Creep Degradation of Structural Alloys in Molten Halide Salt Environments Relevant to MSRs

D-31: Accelerated Dissolution of Manganese Ores Through Active Acidity Control

D-32: An Integrated Strategy for CO2 Mineralization, Value-Added Nano-Silica Recovery, and Critical Metal Extraction Using Industrial Wastes

D-33: Circular Steel for Mass Market Applications

D-34: Development of a Proxy Molding Technique for Accelerated Binder Jet Printing Materials Optimization

D-35: Effect of Mn, Ni Additions on the Hot Shortness Behavior of Cu-Bearing Steels

D-36: Generating Nanoscale Bainitic Structures Within the Carburised Layer of Gear Steels for Wind Turbines

D-37: Lime Sintering of Molybdenite to Produce Molybdenum Without Atmospheric Contamination with SO₂

D-38: Metso's Outotec DRI Smelting Furnace Technology – A Key Component in Decarbonizing the Ferrous Industry

D-39: Molten Metal Halide Salt Electrolysis for Promoting Ethane Decomposition into Ethylene, Hydrogen, and Carbon

Deciphering the Role of Stacking Fault Energy on TWIP–TRIP Interplay in Ni-Rich High Entropy Alloy With Tailored Ti Content

E-38: Data-Driven Screening of Magnetic Materials for Aerospace Applications

E-39: Design and Characterization of Nature Inspired Gradient-Engineered Nano-Multilayered Ti/TiN Coatings

E-40: Development of an Experimental System for Obtaining Heat Transfer Coefficients in Underwater Welding Processes

E-41: Effect of Cu on the Microstructure and Fracture Toughness of Quenched Martensitic Steel

E-42: Hot Forging Aluminum-Doped Boron Carbide Ceramics: Unlocking Intrinsic Toughening Mechanisms

E-43: Multiscale Investigation of Early-Stage Boundary Sliding Mechanisms in Lath Martensite of Low-Carbon-Steel

E-45: Laboratory-Based Evaluation of Edge Ductility in Advanced High-Strength Steels Using Digital Image Correlation

E-48: Extreme Wear Resistance of Borided WRe Alloys

Effects of Temperature and Strain Rate on Dynamic Recrystallization and Recovery of Aluminum Alloy 2618

Electrochemical Evaluation of 70/30 Brass Exposed to Ammonium Hydroxide: Electrolyte Degradation Time

F-59: Advancing Metal Microfabrication: Silver Nanocluster Resin Engineering for Two-Photon Lithography

F-60: Effect of Heat Treatment on Microstructure and Mechanical Properties of Additively Manufactured Inconel 718 alloy

F-61: Influence of Cooling Temperature on Microstructure and Mechanical Properties During WAAM Process

F-62: Intelligent Process Fingerprinting for Defect Mitigation in Metal Additive Manufacturing

F-63: Multi-Wavelength Temperature Measurements of a Titanium Melt Pool in a Wire-Arc Additive Manufacturing Process

F-64: Relationship of Mechanical and Microstructural Properties of Additively Manufactured Inoculated Aluminum with Build Height

F-65: Reuse of Tantalum Powder in Laser Powder Bed Fusion and Its Effect on Microstructure and Microhardness

F-66: Scan-Path-Induced In-Situ Heat Treatment Effects on Austenite Stability and DIMT in PBF-Fabricated Thin Wall Structure

F-67: Thermo-Optical Properties of Metal Alloys Used in Wire and Arc Additive Manufacturing Processes

F-68: Wear Resistance and Microstructure of Laser Cladding Layer on Directly Nitrided Ti-Alloy Substrate

F-69: Copper-Inconel 718 Multimaterial Pad Using Blue Laser Powder Blown Directed Energy Deposition for Thermal Management

F-70: Influence of Storage Time and Conditions on Warping Behavior in Digital Light Processing 3D Printed Ceramic Samples

F-71: Smaller Feature Size Impairs Densification in Digital Light Processing 3D Printed Ceramic Samples

F-73: Design and Application of Wireless Tool Temperature Measurement 1 of Friction Stir Welding (FSW) for Process Monitoring and Control

F-81: Process–Structure–Property Correlations in Al–4.5Cu–0.4Sc Alloy Lattice by Hybrid Investment Casting

G-31: Characterization of Plasma Hydrogen Implantation in Nickel

G-32: Copper Partitioning in Ferrite and Carbides During Spheroidization Treatment

G-33: In Situ Micro-XAFS Study on Stress-Induced Multistage Martensitic Transformation in Cu–Al–Mn Superelastic Alloys

G-34: Probing the Critical Element Chemistry of Coal-Combustion Fly Ash: Electron Microbeam Investigations of the Spent Ash From the Pilot-Scale Acid Extraction of Rare Earth Elements From a Beneficiated Kentucky Fly Ash

G-35: Unusual Behavior at Domain Boundaries in a Metallic Distortive Polar Metal

G-36: Low-kV SEM Characterization of γ' Evolution in Cast-and-Wrought Ren� 65

H-31: Accelerating Discovery of High Entropy Alloy Catalysts for Nitrate Reduction to Ammonia with a Universal Machine Learning Interatomic Potential

H-32: Accelerating Solid Electrolyte Discovery with an Interpretable Multimodal Machine Learning Framework

H-33: CALPHAD-Type Thermodynamic Database from Machine Learning Potential

H-34: Computational Study of the Al-V Alloy Phase Diagram

H-35: Data-Driven Discovery of Stable Lead-Free Perovskites Via Reinforcement Learning

H-36: Data-Efficient Deep Generative Modeling for Bidirectional Process–Structure–Property Relationships With Uncertainty Quantification

H-37: PhaseForge: A Framework for Phase Diagram Predictions and Benchmarking Using Machine Learning Potentials

H-38: Prediction of Schottky Barrier Heights From First-Principles Calculations

H-39: Unsupervised Health Monitoring of High-Pressure Hydrogen Compressor Seals via Optimized Multi-Axis Vibration Analysis and Deep Autoencoders

H-6: Assessing Strengthening Mechanisms and Machine-Learned Potentials in Refractory High-Entropy Alloys

High-Throughput Quantitative Characterization of H-Plasma-Induced Material Degradation of EUV Lithography Mirrors

Improved Selectivity Toward Methanol Detection Via Pd-Functionalized Tungsten Trioxide Nanofiber Gas Sensors

In-Situ Smelting of Discarded Urban Scrap into Aluminum Alloys

In-Situ Smelting of Discarded Urban Scrap into New Aluminum Alloys

Influence of Infill Patterns on the Mechanical Performance of GelMA Scaffolds Produced by 3D printing

Influence of Precipitation Hardening on the Corrosion Behavior of Mg-6Zn-0.6Si-4Sn Alloy in HBSS Solution

J-14: A Study of Inclusions in Direct Chill Cast Aluminium Alloys Revealed by Dissolving of the Aluminium Matrix

J-15: Diffusion Bonding of Ultra-Conductive Composites for Electric Motor Windings: Interfacial Mechanisms and Microstructural Evolution

J-16: Effect of Multi Exposure and Laser Defocus on Residual Stress and Properties of Laser Powder Bed Fusion of Titanium Grade 1

J-17: Effects of Heat Treatment on the Microstructure and Mechanical Properties of High-Strength Al-Li Alloys

J-18: Microstructural and Mechanical Characterization of Resistance Spot-Welded Aluminum Sheet/Casting Joints

J-19: Multi-Level In Vitro Systems for Evaluating Magnesium Materials in Atherosclerotic Environments

J-20: Process Improvement in Open Mold Casting of A356 Alloy for Dross Reduction

J-21: Structure-Property Relationships in Al-10Mg Alloys

K-11: Evaluation of Nondestructive Assay Techniques for Special Nuclear Material Control and Accountability in Metallic Fuel Fabrication

K-12: Mobility of a⟨100⟩ Self-Interstitial Atom Dislocation Loops in BCC Fe

K-13: Rapid AI-Driven Acoustic Inspection of Advanced Nuclear Fuel Pebbles

Real-Time Digital Twin for EAF Process Optimization

Reducing the Waste Production of the Hydride-Dehydride Process for U-6 wt.% Nb Spherical Powders Through Targeted Low Impact Milling

The International Conference on Nuclear Security: An Opportunity to Engage the Next Generation of Nuclear Security Professionals

Thermokinetics and Interfacial Insight Into the U-Nb-O Nuclear Fuel System

Questions about ProgramMaster? Contact programming@programmaster.org | TMS Privacy Policy | Accessibility Statement