Multi-Layer Stamping Parts

Multi-layer stamping parts are specialized components composed of two or more stacked metal layers bonded or formed together through stamping processes, designed to combine the advantages of different materials (e.g., strength, conductivity, corrosion resistance) into a single, integrated part. Unlike single-layer stamping parts (which rely on one material’s properties), multi-layer variants are engineered for complex performance needs—making them ideal for industries like automotive electronics, renewable energy, and medical devices, where a single material cannot meet all functional requirements.

The production of multi-layer stamping parts begins with material selection, where each layer is chosen for a specific purpose. Common layer combinations include:

Stainless steel + copper: The stainless steel layer provides structural strength and corrosion resistance (e.g., for outdoor components), while the copper layer ensures high electrical conductivity (critical for connectors or busbars).

Aluminum + nickel-plated steel: Aluminum reduces weight (ideal for automotive or aerospace parts), and nickel-plated steel enhances solderability (for electronics assembly).

Titanium + rubber: Titanium offers biocompatibility and strength (for medical implants), while a thin rubber layer provides shock absorption (to protect delicate tissues).

The stamping process for multi-layer parts involves two key approaches: pre-bonded stamping and in-stamping lamination. In pre-bonded stamping, layers are first bonded via techniques like roll bonding (applying pressure and heat to fuse metals) or adhesive bonding (using high-temperature adhesives for non-metallic layers), then stamped into the final shape. For example, a multi-layer busbar for an EV battery pack uses pre-bonded copper and stainless steel sheets—stamped into a flat, rectangular shape with pierced holes for mounting, where copper conducts electricity and stainless steel prevents bending under vibration.

In-stamping lamination, by contrast, integrates layer bonding into the stamping process. Multiple metal coils are fed into a progressive stamping press simultaneously, where each station performs a sequence of operations: first, layers are aligned with precision guides; then, they are pressed together under high pressure (100-300 tons) to create a mechanical bond; finally, the stacked assembly is blanked, pierced, or bent into the desired shape. This approach is used for high-volume parts like multi-layer sensors—for instance, a temperature sensor for HVAC systems uses in-stamping lamination to bond a thin nickel layer (heat-sensitive) to a brass layer (structural support), ensuring the sensor responds quickly to temperature changes while maintaining durability.

Quality control for multi-layer stamping parts focuses on layer adhesion and dimensional consistency. Manufacturers use peel tests to verify bond strength (ensuring layers do not separate under stress) and CMMs to check that stacked layers align within ±0.02mm (critical for parts like electrical connectors, where misalignment could cause short circuits). For a multi-layer fuel cell plate (used in hydrogen vehicles), each part undergoes a leak test—pressurizing the plate to ensure no gas escapes through gaps between layers, as even a tiny separation would reduce fuel cell efficiency.

 multi-layer stamping parts are innovative solutions that expand the capabilities of traditional stamping. By combining multiple materials’ strengths, they meet complex performance demands, making them indispensable for advanced industries where material versatility is key.

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