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Copper/steel composite is a kind of composite with excellent performance and broad application prospects. In this paper, the micro-morphology and structure of the interface of copper/steel composite prepared by the hot-dip casting were observed by scanning electron microscope and transmission electron microscope, and the formation mechanism of the interface area was explored. The results show that the hot-dip casting temperature has a great influence on the micro-structure and morphology of the copper/steel interface area. When the hot-dip casting temperature is lower than 1125 °C, the copper/steel interface area is basically in a straight line. Even if the hot-dip casting time is extended, the interface characteristics change little. At 1100 °C, the copper-rich phase precipitated at the interface area is the coherent precipitates of Cu and BCC-Fe, with the crystal orientation <110> and the diameter about 10 nm ~ 30 nm. When the hot-dip casting temperature reaches 1150 °C, the copper/steel interface area begins to appear new micro-morphology, and the range of new micro-morphology becomes larger and larger with the increase in the hot-dip casting temperature and the extension of the hot-dip casting time. At 1200 °C, the copper-rich phase precipitated at the interface is the coherent precipitates of FCC-Cu and FCC-Fe, with the crystal orientation <100> and the size similar to that at 1100 °C. In the process of the hot-dip casting, the formation of the copper/steel interface area experienced three stages: the co-temperature of copper/steel and the wetting of copper liquid on solid steel, the formation and transformation of the solid–liquid mixed layer between steel and copper liquid and the evolution stage of the liquid–solid mixed layer during cooling and solidification. This kind of interface zone with gradual structure tightly connects the steel matrix and solidified copper together, to form a copper/steel composite with strong bonding. [ABSTRACT FROM AUTHOR]

In this paper, 50 ... 680 nm thick AlN-Al2O3 coatings are deposited by magnetron sputtering on the surface of a steel substrate and a piece of copper is melted on top of the ceramic. Upon heating the ceramic layer is cracked, and the phase inversion of the two top phases from steel/ceramic/copper configuration to the steel/copper/ceramic configuration takes place within 30 s of liquid time of copper. This phase inversion process is accompanied by a Gibbs energy change of about − 1.78 J/m2, due to good wettability of solid deoxidized steel by liquid copper in contrary to poor wettability of the ceramic by the copper. When copper is melted on AlN-Al2O3 coating with its thicknesses smaller than a critical value of about 170 ± 60 nm, liquid copper droplets hanging down into the cracks within the ceramic reach the solid steel surface at the bottom of the cracks, thus the flow of Cu down along the cracks is enabled. However, when copper is melted on AlN-Al2O3 with its thickness larger than the critical value of 170 ± 60 nm, Cu first forms a non-wetting droplet on top of the ceramics, and only after a certain incubation time it starts flowing down the cracks. This incubation time was found to depend linearly on the thickness of the ceramic, as cracks are filled from the bottom upwards by liquid copper via the evaporation–condensation mechanism. By the end of the process, the steel/copper/ceramic configuration is further stabilized by gravity. [ABSTRACT FROM AUTHOR]