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Plating aluminum to allow for solderability

My questions concerns high power (30W/in^2) thermal transfer between electronic components and aluminum heat sinks. I am trying to figure out a way to create a thermally conductive method of soldering directly to an aluminum substrate without the use of a thermal interface material (i.e., grease). Is there any processes that can be done to 6061 aluminum to allow for direct soldering to the aluminum? Maybe an economic plating?

Brad Smith
Electrical Engineer - Phoenix, Arizona, USA
October 22, 2009

Hi, Brad. Aluminum is commonly zincated, followed by copper plating, followed by tin plating for very easy solderability. It can also be zincated followed by electroless nickel plating if you can reliably solder the electroless nickel.

Regards,

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
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