[ethbr0]

Isn't a big part of the problem the thermal expansion difference between aluminum and copper? (~20%)

Wouldn't that eventually cause mechanical adherence issues with dissimilar metal plating?

[londons_explore]

One would imagine so, but it seems it isn't a problem. Not sure why. Perhaps the elasticity of the metals is sufficient to absorb that change over typical temperature variations? Maybe they would fail if you poured liquid nitrogen over them?