Cu/Al clad plates prepared using a corrugated + flat rolling (CFR) technique were annealed at 300–450 °C for 10–240 min. Furthermore, the interfacial diffusion behavior and the bonding properties of the Cu/Al clad plates were studied in detail. The results demonstrated that, at the initial stage of the annealing process, the development of the first IMCs layer was restrained by the high atomic concentration gradient in the new bonding interface zone, and the second intermetallic compounds (IMCs) layer preferentially formed in the new bonding interface zone, leading to a slight increase in the growth activation energy of the clad plates. In addition, the atoms’ diffusion behavior at the peak and trough interfaces was not significantly affected by the matrix microstructure, and there was no discernible difference in the growth activation energy at these two positions. Ultimately, it was shown that the maximum average peel strength at the peak and trough interfaces reached 53.07 N/mm and 41.23 N/mm, respectively, when annealing at 350 °C for 10 min.

To extend the service life of sensors in seawater, this work prepared an integrated diffusion-plated Al₂O₃ film using high-power impulse magnetron sputtering (HiPIMS). The tribological properties of the Al₂O₃ film in a marine environment were tested using a tribometer. The morphology and evolution of the Al₂O₃ film before and after the friction tests were investigated by characterization techniques such as field emission scanning electron microscopy (FESEM). The results demonstrate that the Al₂O₃ film exhibits excellent tribological performance in the marine environment, significantly enhancing the wear resistance of the substrate material. Furthermore, with the protection of the Al₂O₃ film, the designed pressure sensor achieved high-sensitivity detection of minute operational forces underwater. When applied to a robotic gripper for manipulation tasks, the coated underwater sensor enabled accurate perception of subtle motion states of the grasped objects.