What about soldering it on? Yes youd need a metal melts below 150c, well 130c for safty of the chip. Should work better than current TIMs? probebly not by much though. A very small amount of mercury would be interesting as a test, but it could never be used on a more than tempory scale beucase of health issues - unless maybe it was cooled way below freezing point using cascade phasechange, which would then have to be on 24/7 etc.. does (normalish/diy) phasechange even go that low?
There are ways to get things VERY flat, perfectly flat is sorta impossible though, I think, because of the structures of atoms... Lapping helps (which should be done anyway or whats the point in this thread?) but overall its best to just have lapped + lots of pressure there to sqaush out all the extra paste, giving a much better tim layer..
It would seem possible that the core can be plated safely with silver or copper (maybe using electroless plating?) and then joined using different method to another metal...
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