Custom Nickel Aluminum Clad Strip | Lightweight Bimetal for Battery Tabs & Busbar Connections

Custom Nickel Aluminum Clad Strip

Introduction

1. Nickel Aluminum Clad Strip is a bimetal composite that bonds a nickel layer to an aluminum core by roll‑bonding and diffusion bonding. The aluminum side provides low density, good electrical and thermal conductivity, and significant cost and weight savings, while the nickel side offers excellent corrosion resistance and reliable welding/contact performance. This makes Ni–Al clad strip widely used in lithium‑ion battery tabs, EV and energy‑storage pack connections, aluminum–copper transition joints, and lightweight busbar systems where stable joining to nickel‑, steel‑ or copper‑based components is required.

2. We offer fully customizable Nickel Aluminum Clad Strips, including total thickness, Ni/Al layer ratio, strip width, coil length, mechanical properties, and surface finish. The material features strong metallurgical bonding, low interface resistance, and good formability for slitting, stamping, bending, and automated ultrasonic or resistance welding. Optional surface cleaning and oxidation‑control treatments are available for battery‑grade applications to improve weldability and long‑term reliability. OEM/ODM service and engineering support are provided to match your drawings and performance targets for mass‑production battery and power‑electronics projects.

   Specifications

   Type	Nickel‑Aluminum Clad Strip / Coil / Ribbon / Bimetal Composite
   Structure	Metallurgically bonded Ni–Al composite: typically Ni/Al or Al/Ni/Al layered structures produced by solid‑state roll‑bonding and diffusion bonding
   Material Grade	Commercial‑purity or high‑purity nickel (e.g., Ni200/201 or equivalent) clad to electrical/structural aluminum (e.g., 1xxx, 3xxx series such as AA1050, AA1060, AA1100, AA3003)
   Ni/Al Ratio (Volume/Area)	Customizable nickel and aluminum thickness ratio (e.g., 5/95, 10/90, 20/80, 30/70, 50/50 etc.), optimized for welding, conductivity, weight, and cost
   Electrical & Thermal Conduct.	Aluminum core provides low density and good electrical/thermal conductivity; nickel layer offers stable contact resistance and reliable weldability to nickel‑, steel‑ or copper‑based busbars
   Form	Narrow strip, coil, ribbon, or flat stock; supplied as continuous coils, cut‑to‑length strips, or pre‑processed tabs and connector parts
   Thickness Range	Customizable total thickness, typically from about 0.05 mm to 2.0 mm (or more on request); individual Ni and Al layer thicknesses adjustable according to design and current‑carrying or welding requirements
   Width & Length	Strip width typically from a few millimeters up to about 200–300 mm (depending on thickness); supplied in coils or fixed cut lengths according to customer specifications
   Bonding Method	Solid‑state roll bonding followed by thermal treatment/diffusion bonding to create a continuous, high‑strength metallurgical interface between nickel and aluminum layers
   Interface Quality	High bonding strength, uniform cladding, low interface resistance, and good peel strength suitable for high‑reliability battery, busbar, and power‑electronics applications
   Mechanical Properties	Good strength‑to‑weight ratio and formability; suitable for slitting, stamping, bending, and tab forming; nickel surface improves wear and contact durability at welded or clamped joints
   Density & Cost Balance	Bimetal design reduces the use of solid nickel while maintaining a nickel working surface, lowering both weight and cost compared with all‑nickel strips or connectors
   Surface Finish	As‑rolled, bright‑annealed, matte, or brushed; controlled roughness on Ni or Al side to improve welding, bonding, or coating adhesion
   Surface Treatment	Degreased and cleaned as standard; optional oxidation‑control treatment, special cleaning for battery‑grade use, or pre‑plating on the nickel side (e.g., tin) if required by the joining process
   Weldability & Joining	Designed for ultrasonic welding, resistance welding, laser welding and spot welding; good compatibility with common joining of battery tabs, busbars, and laminated conductors
   Corrosion & Wear Resistance	Nickel layer provides improved resistance to oxidation, corrosion, and mechanical wear, helping protect the aluminum substrate in typical battery and power‑electronics environments
   Dimensional Tolerances	Tight control of thickness, width, and flatness to ensure stable automated feeding, consistent welding results, and reliable electrical performance
   Standards & Reference	Manufactured with reference to relevant nickel and aluminum material standards (e.g., ASTM/EN/GB for base metals and composite strip quality); specific grades and tolerances available on request
   Application Range	Lithium‑ion and LiFePO₄ battery tabs, EV and energy‑storage pack connections, aluminum–copper transition joints, busbar connections, power‑electronics interconnects, and other lightweight electrical conductors
   Processing Capability	Supports slitting, shearing, precision stamping, progressive die forming, punching, tab forming, and CNC profiling; suitable for high‑volume automated production of battery and connector components
   Customization	Tailored Ni/Al structure, thickness, width, coil inner/outer diameter, mechanical properties, surface finish, and pre‑stamped/weld‑ready geometries according to drawings or CAD files
   Packaging	Supplied in sealed coils or bundled strips with edge protection; anti‑corrosion wrapping and reel/wooden‑case packaging available for safe transport and long‑term storage

Reference dimensions