Copper-Nickel Composite (Nickel Clad Copper)
Combine the massive conductivity of Copper with the ease of Nickel spot welding. The definitive solution for high-drain battery packs, eliminating voltage sag and thermal bottlenecks.
The "Sandwich" Revolution
Engineers have always faced a dilemma: Copper is the best conductor but impossible to spot weld with standard equipment. Nickel welds easily but has high resistance. Our composite material solves this physics problem.
Cladding Technology
We don’t just plate copper; we use advanced solid-state explosive bonding or high-pressure rolling to fuse a layer of Pure Nickel N6 onto a core of C1100 Oxygen-Free Copper. This creates a metallurgical bond that will never peel or separate.
Unmatched Electrical Performance
Compare the data. For high-current applications (100A+), Nickel Clad Copper is the only logical choice to prevent overheating.
4x Conductivity
Pure Nickel has an electrical conductivity of ~22% IACS. Our Copper Composite reaches >70% IACS. This means 4 times less heat generation ($I^2R$) for the same current.
Thermal Management
Copper is an excellent heat sink (385 W/m·K). The strip itself acts as a thermal bridge, pulling heat away from the battery terminals and radiating it out, keeping cells cooler.
Easy Welding
The outer Nickel layer provides high electrical resistance at the contact point, generating the necessary heat for a strong spot weld, while the copper core carries the load.
| Material Type | Composition Ratio | Total Thickness | Conductivity (IACS) | Max Continuous Current (10mm Width) |
|---|---|---|---|---|
| Pure Nickel (Reference) | 100% Ni | 0.15 mm | ~22% | ~9 Amps |
| Cu-Ni Composite | 10% Ni / 80% Cu / 10% Ni | 0.20 mm | ~65% | ~35 Amps |
| Cu-Ni Composite | 10% Ni / 80% Cu / 10% Ni | 0.30 mm | ~70% | ~55 Amps |
*Current ratings are estimates based on 10°C temp rise. Actual performance depends on cooling.
Built for Extreme Discharge
When standard nickel strips turn into heating elements, industry leaders switch to Copper-Nickel Composites. This material is engineered for applications where "Voltage Sag" is unacceptable.
EV & Hybrid Modules
For 400V+ architectures, busbar resistance equates to significant energy loss. Our strips improve range and charging efficiency.
UAVs & Racing Drones
Drones pull massive burst currents (100C+). High resistance strips cause immediate voltage drop and reduced flight time. Cu-Ni strips deliver full power to the motors.
Cordless Garden Tools
Chainsaws and lawnmowers demand high torque. Composite strips prevent the battery interconnects from becoming the bottleneck.
Slightly. Because copper dissipates heat so fast, you need a spot welder with higher power (pulse current) than for standard nickel. We recommend capacitor-based welders (like Glitter or Kweld) or industrial AC welders. Standard hobby welders may struggle.
No. We use metallurgical bonding (rolling under extreme pressure or explosive bonding). This is not a simple electroplating. The layers are fused at the atomic level and will not peel even when bent 180 degrees or stamped.
Yes. While we sell rolls, we highly recommend Laser Cutting or Stamping for this material. Cutting copper composite by hand is difficult due to its thickness. We can produce custom busbars based on your DXF files.
The most common ratio is 10/80/10 (10% Nickel, 80% Copper, 10% Nickel). This provides the best balance of conductivity and weldability. Other ratios like 20/60/20 are available for custom orders if you need deeper welding capability.
The manufacturing process (bonding two dissimilar metals) is complex and energy-intensive. However, the performance gain is 3x-4x. You often need less material width to carry the same current, which can offset the cost in tight spaces.
Upgrade Your Battery Performance
Don’t let resistance hold back your project. Switch to Nickel Clad Copper for maximum power delivery.
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