Premium Aluminum Nickel Composite Sheet Al/Ni Custom Thickness For 18650 Battery Tabs

DLX Alloy’s Al/Ni (Aluminum-Nickel) composite sheet is an advanced bimetal clad material engineered specifically for 18650 lithium-ion battery tab interconnections. By metallurgically bonding battery-grade aluminum and high-purity nickel, this composite foil provides a seamless electrical bridge that eliminates galvanic corrosion and ensures superior ultrasonic and spot welding performance in high-drain cylindrical battery packs.

Connecting aluminum battery tabs to external nickel or copper terminals poses significant challenges due to fragile intermetallic compounds formed during direct welding. DLX Alloy resolves this issue with our continuous solid-phase roll-cladding technology.

Our Al/Ni bimetal composite sheets feature atomic-level metallurgical bonding across the interface. The aluminum side easily welds to the internal positive aluminum electrode/can, while the nickel side welds cleanly to nickel-plated steel strips, copper busbars, or protection circuit boards (PCBs). This ensures minimal electrical transition resistance, high shear strength, and long-term electrochemical reliability in automated battery pack assembly lines.

• Atomic-Level Interfacial Bonding: Manufactured via hot roll bonding and controlled diffusion annealing, guaranteeing zero delamination or void formation under severe stamping and forming operations.
• Low Interfacial Contact Resistance: Continuous bimetal transition drastically reduces internal pack resistance, lowering heat generation during high-rate fast-charging and discharging cycles.
• Optimized Ultrasonic & Laser Weldability: Eliminates brittle Al3Ni compound formation during battery pack welding, ensuring maximum pull strength on automatic high-speed tab welders.
• Superior Corrosion Barrier: Hermetically sealed solid-phase bond prevents electrolyte penetration and galvanic degradation at the aluminum-nickel junction.
• Burr-Free Slitting Quality: High-precision rotary slitting guarantees uniform edge condition (burr≤0.01 mm), preventing puncturing of battery insulators.

• 18650 / 21700 Cylindrical Battery Cells: Positive terminal current collector transition tabs and safety valve connection strips.
• Lithium-Ion Battery Pack Busbars: High-power battery modules for electric vehicles (EV), e-bikes, and cordless power tools.
• Energy Storage Systems (ESS): Long-cycle life residential and commercial energy storage connection links.
• Consumer Electronics & Drones: Compact battery connection plates requiring ultra-low impedance and lightweight design.

• 20+ Years of Precision Metallurgy: Deep engineering expertise in specialty nickel alloys and multi-layer clad metal manufacturing.
• Full Process Quality Control: From raw ingot selection, precision rolling, continuous bright annealing, to cleanroom slitting and automated optical inspection (AOI).
• ISO9001 Certified Management: Stringent production and batch traceability systems ensuring tight gauge control, high bond yield, and consistent temper.
• Tailored Engineering Support: Custom layer thickness ratios, hardness tempers (annealed to full hard), and pre-cut stamping shapes per customer drawings.
• Rapid Global Delivery: Flexible MOQ for prototype trials with rapid 3–7 day dispatch for standard dimensions.

Q1: Why is an Al/Ni composite sheet preferred over direct aluminum-to-nickel welding?
A: Direct fusion welding between aluminum and nickel generates brittle intermetallic compounds and high interface resistance. DLX Alloy’s roll-bonded Al/Ni composite material solves this by providing a pre-bonded atomic transition layer, allowing standard Al-to-Al ultrasonic welding on one side and Ni-to-Ni spot welding on the other.

Q2: What is the standard thickness and layer ratio for 18650 battery tabs?
A: The most common total thickness is 0.15 mm or 0.20 mm with a 1:1 thickness ratio (e.g., 0.10 mm Al + 0.10 mm Ni). However, DLX Alloy can customize the total thickness from 0.08 mm to 1.0 mm and adjust the layer ratios to meet specific current-carrying and structural requirements.

Q3: Does the Al/Ni clad material delaminate during battery tab stamping or 90°/180° bending?
A: No. Our solid-state cladding process creates a permanent metallurgical bond. Every production coil passes 180° reverse bend tests without flaking, cracking, or layer separation.

Q4: How does DLX Alloy prevent burrs and oxidation during transport?
A: All Al/Ni coils are precision-slit using tungsten carbide blades to maintain edge burrs under 0.01 mm, followed by surface cleaning, vacuum packing with desiccant, and wooden case crating for global export.

Q5: What is your Minimum Order Quantity (MOQ) and sample lead time?
A: For standard trial runs, our MOQ is as low as 5 kg. Custom dimension sample coils can be delivered within 5–7 business days.