The Nickel-Plated Copper Busbar is coated with a dense nickel layer of 1–20 µm on the surface of T2-grade red copper substrates. This double protection is achieved through electroplating or chemical plating processes, providing high-temperature oxidation resistance link truc tiep bong da long-lasting corrosion resistance. Compared to traditional tin-plated or silver-plated copper busbars, nickel-plated copper busbars offer a more reliable solution for specific conditions such as corrosion protection, wear resistance, link truc tiep bong da contact stability.
Comparison of Coated Copper Busbars
| Property | Bare Copper Busbar | Nickel-Plated Copper Busbar | Tin-Plated Copper Busbar | Silver-Plated Copper Busbar |
| Conductivity (% IACS) | 100 | ≥98 | 97 | 105 |
| Maximum Temperature of Coating (°C) | 85 | 300 | 120 | 200 |
| Salt Spray Test (72h ΔR, µΩ | 32 | ≤2 | 8 | 3 |
| High-Frequency Loss (≤30 kHz) | 1.00× | 0.94× | 0.96× | 0.85× |
| Cost (Bare Copper = 1) | 1 | 1.5–2 | 1.25 | 3–4 |
| Typical Industries | General Power Distribution | Aerospace / Rail Transport / Energy Storage | Energy Storage / UPS / EV | Data Centers / Military |
Technical Specifications
| Parameter | Typical Value / Standard | Description |
| Base Material | T2/TU1 Pure Copper | Resistivity ≤0.018 Ω·mm²/m |
| Coating Thickness | 1–20 µm (ASTM B487) | Electroplating / Chemical plating available, thickness uniformity ±0.5 µm |
| Conductivity | ≥98 % IACS | Overall measurement after hot rolling + coating |
| Salt Spray Test | 500 h (ASTM B117) | ΔR ≤2 µΩ, no discoloration |
| Operating Temperature | −55 °C ~ +300 °C | Coating does not crack or peel off |
| Size Range | Width 10–200 mm × Thickness 2–20 mm | Custom sizes available based on drawing, supports bending link truc tiep bong da perforation |
| Adhesion Strength | ≥6 N/mm (ISO 2409) | Exceeds industry average |
| Environmental Compliance | RoHS / REACH | Lead-free, Cadmium-free |
Typical Application Scenarios
- Aerospace busbars can maintain the integrity of the coating under continuous high temperatures of 300 °C link truc tiep bong da strong vibrations, link truc tiep bong da are certified by the AS 9100D quality system.
- Rail transit traction systems remain rust-free after long-term exposure to sulfur link truc tiep bong da high humidity environments, significantly extending maintenance intervals.
- Outdoor energy storage cabinet DC busbars pass a 500-hour salt spray test without developing red rust, making them suitable for long-term operation in coastal link truc tiep bong da high-salt areas.
- Hydrogen fuel cell stacks naturally resist hydrogen embrittlement, preventing hydrogen-induced corrosion link truc tiep bong da extending the stack's lifespan.
- High-frequency power modules maintain low contact resistance link truc tiep bong da good heat dissipation under conditions of <30 kHz, reducing overall temperature rise.
Process link truc tiep bong da Quality Control
A composite process using electroplating link truc tiep bong da chemical plating is employed to form a dense, pinhole-free coating.
Online XRF equipment detects 50 measurement points per meter, recording coating thickness in real-time link truc tiep bong da automatically archiving data.
All products undergo ASTM B117 salt spray link truc tiep bong da ASTM B487 coating thickness tests to ensure corrosion resistance link truc tiep bong da uniformity.
The production system is ISO 9001, SGS, link truc tiep bong da UL certified, with full traceability link truc tiep bong da the option for third-party witnessed inspections.
Customer Case
European Tier-IV Data Center Busbar Retrofit
Problem:The original silver-plated busbars generated heat under 15 kHz harmonic frequencies, with a PUE of 1.42.
Solution:Replaced with 7 µm nickel-plated copper busbars link truc tiep bong da brazed heat sinks.
Result:Busbar temperature rise decreased by 5.2 °C, link truc tiep bong da PUE dropped to 1.37. Annual energy savings of approximately €60, 000, with payback within two years.
Packaging link truc tiep bong da Logistics
Multi-layer packaging consisting of vacuum bags, desiccants, anti-sulfur paper, link truc tiep bong da non-fumigated wooden boxes prevents coating scratches link truc tiep bong da oxidation.
Global shipping insurance is provided with sea or air freight options, link truc tiep bong da a temperature link truc tiep bong da humidity indicator card is included in the packaging.
An online tracking link is generated immediately after shipment, allowing real-time tracking of logistics.
Delivery link truc tiep bong da Service Guarantee
First batch orders of ≤500 kg will be shipped within 7 days.
30-day payment terms are offered to customers with good credit.
If the product fails inspection, we will cover the return shipping costs link truc tiep bong da provide a full refund.
A 30-day worry-free trial is offered, with free returns link truc tiep bong da exchanges during this period.
Frequently Asked Questions(FAQ)
Q1: Can nickel-plated copper busbars directly replace existing tin-plated busbars?
A: The dimensions link truc tiep bong da mechanical properties are identical, link truc tiep bong da it is safe to replace them as long as contact resistance link truc tiep bong da reflow soldering processes are re-verified.
Q2: Will the nickel layer increase losses in high-frequency applications?
A: Nickel layers ≤10 µm have a negligible impact on frequencies ≤30 kHz. For frequencies 100 kHz, we recommend evaluating flexible tin-plating or pure copper solutions.
Q3: How do we assess the durability of the nickel layer?
A: We provide ASTM B117 salt spray link truc tiep bong da IPC-TM-650 soldering reliability test reports, link truc tiep bong da we also support third-party on-site inspections.