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aluminum copper bimetal

Aluminum-Copper Bimetal

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Aluminum-Copper Bimetal: The Ultimate Hybrid Solution for Thermal & Electrical Excellence

Product Overview
Our Aluminum-Copper Bimetal seamlessly combines the lightweight versatility of aluminum with the unmatched conductivity of copper, engineered for applications demanding superior heat dissipation, electrical performance, and structural reliability. Precision-bonded through explosive welding or roll-cladding technology, this hybrid material eliminates compromises, delivering optimized solutions for power electronics, EV components, and high-frequency systems.

Key Features & Benefits

  1. Superior Thermal Management

    • Thermal Conductivity: 220 W/m·K (aluminum layer) + 400 W/m·K (copper layer)

    • Ideal for heat sinks, busbars, and battery connectors requiring rapid heat transfer.

  2. High Electrical Efficiency

    • Low Resistivity: Copper layer ensures <0.017 Ω·mm²/m for minimal energy loss in high-current applications.

  3. Weight Reduction

    • 50% lighter than full-copper designs while maintaining 90% of its conductivity.

  4. Galvanic Corrosion Resistance

    • Proprietary interface bonding prevents oxidation, certified for 1,000+ hours in salt spray (ASTM B117).

  5. Customizable Configurations

    • Thickness ratios (Al:Cu) from 1:1 to 10:1

    • Available in sheets, rods, or complex stamped shapes.

Technical Specifications

Parameter Details
Bonding Method Explosive Welding / Roll Bonding
Aluminum Alloy 1050, 6061, or Custom Grades
Copper Alloy C11000 (ETP), C10200 (OFHC)
Thickness Range 0.5mm – 50mm (Total)
Sheet Size Up to 1,200mm x 2,500mm
Surface Finish Mill, Polished, or Anodized (Al side)

Applications

  • Electric Vehicles: Battery interconnect systems, inverter cooling plates

  • Renewable Energy: Solar PV junction boxes, wind turbine busbars

  • Electronics: IGBT baseplates, LED heat sinks, RF shielding

  • Industrial: Welding electrodes, transformer laminations

Why Choose Our Bimetal?

  • Zero-Delamination Guarantee: Rigorous ultrasonic testing (UT) ensures bond integrity.

  • High-Volume Readiness: Laser cutting and CNC stamping lines support mass production (MOQ: 100kg).

  • RoHS & REACH Compliance: Free from hazardous substances, 100% recyclable.

  • DFM Support: Our engineers optimize designs for cost and performance—submit your CAD file for a free review.

Case Study: High-Power EV Charger Cooling Plate

A global EV supplier reduced thermal resistance by 40% using our Al-Cu bimetal (3:1 ratio), achieving:

  • Continuous Current: 500A without overheating

  • Weight Savings: 2.8kg per unit vs. solid copper

  • Cost Reduction: 25% lower material expense

Certifications & Quality Assurance

  • ISO 9001:2015 Certified Production

  • 100% Eddy Current Testing for Layer Uniformity

  • Lot Traceability via Blockchain-Based Documentation

Ordering Options

  • Prototyping: 5-day lead time for samples (max. 500x500mm)

  • Custom Alloys: Add magnesium, silicon, or nickel for enhanced properties

  • Global Logistics: FOB, CIF, or DDP terms available

Download Resources:

Have Questions?
Contact our material science team at project@hiqalum.com

Innovate with confidence—where aluminum’s lightness meets copper’s power.

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