Nickel Clad Copper: Next-Generation Conductor Solutions

1. Introduction

1.1 Conductor Challenges

applicationsrequirementsConductorsimultaneously High conductivity、corrosion resistance、Stability and Cost Effective。ConductorLimitations：

• ：excellentconductivity（100% IACS）corrosion resistance，performance
• ： Corrosion Resistant and conductivity（~15% IACS），cost
• electroplatingmaterial ：Surfacein Thermal Cycling and Delamination

1.2 Solutions：NCC

NCC（NCC）through technology as Solutions。through High conductivity and Cladding，NCCprovides ：

• performance：two performance
• Cost Effective：decreases 30-50%material cost
• Reliability：ensures
• function ：suitable for multiple applications

2. Material Composition

2.1 Core：

NCC by High purity：

• etc.：C10100（OFE - ） or C10200（OF - ）
• ：99.99%Copper Content
• Conductivity：100% IACS
• volume fraction：cross-section 60-85%

2.2 Claddingmaterial ：

Claddingby ：

• etc.：Nickel 200 or Nickel 201
• ：99.0-99.9%
• Conductivity：13-15% IACS
• volume fraction：cross-section 15-40%
• Thickness：20-200（applications）

2.3 Interface：

NCC Keyinnovation -Interface ：

• ：Diffusion，
• Strength：150 MPaShearStrength
• InterfaceWidth：1-5，Parameter
• complete ：、can

3. ManufacturingProcess

3.1 Key：Clad Welding vs electroplating

important ：

3.2 Manufacturing Process

1：material

• / and
• material （、）Surface
• two material and

step 2：

• material in
• for ensures CladdingThickness

step 3：Welding/

Mainmethodsincluding ：

• ：material in through ，temperature 500-700°C，pressure 200-400 MPa
• ：Impact，suitable for Cross-Section
• etc.（HIP）：from ，temperature 700-900°C，pressure 100-150 MPa

step 4：Drawing/Dimensions

• material Diameter/Thickness
• ， Annealing
• Controlmaintains CladdingThickness

step 5：Verification

• InspectionIntegrity
• Microstructurecross-section
• conductivity
• DimensionsInspection

4. Technical SpecificationsPerformance

4.1 Electrical Performance

ConductivityCalculation：

：

• σ_NCC = OverallConductivity (% IACS)
• V_Cu = volume fraction (0.60-0.85)
• σ_Cu = conductivity (100% IACS)
• V_Ni = volume fraction (0.15-0.40)
• σ_Ni = conductivity (15% IACS)

4.2 Mechanical Performance

4.3 performance

4.4 corrosion resistance

CorrosionMechanism：

• stable （NiO）
• excellent and

5. Performance

5.1 Electrical Performance

：

NCCcan etc.Conductor70-85% current ，Thickness。

ExampleCalculation：

for 2 mmDiameterConductor：

• （100% IACS）：~32 A
• NCC（50% IACS）：~16 A
• NCC（60% IACS）：~19 A

5.2 Solderability

Resistance：

• by Surface，excellent
• quality ，
• ：3-5
• suitable for 、 and

5.3 performance

Anti-oxidation：

• 400°C ：，
• 400-600°C：，
• 600°C ：，

5.4 Fatigue and Durability

Fatigue：

• 10⁷FatigueStrength：~120 MPa
• excellent Vibration and

Thermal Cycling：

• 1000+-40°C200°C
• DelaminationperformanceDegradation

6. Applications

6.1 Alkaline Electrolysis (Hydrogen Production)

ApplicationsBackground：

Electrolysisrequires in Corrosion（KOH）ElectrolysisEnvironment Operation，simultaneously maintains efficiency 。

NCC：

• in 25-30% KOH excellent corrosion resistance
• and conductivity
• decreases Maintenance
• Cost Effective

PerformanceData：

• Corrosion：80°C、30% KOH <0.1 mm/
• voltage ：500 A/m² <50 mV/
• ：8-12

6.2 Aerospace

NCCAdvantages：

• High strengthWeight
• excellent
• Operating Temperature（-55°C260°C）
• in Marine corrosion resistance

applications：System、、Support、System

6.3 and Conductor

NCCAdvantages：

• Electrical performance
• excellent and Welding
• Thermal conductivityused for
• corrosion resistanceensures Reliability

applications：Conductor、Connectors and 、power 、RF and applications

6.4 and Manufacturing

applications：Resistance、、Motor Windings、Control

PerformanceIndicator：

• ：50,000+（as 15,000）
• Maintenance：3-6（vs 1-2）
• Cost Savings：Lifecycle 40-60%

6.5 Battery and

applications：Battery and 、、Batterymanagement System、

7. Comparison

7.1 NCC vs

7.1 NCC vs

standards：

• NCC：corrosion resistance、performanceSolderabilityimportant
• ：requires conductivityEnvironmentConditions and

7.2 NCC vs

cost comparison：

• NCC：30-50%cost
• for 1 mmDiameter： ~$15/kg，NCC ~$8-10/kg

7.3 NCC vs electroplating

electroplating KeyFailure：

• Thermal Cycling Delamination
• Wear
• Thickness

7.4 NCC vs CCA（CCA）

standards：

• NCC：performance、corrosion resistance or Strengthimportant
• CCA：cost Main etc.performancecan Acceptance

8. QualitystandardsTesting

8.1 standards

8.1 standards

ASTMstandards：

• ASTM B432： and Cladding
• ASTM B193：ConductorResistivity
• ASTM E8：material TensionTesting
• ASTM B117：Testing

8.2 quality TestingAgreement

material Testing：

• （ICP-OES）
• Verification（LECOanalysis）
• DimensionsInspection（CMM）
• Surfacequality Assessment

process Testing：

• IntegrityTesting
• Microstructurecross-sectionanalysis
• conductivity
• CladdingThicknessVerification（）

8.3 Quality AssuranceIndicator

KeyIndicator：

• Strength：>150 MPa（Acceptance）
• conductivity：specifications±5%
• Dimensional Tolerance：±0.005 mm
• Surface：Ra < 0.8 μm
• Defect：<100 ppm

9. Cost EffectiveAnalysis

9.1 Cost Comparison

9.2 Total Cost of Ownership Analysis

NCC：

• decreases 64%
• decreases 40%cost
• reduces and Maintenance

9.3 Lifecycle Cost

NCC：

• decreases 69%cost
• decreases 23%cost
• cost

9.4 （ROI）

applicationsROICalculation：

：AutomotiveManufacturing NCCWelding Electrodes

• cost ：$50,000
• Cost Savings：$200,000
• Maintenance：$50,000
• reduces value ：$100,000

：$350,000

Recycling：1.7

5ROI：4,200%

10. Conclusion

10.1 Key

NCC material Solutions，applications Competitionrequires ：

technology ：

• conductivity（40-60% IACS） and Corrosion Resistant
• ensures 、can performance
• Operating Temperature（-55°C260°C，900°C）
• excellent and Stability

advantages：

• 30-50%cost
• Weldingapplications decreases 64%Lifecycle Cost
• reduces Maintenance and
• cost

applicationsfunction ：

• Alkaline Electrolysis
• AerospaceSystem
• and
• Manufacturing and Resistance
• Battery and System

10.2 Future Outlook

NCC requires significant ，including ：

• ：through ElectrolysisExpansionProduction
• ：Electric Vehicle and
• Aerospace：increases and
• ： and Manufacturing

market PredictionDisplayto 2030NCCrequires 8-12%，Alkaline Electrolysis and Aerospaceapplications。

10.3 Recommendations

for Engineer and Designer：

• AssessmentNCCused for requires conductivity and corrosion resistance applications
• Lifecycle Cost，not only material cost
• Clad WeldingManufacturing Process（electroplating）
• through MicrostructureanalysisVerificationSupplier

for ：

• and NCCManufacturer
• Quality AssuranceAgreement
• Consider long-term contracts to stabilize pricing
• Evaluate total cost of ownership across suppliers