High-Conductivity Copper-Aluminum Bimetallic Washers

Short Description:

Product Specifications
Name： Copper-Aluminum Bimetallic Washer (Bimetal Cu-Al Washer)
Standard： ASTM B432 (Cladding), ASTM B152 / B209, RoHS Compliant, REACH Compliant
Material： C11000 Pure Copper Layer Clad on High-Purity Aluminum Base
Surface： Smooth, Precision Stamped, Optional Tin-Plated
Inner Diameter (ID)： 6mm – 100mm
Outer Diameter (OD)： 12mm – 200mm
Thickness： 1mm – 10mm
Product Features:
Combines copper’s superior conductivity with aluminum’s lightweight advantage · Strong metallurgical bond with no delamination · Excellent corrosion resistance and long-term reliability · Cost-effective alternative to solid copper washers · High mechanical strength and dimensional stability · Good thermal dissipation · Reliable in vibration and thermal cycling
Application Field:
New energy vehicle battery packs and connections, Power distribution panels and switchgear, Industrial control cabinets, Renewable energy inverters and storage systems, Data center power rails, Transformer and generator connections, Marine and offshore electrical equipment

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Copper-Aluminum Bimetallic Washer – Process & Quality Assurance Statement

Our copper-aluminum bimetallic washers are engineered to deliver the optimal balance of conductivity, weight, and cost for modern high-current electrical systems, particularly in new energy vehicles and power distribution applications.

Key process features

Production integrates advanced cladding technology with precision stamping to ensure a strong, reliable bond:

●Base Material Preparation: High-purity aluminum sheets are selected and machined to create precise grooves or channels for copper inlay.
●Copper Inlay / Cladding: High-conductivity C11000 copper strips are press-fitted or explosion-bonded/roll-bonded into the aluminum base, forming a metallurgical bond at the atomic level.
●Hot Rolling / Consolidation: Controlled rolling further consolidates the interface for excellent electrical and mechanical integrity.
●Annealing: Protective atmosphere annealing relieves stresses and optimizes conductivity without compromising the bond.
●Precision Stamping: High-accuracy progressive dies stamp the final washer shape, ID, OD, and thickness with clean edges.
●Surface Treatment: Optional tin plating or protective coating is applied for enhanced corrosion resistance and solderability.
●Final Cleaning & Packaging: Parts are thoroughly cleaned and packed with protective interleaving to prevent damage during global shipping.

Quality control system

● Full traceability from raw aluminum and copper materials to finished washer
● Material test reports including conductivity, bond strength, and dimensional data provided with every batch
● Sample retention ≥3 years for third-party verification (SGS, BV, TÜV, etc.)
● 100% inspection of essential parameters:
• Chemical composition and purity of both layers (spectrometric analysis)
• Bond integrity (ultrasonic and shear testing)
• Dimensional accuracy (CMM and laser gauges; typical tolerance ±0.1mm)
• Surface quality and plating thickness (where applicable; X-ray fluorescence)
• Electrical conductivity (eddy current testing)
● Internal standards exceed ASTM B432 and industry cladding requirements. Typical performance:
Conductivity approaching pure copper at contact surfaces while maintaining aluminum’s weight advantage, Excellent thermal transfer, Strong metallurgical bond with no delamination under thermal cycling or vibration.
● ISO 9001:2015 certified production ensures every copper-aluminum bimetallic washer delivers consistent quality, reliability, and performance for your critical power systems.