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Why Nickel Sheets Must Be Laminated When Welding Aluminum Sheets with Polymer Diffusion Welders

Jul 01,2026

Polymer diffusion welders are core equipment for aluminum sheet welding in new energy vehicle power battery flexible connections and electrical busbar manufacturing, featuring solid-state bonding, no spatter and dense weld seams. However, thin nickel sheets must be laminated on welding interfaces when welding aluminum sheets; otherwise, defects such as weak bonding, weld pores and joint cracking will emerge. Detailed principles and lamination specifications are provided below.

1. Core Principles and Pain Points of Aluminum Sheet Welding

1.Working principle of polymer diffusion welding: Under high temperature and high pressure, composite welding agents generate active atmospheres to facilitate atomic diffusion at welding interfaces, realizing fusion-free metallurgical bonding with weld strength close to base materials.

2.Key drawbacks of aluminum sheet welding: Aluminum easily forms dense insulating aluminum oxide films that block atomic diffusion and induce welding defects. In addition, aluminum sheets suffer from severe high-temperature oxidation and deformation, while joints lack sufficient corrosion and wear resistance for long-term service.

2. Core Functions of Laminated Nickel Sheets

1.Break aluminum oxide films to create channels for atomic diffusion;

2.Reduce diffusion resistance and accelerate efficient fusion of aluminum atoms;

3.Strengthen welded joints to improve mechanical performance and stability;

4.Boost corrosion and wear resistance to adapt to diverse application environments.

3. Nickel Sheet Lamination Specifications

1.Surface cleaning: Remove oil stains and impurities on welding surfaces of aluminum sheets and nickel sheets, wipe dry before lamination;

2.Precise lamination: Attach nickel sheets flatly to the center of welding interfaces without wrinkles, offset or gaps;

3.Secure fixation: Lightly compress with fixtures to avoid nickel sheet displacement during welding and ensure full contact for sufficient metallurgical reaction.