Every gram matters when building the next generation of battery packs, as discovered by an EV integrator replacing plain copper links with Copper-Aluminum Sandwich Busbars. Here, copper’s conductivity meets aluminum’s weight savings, enabling fleet manufacturers and hardware supply stores to deliver cost-effective, scalable packs without sacrificing reliability. Aurico Alloys LLP provides these hybrid busbars combining durability, optimal ampacity, and proven ASTM certification for modern energy storage, solar, and mobility projects.
Table of Contents:
What is a Copper-Aluminum Sandwich Busbar?
These are engineered bimetallic connectors consisting of an aluminum core cladded by an outer copper shell. Used across modern prismatic, pouch, and cylindrical lithium-ion battery packs, this design enables high current capacity and weight savings while preserving reliable weldability and corrosion resistance.
Copper-Aluminum Sandwich (CCA or bimetal) busbars feature a high-purity aluminum core clad with a thick copper layer (typically 10–35% by volume), delivering 65–74% IACS conductivity with around half the weight of a pure copper bar. Extensive applications across battery modules, energy storage systems, and compact power banks make these busbars a favorite for projects prioritizing pack energy density and manufacturing economy. Their composite structure ensures reliable welding, low resistance, and long-term corrosion performance at critical joints.
Aurico Alloys LLP’s Copper-Aluminum Sandwich Busbars are batch-certified to GB/T 30586-2014 and ASTM B1005 standards, ensuring consistent bonding strength and mechanical properties. Design flexibility allows specification of length, thickness, copper/aluminum ratios, and finishing supporting both high-volume and bespoke assemblies for battery, EV, or power distribution hardware.
These hybrid busbars offer weight savings of up to 48% compared to copper, reducing installation burden and materials cost for pack assemblers and hardware suppliers. With Aurico’s established supply chain and technical documentation, every project is optimized for efficiency without compromise on global standards or verified purity.
High-quality Copper-Aluminum Sandwich Busbar ready for industrial use.
Specifications
| Supplier & Manufacturer | Aurico Alloys LLP |
|---|---|
| Materials | T2/C11000 Copper (cladding), 1050/1060/1070/1100 Aluminum (core) |
| Cu:Al Volume Ratio | 10–35% copper, remainder aluminum |
| Thickness | 3–120 mm |
| Width | 10–250 mm |
| Length | 1000, 2000, 3000 mm standard (customizable) |
| Certification | GB/T 30586-2014, ASTM B1005-17 |
| Surface Finish | Bright, anti-oxidation, tinned |
| Form Factors | Rectangular, cut-to-length, custom-bent/slot as per pack spec |
Equivalent Grades & Standards
| Standard | Copper Grade | Aluminum Grade | UNS | Certification |
|---|---|---|---|---|
| ASTM/GB | C11000 / T2 | 1050/1060/1070/1100 | C11000 / A91050 / A91060 / A91070 / A91100 | GB/T 30586-2014, ASTM B1005-17 |
Chemical Composition
| Element (Cu layer) | Composition (%) |
|---|---|
| Copper (Cu) | 99.9 |
| Phosphorus (P) | <0.015 |
| Lead (Pb) | <0.005 |
| Zinc (Zn) | <0.005 |
| Iron (Fe) | <0.005 |
| Tin (Sn) | <0.002 |
| Element (Al core) | 1050 | 1060 | 1070 | 1100 |
|---|---|---|---|---|
| Al | 99.5 | 99.6 | 99.7 | 99 |
| Si | 0.25 | 0.25 | 0.2 | 0.95 |
| Fe | 0.4 | 0.35 | 0.25 | 0.7 |
| Cu | 0.05 | 0.05 | 0.04 | 0.05 |
| Other | <0.15 | <0.15 | <0.15 | <0.15 |
Mechanical & Electrical Properties
| %Cu Layer | Temper | Density (g/cm³) | Yield Bonding (MPa) | Tensile Strength (MPa) | Elongation (%) | Max DC Resistance (Ω·mm²/m) | Conductivity (%IACS) | Brinell Hardness |
|---|---|---|---|---|---|---|---|---|
| 20 | O (Annealed) | 3.94 | ≥40 | ≥110 | ≥25 | 0.0255 | 67.6 | 20-30 |
| 25 | H24 | 4.25 | ≥40 | ≥170 | ≥16 | 0.0255 | 69 | 50-60 |
| 30 | H26 | 4.56 | ≥40 | ≥200 | ≥8 | 0.0242 | 72.4 | 65-75 |
| 35 | H28 | 4.87 | ≥40 | ≥230 | ≥3 | 0.0242 | 72.4 | ≥80 |
Applications & Benefits
- Battery pack current collector/interconnect for e-mobility and ESS: light, power-dense, weldable.
- Power distribution, solar, telecom: Lower installation burden, strong cost/performance profile.
- OEM/hardware stores: Batch supply, tech documentation, easy spec for competitive projects.
- Marine/transportation: Strong, corrosion-resistant connector for exposed installations.
FAQ & Search Trends
Global Export Destinations
We ship worldwide from Mumbai. See every destination we export to on our export markets page.
Domestic Supply Network
We deliver across India from our Mumbai stockyard. See every city we supply on our supply locations page.
Conclusion
Aurico Alloys LLP copper-aluminum sandwich busbars enable battery makers and hardware stores to create lighter, more efficient, and globally-compliant packs for every application. Could your next innovation move further with hybrid busbar technology?