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Copper Aluminum Dovetail Clad is a breakthrough technology  for joining copper and aluminum side-by-side in long continuous master coils. These coils can easily be stamped and formed to create busbars or lead tabs, enabling high-volume, low-cost laser assembly especially fitted to automotive format lithium-ion battery packs.  Based on nearly 50 years of expertise in cladding aluminum to copper for high-reliability automotive lead frame applications, Materion Technical Materials has taken their state-of-the-art metal cladding technology to a new level to meet the challenges facing every lithium-ion battery cell and pack designer:  how to join copper and aluminum in your battery pack. To learn how our Copper-Aluminum Dovetail Clad® Metal Technology enables laser welding in your battery pack, PLEASE CLICK ON THE IMAGES BELOW:

Copper  Aluminum Dovetail Clad Battery Busbars Battery Lead Tabs

Our cladding process achieves an excellent metallurgical bond by combining extreme reductions in cross-sectional area and thermal diffusion to create a controlled formation of a “thin” intermetallic compound resulting in a robust copper-aluminum dovetail joint which matches the strength and fatigue toughness of the aluminum alloy.


  • Superior mechanical, electrical, & thermal performance over ultrasonic or bolted attachments.
  • No resistance or thermal rise at dovetail joint
  • Narrow joint widths (4mm max)
  • Overall thickness range from 0.1mm to 2.0mm
  • Overall widths up to 165mm

For additional technical information, click on the links below or CONTACT US to discuss how Materion's Dovetail he aluminum alloy.

Clad Metal Technology can solve your battery pack assembly challenges.

Contact Us today to learn more about this unique clad metal solution for Busbars and Lead Tabs.