Nickel foils are ultra-thin flat products of nickel, typically manufactured in thicknesses from approximately 2 µm up to 0.2 mm. They provide a unique combination of high purity, excellent electrical and thermal conductivity, corrosion resistance, ductility, and exceptional dimensional precision.
Nickel foils are critical materials in electronics, batteries, fuel cells, aerospace systems, EMI shielding, and advanced research applications where micron-level consistency and reliability are essential.
Common Grades & Standards
| Grade | UNS | Typical Standard | Notes |
|---|---|---|---|
| Nickel 200 | N02200 | ASTM B162 | General-purpose foil |
| Nickel 201 | N02201 | ASTM B162 | Low-carbon, high-temperature use |
| High-Purity Nickel Foil | — | ASTM B39 | Electronics & batteries |
| Electrolytic Nickel Foil | — | ASTM B39 | Very high conductivity |
Chemical Composition (Typical)
| Element | wt% |
|---|---|
| Nickel (Ni) | ≥ 99.0 |
| Carbon | ≤ 0.15 |
| Iron | ≤ 0.40 |
| Copper | ≤ 0.25 |
| Manganese | ≤ 0.35 |
| Silicon | ≤ 0.35 |
| Sulfur | ≤ 0.01 |
Nickel 201 limits carbon to ≤ 0.02%, ensuring microstructural stability and preventing graphite precipitation above 315 °C.
Mechanical Properties
| Property | Typical Value |
|---|---|
| Tensile Strength | 300 – 500 MPa |
| Yield Strength (0.2%) | 80 – 150 MPa |
| Elongation | 25 – 45% |
| Hardness | 60 – 90 HRB |
| Fatigue Resistance | Moderate |
| Tear Resistance | Good (thickness-dependent) |
Cold-rolled foils exhibit higher strength but reduced ductility compared to annealed foils.
Physical Properties
| Property | Value |
|---|---|
| Density | 8.90 g/cm³ |
| Melting Point | 1455 °C |
| Thermal Conductivity | ~90 W/m·K |
| Electrical Conductivity | ~22% IACS |
| Elastic Modulus | ~200 GPa |
| Thermal Expansion | ~13.3 µm/m·K |
| Magnetic Behavior | Ferromagnetic |
Metallurgical Behavior
Nickel foils have a face-centered cubic (FCC) crystal structure, providing excellent ductility even at extremely low thicknesses. Strengthening is primarily achieved through cold rolling, grain refinement, and controlled annealing.
Corrosion Resistance
Nickel foils exhibit strong resistance to caustic alkalis, neutral and mildly acidic media, organic chemicals, and dry industrial gases. Resistance is limited in strong oxidizing acids and chloride-rich environments under tensile stress.
Available Forms & Sizes
Thickness: 2 µm – 0.2 mm
Width: Up to 600 mm (coil form)
Supply Forms: Coils, sheets, precision-cut strips
Surface Finishes: Matte, bright, mirror-polished
Applications
Electronics & Electrical: Battery current collectors, EMI/RFI shielding,
flexible circuits, sensor elements
Energy: Fuel cells, electrolyzers, lithium-ion and solid-state batteries
Aerospace & Research: Thermal barriers, precision instrumentation,
experimental materials
Chemical & Industrial: Catalyst supports, filtration media,
chemical membranes
Advantages
✔ Excellent electrical and thermal performance
✔ High corrosion resistance
✔ Superior formability at micro thickness
✔ Stable over wide temperature range
✔ Clean surface for bonding and coating
✔ Long service life
Limitations
❌ Higher cost vs aluminum or copper foils
❌ Magnetic behavior may limit some electronic uses
❌ Handling damage risk at very thin gauges
❌ Oxidation at high temperature without protection
Why Choose Nickel Foils?
Nickel foils are selected when precision thickness, electrical conductivity combined with corrosion resistance, and long-term thermal stability are critical. They enable advanced energy systems, electronics, and aerospace technologies where performance at micron scales cannot be compromised.