Cost Savings with Nickel-Tin Plated Busbars
For manufacturers and buyers of busbars – cost is a crucial factor. Selecting the right plating material directly impacts overheads, durability, and performance. While materials like silver and gold offer excellent conductivity and corrosion resistance, their high cost often makes them impractical for large-scale applications.
Why Nickel and Tin Plating is a Cost-Effective Choice
Nickel and tin plating provides a more economical alternative without compromising on quality.
Aluminium Busbars: The Need for a Base Layer
Due to their reactive nature, including oxidisation, aluminium busbars cannot be directly plated with tin or silver. A base layer (substrate) is required to ensure adhesion and durability. Nickel serves as an excellent intermediary layer, enabling effective tin plating. This combination not only improves conductivity but also enhances corrosion resistance, making it a reliable and cost-efficient solution.
Reducing Costs with Nickel and Tin Plating
Unlike costly alternatives like silver and gold, nickel and tin plating offers a budget-friendly approach. Tin, in particular, is significantly cheaper while still delivering excellent conductivity and corrosion resistance. Nickel, when used as a base layer, ensures strong adhesion and a dense, corrosion-resistant surface. This combination is particularly advantageous for:
- Aluminium busbars – Achieving a reliable plated surface without the high cost of alternative metals.
- Copper busbars – Providing enhanced durability and heat resistance for high-temperature applications.
Addressing Tin Whiskers: Enhancing Reliability
One common issue with tin plating is the formation of “tin whiskers”—tiny, hair-like structures that can cause short circuits in electronic applications. According to research, the nickel base layer significantly mitigates this risk by acting as a barrier, reducing whisker growth. This added reliability translates to long-term cost savings by minimising the need for more frequent maintenance and replacements.
Extended Lifespan and Lower Maintenance Costs
Nickel and tin-plated busbars require less routine maintenance compared to uncoated or alternative metal finishes. The superior wear resistance and durability provided by this plating combination reduce the frequency of replacements, further cutting down costs over time..