Weldability

Weldability of electroless nickel plating coatings

Weldability is a key functional property for many electrical and electronic applications, especially when the surface coating must ensure not only protection of the base material, but also long-term reliability and stability of the joint.

Electroless nickel plating coatings NIPLATE®, thanks to their composition and deposition uniformity, are generally suitable for soldering and brazing, with some important distinctions related to the coating type and process conditions.

With the exception of NIPLATE® 500 PTFE, which—due to the presence of polymer particles—is not designed for solderable applications, traditional NIPLATE® coatings can be used for:

• brazing with tin alloys;
• ultrasonic welding, especially for electrical and interconnection applications.

Weldability mechanism and critical factors

The weldability of electroless nickel coatings is linked to the surface’s ability to ensure adequate wettability by the filler material and to maintain this property over time.

The main factors affecting joint quality are:

• chemical condition of the coating surface;
• presence of nickel surface oxides, which may form over time or as a result of heat treatments;
• storage time between nickel plating and the welding operation;
• type of welding process (brazing, ultrasonic, induction).

In conventional brazing, the use of acid fluxes (RMA, RA) is generally recommended, especially when soldering is not performed immediately after coating deposition. Chemical activation of the surface helps remove or overcome any passive oxide layers, improving adhesion of the solder alloy.

Typical applications: electrical contacts and busbars

A particularly relevant application area for the weldability of NIPLATE® coatings is copper or aluminum electrical components, such as contacts, terminals, and busbars, especially in the automotive and e-mobility sectors.

Ultrasonic welding of coated busbars and electrical contacts makes it possible to obtain mechanically robust joints with low electrical resistance, reducing the risk of connection defects and increasing system reliability over time.

Dedicated coating: Niplate Link

For applications where long-term weldability, corrosion resistance, and industrial repeatability are critical requirements, Micron has developed Niplate Link, an electroless nickel plating treatment specifically designed for electrical and interconnection components.

Niplate Link is a proprietary technology, covered by a filed patent application, optimized for:

• copper busbars;
• electrical contacts and connectors;
• components intended for soldering and brazing.

The coating is based on an optimized Ni–P alloy designed to maintain a solderable, stainless, and stable surface over time, reducing the risk of surface oxidation that could compromise joint quality.

Compared to traditional electrolytic solutions, Niplate Link offers:

• uniform thickness even on complex geometries, without edge build-up;
• a repeatable industrial process, free of costly metals;
• compatibility with brazing and ultrasonic welding of tin and aluminum alloys;
• high corrosion resistance, with performance exceeding 1000 hours in neutral salt spray (ISO 9227) on copper with thickness ≥ 5 µm.

These features make Niplate Link particularly suitable for applications in electric vehicles, inverters, battery packs, power converters, and HV distribution systems, where electrical connection reliability is an essential requirement.

Considerations on heat treatments and storage

A critical aspect for the weldability of electroless nickel coatings is the effect of post-deposition heat treatments. Hardening treatments can generate a surface layer of nickel oxide, which reduces wettability and may hinder solder adhesion.

Similarly, even in the absence of heat treatments, the electroless nickel surface may passivate over time due to exposure to the environment.

In conclusion, the weldability of electroless nickel plating coatings depends on a combination of coating composition, surface condition, subsequent treatments, and operating conditions. Correct definition of the coating and welding process is essential to ensure reliable and durable joints, especially in high-criticality electrical systems.