How Do I Choose Nickel Strip Thickness for Spot Welding?

Nickel strip, usually pure nickel or nickel-plated steel, connects cells in a battery pack, and its thickness must be chosen around the discharge current it will carry. A strip that is too thin restricts current, heats up under load and raises resistance; one that is too thick becomes hard to spot-weld reliably and adds weight and space.

Current Carrying Is the Key Factor

The strip must safely carry continuous current without excessive temperature rise or voltage drop. Higher loads demand a thicker strip, a wider strip, or both. Single-cell, low-current packs can use thinner foils, while high-rate packs need more cross-section.

Balance Thickness, Width and Weldability

Selection is a combination of strip thickness, width and material. Welding equipment settings must also match the strip material and thickness, because a mismatch causes cold welds or burn-through. Undersized tabs also reduce pack efficiency because heat that should go to the load instead warms the enclosure. For multi-string or high-rate packs, design reviews should cover expected continuous and peak currents so the strip layout stays safe and durable. Final gauges are confirmed during sample build, subject to project evaluation.