80-Micron Anodized Aluminum Foil Strip

1. Introduction

The 80-micron Anodized Aluminum Foil Strip is a high-performance, precision-engineered material that combines the inherent properties of an aluminum substrate with the superior characteristics of a ceramic surface layer.

With a nominal thickness of 0.08 mm, this material is not a simple foil but a composite system created through a sophisticated electrochemical process called anodization.

This process grows a controlled layer of aluminum oxide (Al₂O₃) directly from the base metal, fundamentally transforming its surface properties.

The resulting material retains the excellent thermal conductivity and light weight of the aluminum core while gaining high dielectric strength (making it an excellent electrical insulator), exceptional surface hardness (often exceeding 500 HV), and superior corrosion resistance.

This unique combination of properties makes it an indispensable material for demanding applications in the electronics and new energy sectors, such as transformer and motor windings, lithium-ion battery tab insulation, and thermally conductive insulating substrates.

80-Micron Anodized Aluminum Foil Strip

2. Fundamental Characteristics of 80-Micron Anodized Aluminum Foil Strip

Base Aluminum Alloy

• Mechanical values are indicative. Actual thin-gauge behavior depends on rolling history, temper, and supplier-specific processing.

Anodized layer composition

• The anodic film is primarily amorphous/nanoporous aluminum oxide (Al₂O₃) formed electrochemically.
• Typical decorative/hard anodize processes produce film thicknesses in the range ~2 – 25 µm (decorative: ~5–15 µm; hardcoat: 20–60 µm but hardcoat at very high µm is usually not applied to very thin foils because of brittleness).
• Films are sealed (hot water, nickel acetate or silicate seal) to reduce porosity, increase corrosion resistance and lock in dyes where applied.
• The oxide is electrically insulating and much harder than the base metal.

Aluminum alloy anodizing process

3. Mechanical and Physical Properties — 80-Micron Anodized Aluminum Foil Strip

Thickness and dimensions

Nominal substrate thickness

• 80 µm (0.080 mm). Specify tolerance in POs — typical industrial tolerances are ±3–5 µm for precision foil/strip (adjust per supplier capability).

Typical coil / strip formats

• Coil ID / OD: common inner diameters 152 mm (6″) or 305 mm (12″) depending on customer equipment; outer diameter limited by coil mass handling.
• Slit widths: from 3 mm up to 300+ mm (customer-specified).
• Edge quality: specify maximum burr height (e.g., ≤ 10 µm) and maximum edge roll for automatic handling.

Physical properties

Mechanical properties

Corrosion resistance

What anodize does

• A properly sealed anodic film converts the metal surface into a corrosion-resistant Al₂O₃ barrier. For decorative/architectural exposure, a sealed Type II film (5–12 µm) plus PVDF topcoat typically meets long-life expectations.

Typical qualification tests & guideline hours

• Salt spray (NSS — ASTM B117 / ISO 9227): for painted or sealed anodize on architectural components, 240 h is often the baseline acceptance; 480 h or more is specified for marine/coastal hardware. (Set specific hours per project risk.)
• Cyclic corrosion / condensation tests recommended for coastal/industrial environments because real-world exposure cycles are more aggressive than static NSS.

Surface hardness

Anodic film hardness (typical)

• Decorative (sulfuric, 5–15 µm): micro-Vickers hardness on the oxide typically ~300 – 600 HV (process dependent).
• Hard anodize (20–60 µm): ~600 – 1000 HV or higher, but brittle and not recommended on very thin strip without qualification.

Thermal and electrical properties

Thermal properties

• Thermal conductivity (substrate): bulk aluminium ~205 – 235 W·m⁻¹·K⁻¹ (depends on alloy). For thin strip the conduction is dominated by substrate; anodic film is a poor thermal conductor and contributes negligibly to in-plane conduction.
• Thermal mass: combined areal heat capacity approximated from substrate mass per area (0.216 kg·m⁻²) × specific heat (~900 J·kg⁻¹·K⁻¹) → ≈0.216×900=194.4≈ 0.216 × 900 = 194.4≈0.216×900=194.4 J·m⁻²·K⁻¹ (approximate). If you require the digit-by-digit check, I can show it similarly to above.

Electrical properties — oxide as dielectric

• Oxide is insulating. Typical practical dielectric strength for anodic films is often used as a rough engineering rule of ~10–20 V/µm (process dependent). This means:
  • A 5 µm film → ~50–100 V (rough estimate),
  • A 10 µm film → ~100–200 V (rough estimate).
• Capacitance per unit area of the film can be estimated using the oxide thickness and relative permittivity (εr ≈ 8–10) if you are designing sensors or capacitive components — but always validate with dielectric breakdown and leakage tests on production material.

Aluminum strip slitting

4. Manufacturing Process of 80-Micron Anodized Aluminum Foil Strips

Foil production

• Casting/rolling: primary aluminium slab → hot roll → cold roll to final gauge (80 µm) with controlled anneal steps as needed. For narrow strip, master coils may be cold-slit or milled to width after rolling.
• Tempering & cleaning: final temper (O, H14, etc.) and cleaning/degreasing are performed before anodizing to ensure proper oxide formation and adhesion.

Anodization process

• Electrolytic oxidation: aluminum strip is made anodic in an electrolyte (commonly sulfuric acid for Type II decorative anodize). Current density, temperature and time control film thickness and porosity.
• Typical decorative film thickness: ~5–15 µm; hard anodize thicker (20–60 µm) but not commonly applied to very thin foil because thick hard oxides can crack and flake when the substrate bends or is slit.
• Sealing: immediate post-anodize sealing (hot water or chemical seal) hydrates/blocks pores improving corrosion resistance and dye retention.
• Coloring (optional): dyes infiltrate pores before sealing; electrolytic coloring or interference methods are alternatives.

Key constraints for 80 µm strip: the oxide is brittle relative to metal; deep/hard anodize film can cause cracking on slit edges or during bending. Process parameters must be matched to reduce internal stresses and preserve strip flexibility.

Surface finishing & post-treatments

• Dry film coatings (PVDF, polyurethane) can be applied after anodize for outdoor durability or to add functionality (scratch resistance).
• Masking & slitting: care is taken to avoid scoring the anodic surface; slitting tools and winding tension must be controlled to avoid flaking.

Quality control

• Film thickness measurement: eddy-current (non-destructive) or cross-section microscopy for calibration.
• Porosity/pinhole inspection: visual or electrolytic dye tests.
• Adhesion tests: tape/cross-cut or bend tests to ensure oxide and any topcoat adhesion.
• Electrical/dielectric testing: breakdown voltage tests if anodize used as dielectric.
• Salt spray & abrasion tests: for environmental durability.

Huawei Packaging 80-Micron Anodized Aluminum Strip

5. Advantages of 80-Micron Anodized Aluminum Foil Strip

Electrical properties — transition from conductor to insulator

Anodize turns the thin surface into an insulating film while leaving a conductive substrate beneath.

That enables patterned insulation, local dielectric behavior for sensors, and safer handling where surface insulation is required.

Designers should test actual dielectric strength of the film + substrate stack for target voltages.

Mechanical properties — improved surface hardness

The oxide layer provides a hard, wear-resistant surface (better scratch resistance) while substrate flexibility allows bending and forming within limits.

For light wear applications, anodized strips perform significantly better than bare thin foil.

Thermal properties — efficient thermal management

For heat-spreading or lightweight thermal solutions the substrate (80 µm Al) provides good thermal conductivity with minimal mass.

The anodic layer has low thermal conductivity but is thin enough that substrate conduction dominates; therefore anodized strip can serve as a lightweight heat spreader with a protective surface.

Chemical properties — excellent corrosion resistance

Properly sealed anodic films substantially increase corrosion life against moisture and many corrosives.

When combined with a corrosion-resistant alloy (e.g., 5052) and proper edge sealing the assembly performs well in humid and mildly corrosive environments.

80-Micron Aluminum Foil Strip for Transformer

6. Applications of 80-Micron Anodized Aluminum Foil Strips

Electrical and Electronic Components

• Insulating spacer strips in transformers and inductors
• Busbar insulation layers (low-voltage, compact designs)
• Capacitor components and current collectors
• EMI shielding elements with controlled insulation

Thermal Management and Heat-Control Systems

• Heat spreader layers in LED modules
• Thermal interface backings in electronic assemblies
• Heat dissipation substrates combined with insulating layers
• Radiant heat control and reflective elements

80-Micron Aluminum strip for interior decoration

Precision Insulation and Functional Laminates

• Laminated insulation tapes
• Composite barrier layers in industrial equipment
• Backing layers for pressure-sensitive adhesives
• Multilayer technical foils

Decorative and Architectural Trim Elements

• Narrow decorative strips and inlays
• Interior design accents
• Furniture trim and appliance detailing
• Anti-glare reflective elements

Industrial Labeling and Identification Systems

• High-durability nameplates
• Warning and instruction labels
• Barcode and QR code carriers
• Asset tracking tags for industrial equipment

Specialized and Emerging Applications

• Sensor substrates and functional electrodes
• Battery and energy-storage components (non-current-carrying roles)
• Optical and reflective control layers
• Laboratory and analytical equipment components

7. Comparison with Other Aluminum Foil Products

8. Conclusion

The 80-micron Anodized Aluminum Foil Strip is a testament to the power of advanced surface engineering.

By transforming the surface of a basic metal into a high-performance ceramic layer, it creates a new material with a combination of properties that neither constituent could achieve alone.

It is not simply a piece of aluminum foil; it is a sophisticated, multifunctional solution engineered to solve the increasingly complex challenges of insulation, thermal management, and durability in the modern electronics and energy sectors.

Its ability to provide electrical insulation, surface hardness, and efficient heat dissipation in a single, lightweight package makes it an indispensable and intelligent material choice for high-performance applications.

FAQs

Q1 — Does “80 µm” refer to the anodic film thickness or the substrate?
Usually it denotes the substrate thickness (foil) = 80 µm. If you require an 80 µm anodic film, explicitly state “anodic film thickness = 80 µm” — this is uncommon and will impose severe handling constraints.

Q2 — What anodize film thickness is typical on 80 µm strip?
Decorative anodize: ~5–15 µm. Hard anodize: 20–60 µm but thick hardcoats risk cracking on thin substrates. Choose modest film thickness for flexible strips.

Q3 — How much does an 80 µm strip weigh per m²?
Calculated earlier: 0.216 kg/m² (substrate only). Add a few g/m² for anodic film & seal depending on film thickness.

Q4 — Can an anodized 80 µm strip be bent or formed?
Yes within limits. Bending radius limits depend on alloy/temper and film thickness; tight bending can crack the oxide. Run forming trials for critical bends.

Q5 — How does anodize affect electrical conductivity?
The oxide is insulating. The bulk substrate remains conductive if oxide is removed locally (mechanically or chemically) or pierced. If anodize is used as dielectric, measure dielectric strength on the manufactured lot.