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Solid Aluminum Busbar
An Aluminium Busbar is a highly efficient electrical conductor widely used in power distribution systems, offering excellent conductivity, lightweight properties, and cost-effectiveness compared to copper alternatives. It serves as a crucial component in electrical panels, switchgear, transformers, and distribution boards, ensuring stable current flow and energy efficiency. Many Aluminium Busbar Suppliers provide customized sizes, shapes, and finishes to meet diverse industrial requirements, making Aluminium Busbar a preferred choice in automotive, renewable energy, and construction applications due to its durability, corrosion resistance, and ease of installation.
Aluminium busbar suppliers are manufacturers and distributors who provide high-quality aluminium busbar products for electrical power distribution systems. Unlike traditional copper busbars, aluminium busbars are lightweight, cost-effective, and still offer reliable conductivity for medium to high current applications.
For many engineers comparing busbar copper vs aluminium, the aluminium option is often selected when weight reduction, cost savings, and corrosion resistance are key considerations. Professional aluminium busbar suppliers ensure compliance with international standards, precision fabrication, and customized solutions for different industries.
Material Selection
High-purity aluminium or aluminium alloys are chosen for optimal conductivity and mechanical strength.
Cutting & Shaping
Sheets or extruded profiles are processed using CNC cutting machines for precise dimensions.
Drilling & Punching
Holes and slots are created to allow easy connection in electrical systems.
Bending
Using an aluminium busbar bending machine, busbars are shaped into the required forms without compromising structural integrity.
Surface Treatment
Anodizing, tin plating, or silver plating can be applied to improve corrosion resistance and conductivity.
Quality Testing
Tests for electrical resistance, mechanical durability, and thermal performance are conducted to meet strict industry standards.
Material Options: Pure aluminium (99.5%), aluminium alloys (for strength and conductivity balance).
Surface Finishes: Bare aluminium, anodized aluminium, tin-plated aluminium.
Certification Compliance: IEC, RoHS, ISO 9001, and regional electrical IS standard for aluminium busbar.
| Parameter | Specification Range |
|---|---|
| Material | High-conductivity Aluminium (99.7% purity or higher, Grade 1350/6101/6061/6082) |
| Width | 10 mm – 300 mm (customizable) |
| Thickness | 2 mm – 30 mm (customizable) |
| Length | Standard 1 m – 6 m; custom lengths available |
| Cross-Sectional Area | 20 mm² – 5000 mm² |
| Current Carrying Capacity | 100 A – 5000 A (depending on cross-section, installation, and cooling conditions) |
| Electrical Conductivity | ≥ 61% IACS (International Annealed Copper Standard) |
| Thermal Conductivity | ~235 W/m·K |
| Tensile Strength | 80 – 150 MPa (depending on alloy and temper) |
| Elongation | 8% – 25% |
| Operating Temperature | -50 °C to +150 °C (continuous service) |
| Surface Treatment Options | - Bare Aluminium (mill finish) - Tin Plated (improves corrosion resistance & solderability) - Silver Plated (enhanced conductivity & oxidation resistance) - Anodized (protective oxide layer) |
| Standards Compliance | ASTM B317, ASTM B221, IEC 60105, RoHS compliant |
| Applications | Power distribution, switchgear, transformers, EV battery systems, renewable energy systems |
When designing an aluminium busbar system, engineers often ask:
How to calculate aluminium busbar size?
Formula: Required cross-sectional area depends on current, allowable temperature rise, and installation method.
How to calculate current carrying capacity of aluminium busbar?
Capacity is lower than copper for the same size, so aluminium busbars are designed with larger cross-sections to achieve the same ampacity.
Professional aluminium busbar suppliers provide engineering support to select the correct size based on current requirements.
Electrical Distribution Panels – Lightweight and cost-efficient solution.
Power Plants & Substations – Used in bus ducts, transformers, and switchgear.
Renewable Energy Systems – Solar farms, wind turbines, and energy storage systems.
Automotive & EV Industry – Aluminium busbars reduce weight in electric vehicles.
Industrial Machinery – High-current equipment requiring stable power transfer.
Global Supply Chain: We serve clients in Asia, Europe, Middle East, and North America.
Custom Fabrication: Tailored busbar size, thickness, length, and surface treatment.
Advanced Equipment: CNC machining and aluminium busbar bending machine for high-precision products.
Quality Assurance: Compliance with IEC and ISO standards, ensuring safety and durability.
Technical Support: Guidance on busbar copper vs aluminium selection, size calculation, and installation.
Q1: Why choose Aluminum Busbar instead of copper?
Busbar copper vs aluminium depends on project needs. Aluminium busbars are lighter and more affordable, while copper offers higher conductivity.
Q2: How to calculate aluminium busbar size?
Engineers use current load, ambient temperature, and installation method to determine the cross-sectional area.
Q3: How to calculate current carrying capacity of aluminium busbar?
This depends on conductor size, insulation, and temperature rise. Larger aluminium busbars are required to match copper’s ampacity.
Q4: What is the IS standard for aluminium busbar?
The IS standard for aluminium busbar ensures safety, material purity, and electrical performance in compliance with international norms.
Q5: Can aluminium busbars be bent?
Yes, with a dedicated aluminium busbar bending machine, busbars can be formed into precise shapes without cracks or stress damage.
Q6: Do aluminium busbar suppliers provide custom solutions?
Yes, trusted suppliers provide custom dimensions, finishes, and certifications based on your project requirements.
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