Why Aluminum Busbars Stand Out
Worthwill brings 20 years of precision metal experience to the global power distribution market. Balancing performance, cost, and weight is critical in modern engineering. Here is why aluminum is the superior choice for many applications.
70% Lighter
A 100-amp aluminum bar can be carried by one person. Copper needs two.
- Faster installation
- Less structural support
30-60% Savings
Massive material cost reduction plus logistical savings due to lower weight.
- Lower shipping costs
- Lower scrap rates
Excellent Thermal
235 W/m·K conductivity allows for efficient heat dissipation.
- Lower operating temp
- Ideal for fins
Alloy Selection Guide
6061-T6
High StrengthThe "Workhorse" alloy. Excellent corrosion resistance and structural integrity. Suitable for outdoor use.
6063-T5/T6
UniversalSuperior surface finish and formability. Easily extruded into custom profiles. Great for powder coating.
6101-T6
EV OptimizedHigh conductivity with superior creep resistance compared to 1350. Minimal degradation over time.
1060/1350/1370
Max Conductivity≥99.5% Aluminum. Lowest resistance for precision applications where strength is secondary.
Copper-Clad Aluminum (CCA)
CCA leverages the skin effect to concentrate current in the high-conductivity copper outer layer. It offers a copper-to-copper connection interface with the weight savings of an aluminum core.
Ideal Applications
- Retrofit projects replacing pure copper
- Scenarios requiring copper contact interface
- Hybrid systems
Custom Manufacturing
Processes
-
01
Cutting & Sizing
Standard lengths 2-6m (up to 12m). Laser precision cutting. Tolerance ±0.1mm.
-
02
Forming & Bending
CNC bending for repeatability. U/L/T profiles. Radius 1.5-3x thickness.
-
03
Joining
TIG welding (argon), friction stir welding, brazing, crimping.
Laminated Busbars
Low inductance, multi-layer insulated design.
Accessories
Insulators, covers, expansion joints, hardware.
Aluminum vs. Copper: The Comparison
| Parameter | Aluminum | Copper | Winner |
|---|---|---|---|
| Cost | 1.0x (Baseline) | 2.5x - 3.0x | Al |
| Weight | 2.7 g/cm³ (Light) | 8.9 g/cm³ (Heavy) | Al |
| Conductivity (Vol) | ~61% IACS | 100% IACS | Cu |
| Therm Expansion | Higher | Lower | Cu |
When to choose Aluminum
- Weight restrictions apply
- Budget constraints
- Large-scale outdoor projects
When to choose Copper
- Extremely tight spaces
- Maximum conductivity required
- Corrosive environments (without plating)
Core Technical Parameters
Electrical
- Conductivity 40-61% IACS
- Resistivity 2.6-4.6 μΩ·cm
- Voltage Up to 1000V+
Mechanical
- Tensile 130-310 MPa
- Yield 80-276 MPa
- Hardness 30-95 Brinell
Thermal
- Conductivity ~235 W/m·K
- Melting Point 658°C
- Max Operating 90°C Cont.
Sizing & Ampacity Reference (6101-T61)
Aluminum 6101-T61 is the preferred alloy for high-current busbars, offering the best balance of conductivity (~57-59% IACS) and mechanical strength. Below is a reference for 6101-T61 busbars at 30°C rise (Indoor/Still Air).
| Bar Size (mm) | Section (mm²) | Weight (kg/m) | Est. Ampacity (AC) |
|---|---|---|---|
| 25 x 3 | 75 | 0.20 | ~185 A |
| 40 x 6.3 | 252 | 0.68 | ~420 A |
| 60 x 10 | 600 | 1.62 | ~840 A |
| 100 x 10 | 1000 | 2.70 | ~1250 A |
| 120 x 12.5 | 1500 | 4.05 | ~1680 A |
*Data based on 6101-T61 Alloy (57% IACS) at 30°C ambient temperature rise. Actual ampacity depends on orientation and ventilation.
Surface Treatment Options
Tin Plated
Standard. Prevents oxidation. 0.05-0.1mm
Silver Plated
Premium. Lowest resistance. 0.01-0.03mm
Nickel Plated
Anti-corrosion. Marine use. 0.05-0.15mm
Powder Coat
Insulation & Color coding. 50-100μm
Anodized
Hard surface. Weathering. 5-20μm
Installation Guide
Oxidation Management
Aluminum naturally forms an oxide layer. For best results:
- Clean surface (wire brush).
- Apply joint compound (e.g., Penetrox).
- Torque immediately to specifications.
Thermal Expansion
Expands ~42% more than copper.
- Use Belleville (spring) washers on bolts.
- Install expansion joints every 10-15m.
- Use flexible braided connectors for long runs.
Packaging & Logistics
Export Standard Crates
Fumigated wooden cases compliant with ISPM 15. Reinforced with steel straps for ocean freight.
Moisture Protection
Each bundle wrapped in plastic with desiccant packs to prevent water stain/oxidation during transit.
Global Logistics
CIF/DDP terms available to 74 countries. We handle customs documentation.
Pricing Model
We provide factory-direct custom quotes. No hidden fees.
Quality Control
ISO 9001:2015 Certified. < 0.5% Rejection Rate.
Frequently Asked Questions
Will aluminum busbars loosen over time?
Thermal cycling can reduce bolt tension. Solution: Use Belleville washers and follow specified tightening sequences. Our T6 temper alloys have excellent creep resistance.
How do I size aluminum busbars to match copper?
Rule of thumb: Aluminum busbars need ~62% larger cross-section than copper for equivalent current capacity. We provide sizing charts and engineering support.
Can aluminum and copper busbars be mixed?
Yes, but use transition washers or bimetallic connectors to prevent galvanic corrosion, or choose our tin-plated busbars.
