The 1050 aluminum busbar is made of 1050 industrial-grade pure aluminum, which is a high-purity material (aluminum content ≥ 99.5%). Due to its excellent conductivity, lightweight properties, and cost-effectiveness, it is widely used in power transmission and distribution systems.
With its superior conductivity and cost-effectiveness, the 1050 aluminum busbar is the ideal choice for medium and low voltage power systems, especially in scenarios where weight sensitivity or strict cost control is required. However, attention must be given to its mechanical strength limitations and oxidation prevention measures.
1050 Aluminum Busbar Conductivity
- Electrical Conductivity: Approximately 61% IACS (International Annealed Copper Standard), second only to copper, offering a high cost-performance ratio.
- Current Carrying Capacity: Must be calculated based on cross-sectional area, ambient temperature, and heat dissipation conditions. Typically, the cross-sectional area needs to be increased by about 50% compared to the same specification copper busbar to achieve equivalent current carrying capacity.
1050 Aluminum Busbar Chemical Composition
The 1050 aluminum alloy includes:
- Aluminum (Al): At least 99.5% in the alloy.
- Silicon (Si): Up to 0.25%.
- Iron (Fe): Up to 0.40%.
- Copper (Cu), Manganese (Mn), Magnesium (Mg): Each element's content is limited to around 0.05%.
- Other Elements: Trace amounts of Zinc (Zn), Titanium (Ti), and other elements.
This composition (typically also specified as Al99.5 or 1050A) ensures that impurities are kept to a minimum, which is why this material exhibits high conductivity and corrosion resistance.
1050 Aluminum Busbar Physical and Mechanical Properties
- Electrical Conductivity: Typically about 57% of the International Annealed Copper Standard (IACS), making it highly suitable for power distribution.
- Thermal Conductivity: Ranges from 210–220W/m·K, which helps with effective heat dissipation.
- Density: 2.71 g/cm³ (only 30% of copper's weight, providing a significant lightweight advantage).
- Strength: In the annealed (O-temper) state, its tensile strength is relatively low (around 60–100MPa), but it has excellent ductility and elongation. Cold working can moderately improve its strength (such as H14 or H18 temper) while still maintaining good conductivity.
- Corrosion Resistance: Its high purity allows it to form a protective oxide layer, enhancing its resistance to atmospheric and chemical corrosion.
- Workability: The alloy has high formability, making it easy to roll, extrude, cut, stamp, and weld.
- Elongation: Approximately 20–35% (excellent ductility in the soft state, making it easy to process into various shapes).
- Melting Point: Around 660°C.
1050 Aluminum Busbar Specifications and Models
1050 Aluminum Busbar Typical Specifications
| Attribute | Specification |
| Model Number | AL1050 |
| Material | Aluminum |
| Product Name | Customized Aluminum Busbar |
| Surface Treatment | Zinc, Nickel, Tin, Silver, etc. |
| Tolerance | +/- 0.1mm |
| Length | Up to 6m |
| Width | 10mm - 200mm |
| Thickness | 0.15mm - 40mm |
| Application | Electric |
| Processing | Stamping, Bending, Drilling, Threading, Polishing, etc. |
| Electrical Conductivity | ~61% IACS (International Annealed Copper Standard) |
| Thermal Conductivity | 235 W/m·K (Good heat dissipation) |
| Density | 2.71 g/cm³ (Lighter than Copper: 8.96 g/cm³) |
| Mechanical Strength | Compared to 6061 (310 MPa), tensile strength is lower (≈70 MPa) |
| Corrosion Resistance | Forms protective oxide layer; suitable for indoor use, may require coating in harsh environments |
| Size Range | From 10x2 mm to 200x20 mm, depending on current requirements |
| Rated Current | Example: 100x10 mm busbar can carry ~1500 A at 30°C |
How to Choose the 1050 Aluminum Busbar Specifications?
| Key Selection Points | Description |
| Current Carrying Capacity | Choose the appropriate specifications based on the cross-sectional area (width × thickness), ambient temperature, and heat dissipation conditions. Refer to IEC 60439 standard for calculations, or use the table method (for example, the current carrying capacity of a 30×4mm² busbar at room temperature is about 400A). Typically, the temperature rise limit should not exceed 70°C (ambient temperature of 40°C). |
| Mechanical Strength | 1050 aluminum is relatively soft, so additional thickness or support structures are needed to prevent deformation. The typical thickness range is from 3mm to 12mm, and the width range is from 20mm to 200mm. |
| Installation Conditions | If space is limited, multiple thin busbars in parallel (e.g., 4×30mm) can be selected. Generally, an insulating support point should be set every 300–500mm to ensure the stability of the busbar. |
| Environmental Factors | In corrosive environments, it is recommended to tin-plate or coat the busbar surface with insulating paint (such as RTV silicone rubber) to enhance corrosion resistance and ensure service life. |
What are the Models of 1050 Aluminum Busbars?
The models of 1050 aluminum busbars are usually classified based on cross-sectional shape and size parameters:
| Model Type | Typical Examples | Applicable Scenarios |
| 1050 Rectangular Aluminum Busbar | 30×4mm, 50×6mm | Distribution cabinets, transformers, and other standard installations |
| 1050 Special-shaped Aluminum Busbar | Channel-type, L-type | Special space layouts (such as compact switchgear) |
| Flexible Busbar | Braided strip type | Vibration environments or places requiring flexible connections |
What Are the Differences Between Different Models of 1050 Aluminum Busbars?
| Comparison Dimension | Rectangular 1050 Aluminum Busbar | Round 1050 Aluminum Busbar | Special-shaped 1050 Aluminum Busbar |
| Current Carrying Capacity | Larger surface area, better heat dissipation | Lower skin effect, better for high-frequency scenarios | Optimized local current carrying based on design |
| Mechanical Strength | Edges are prone to deformation, thickness needs to be increased | Higher bending strength | Structural reinforcement design (e.g., reinforcing ribs) |
| Installation Convenience | Easy to drill for fixing, reliable connection | Requires special fixtures, anti-rotation design | Customized installation, compatible with special structures |
| Cost | Simple processing, lowest cost | Requires precision extrusion, cost 20%–30% higher | High mold cost, suitable for mass production |
Special Model Differences:
- Tinned Busbar: Reduces surface resistance by 15%, improves corrosion resistance, suitable for coastal areas.
- Insulated Busbar: Equipped with a 3mm thick PVC or epoxy coating, increases voltage withstand rating to 3kV/mm.
1050 Aluminum Busbar Fabrication and Surface Treatment
1050 aluminum busbars are typically produced through extrusion or rolling processes to form flat strips with rectangular cross-sections. These manufacturing methods have the following advantages:
- Easy to Manufacture: Flat busbars can be easily cut, bent, stamped, and drilled to meet custom design requirements.
- Tolerances and Customization: Busbars are usually delivered in lengths cut to customer specifications, with strict tolerances (e.g., ±0.1 mm).
- Forming Process: Cold-rolled or hot-rolled into sheet/strip, then processed into busbars through cutting, punching, bending, etc.
Surface Treatment
- Surface Treatment: Common surface treatments include rolling, anodizing, or various metal coatings (such as zinc, nickel, tin, or silver) to enhance corrosion resistance and aesthetics.
- Anodizing: Enhances corrosion resistance but may slightly reduce conductivity.
- Tin/ Silver Plating: Improves the oxidation resistance of contact surfaces and reduces contact resistance.
- Coating with Insulating Paint: Used in applications requiring insulation protection.
1050 Aluminum Busbar Applications
The primary function of busbars is to efficiently distribute electricity. Due to their high conductivity and lightweight characteristics, 1050 aluminum busbars are widely used:
As conductive busbars in low and high-voltage distribution cabinets, transformers, substations, etc., replacing copper bars to reduce costs.
- Power Distribution: Efficient current transmission is crucial in substations, switchgear, and transformer connections.
- Battery and Cable Sheaths: Used as conductive components in electric vehicles (EV) and energy storage devices, battery assemblies, and cable connections.
- Heat Sinks and Thermal Management: Its high thermal conductivity makes it suitable for components requiring effective heat dissipation.
- Renewable Energy Systems: Solar/wind energy installations, where weight reduction is critical.
- New Energy Systems: Photovoltaic inverters, busbars for battery storage systems.
- Rail Transport: Power distribution systems for subways and high-speed trains.
- Industrial Sector: Internal conductive structures for high-current equipment, electrical enclosures requiring efficient power wiring.
1050 Aluminum Busbar Advantages
- Cost-effective and lightweight: 1050 aluminum is cheaper and significantly lighter than copper, reducing material and installation costs.
- Lightweight: 1050 aluminum busbars are about 50% lighter than copper busbars, reducing structural load.
- High recyclability: Aluminum is widely recycled, making this alloy a sustainable choice.
- Versatility: Available in various temper states (such as O, H14, H18), allowing for a balance between formability and mechanical strength based on specific application needs.
- Easy to install: The flat rectangular shape of the 1050 aluminum busbar enables direct assembly through bolted connections, welding, or mechanical fastening.
1050 Aluminum Busbar Standards and Compliance
- ASTM B317: Standard specification for aluminum bus conductors.
- IEC 61439: Guidelines for low-voltage switchgear components.
1050 Aluminum Busbar vs. Other Materials
| Comparison Material | Feature Comparison |
| Compared to Copper | 1050 aluminum busbars have lower conductivity but better weight-to-conductivity ratio, reducing costs by more than 50% and cutting weight by 50%. Although conductivity is lower than copper, by increasing the cross-sectional area, costs can be reduced, making it suitable for applications where cost and weight reduction are important (e.g., power transmission systems). |
| Compared to 1060 Aluminum Busbar | 1050 aluminum busbar has a higher aluminum purity, which means it has slightly better conductivity than 1060 aluminum busbar. The mechanical strength of 1050 aluminum busbar is slightly lower, making it suitable for applications that do not require high strength, especially where high conductivity and light weight are needed (e.g., power transmission, heat dissipation components). |
| Compared to 6101 Aluminum Busbar | 1050 aluminum busbar has higher conductivity but lower mechanical strength. 6101 aluminum busbars are typically used in high-stress environments and are better suited for applications that require significant mechanical stress. 1050 aluminum busbars are more suitable for low mechanical stress but high conductivity applications, such as power transmission. |
| Compared to 6061 Aluminum Alloy | 1050 aluminum busbar has better conductivity (61% IACS vs. 47% IACS), but 6061 aluminum alloy has higher strength, making it better suited for applications that require higher mechanical strength. If conductivity is the priority, 1050 aluminum busbars are more suitable; if strength is the primary requirement, 6061 aluminum alloy is better. |
1050 aluminum busbars are well-suited for cost-sensitive, high-conductivity applications where mechanical strength is secondary. They are lightweight and easy to manufacture, making them popular in modern power systems, but careful design is required to address thermal and mechanical limitations. Proper installation and maintenance ensure long-term reliability.
1050 Aluminum Busbar Limitations
- Low mechanical strength: Requires increased thickness or additional support structures, especially in vibrating environments.
- Susceptible to oxidation: The surface oxide film increases contact resistance, requiring regular maintenance or coating protection.
- High thermal expansion coefficient: Higher than copper (23.1 µm/m·K), requiring design adaptations for thermal cycles. Expansion compensation structures should be designed to avoid thermal stress deformation.
- Connection challenges: Softness may cause loosening under vibration; it is recommended to use torque-controlled fastening.
Manufacturing and Design Considerations
- Forming Methods: Extrusion, rolling, or cutting from sheet material.
- Surface Treatment: Anodizing or tin-plating to enhance corrosion resistance and conductivity.
- Current Capacity: Determined by cross-sectional area; derating is necessary at high temperatures.
- Cooling: High-current applications may require passive or active cooling systems.
Selection and Installation Considerations
- Current Carrying Capacity Calculation: Refer to IEC 61439 or ANSI/IEEE standards, considering temperature rise limits (usually ≤70K).
- Connection Methods: Use dedicated copper-aluminum transition terminals or conductive grease to prevent galvanic corrosion.
- Bending Radius: Minimum bending radius should be ≥ 2 times the thickness to avoid cracking at the bend.
Environmental Considerations
- Indoor Use: Usually safe to use without coating.
- Outdoor/Harsh Environments: Requires protective coatings (e.g., powder coating) to resist moisture and chemicals.
1050 aluminum busbars are an excellent choice for many power distribution and industrial applications due to the following characteristics:
- High purity (≥99.5% aluminum) and excellent conductivity.
- Good thermal performance and outstanding corrosion resistance.
- Easy to manufacture and versatile for finishing.
- Lightweight properties help reduce overall system weight and costs.
Its fine composition, manufacturing flexibility, and reliable performance make it the standard material for industries where efficient power distribution and corrosion resistance are critical.