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6101 aluminum busbar

6101 aluminum busbar is a conductor made of 6101 aluminum alloy (a material composed of magnesium and silicon). It is designed to balance high conductivity with enhanced mechanical strength. This alloy is widely used in power distribution, switchgear, battery systems, and other high-current applications where weight reduction and cost efficiency are critical.

Although the conductivity of 6101 is slightly lower than that of 1350 (a nearly pure aluminum alloy), it has higher yield strength and better creep resistance.

6101 aluminum busbar

6101 aluminum busbar Alloy Composition

6101 EC (Electrical Conductor) is an aluminum alloy optimized for electrical applications.

  • Primary Elements: Aluminum (Al), Magnesium (Mg), Silicon (Si).
  • Trace Elements: Tight control over impurities (e.g., iron, copper) to enhance conductivity.
Alloy Si Fe Cu Mn Mg Cr Zn B Standard(wt%)
6101 0.30-0.70 ≦0.50 ≦0.10 ≦0.03 0.35-0.80 ≦0.03 ≦0.1 ≦0.06 EN573-3-2007

6101 aluminum busbar Available Tempers

Common Temper: T6 (solution heat-treated and artificially aged), providing a balance of strength and conductivity.

Temper Description
6101-T6 Aluminum Busbar Achieved through solution heat treatment and artificial aging, the 6101-T6 aluminum busbar provides maximum mechanical strength and is widely used in high-performance busbar applications, such as power distribution systems and industrial busbar systems, where high strength and good conductivity are required.
6101-T61 Aluminum Busbar In an over-aged state, the 6101-T61 aluminum busbar offers better conductivity at the cost of ductility. This busbar is suitable for applications that require high conductivity, such as transformer windings and large power grid systems, helping to reduce energy losses.
6101-T63 Aluminum Busbar As an intermediate state, the 6101-T63 aluminum busbar balances conductivity and strength, making it suitable for applications that require moderate strength and formability, such as switchgear components and electrical panels.
6101-T64 Aluminum Busbar In a partially annealed state, the 6101-T64 aluminum busbar maximizes formability and provides the highest conductivity. This busbar is typically used in applications that require complex bending and forming, such as battery connectors and flexible electrical joints.
6101-T65 Aluminum Busbar Offering medium conductivity with controllable tensile strength and yield strength, the 6101-T65 aluminum busbar enhances bend repeatability, making it particularly suitable for busbar systems that require precise installation tolerances and repeatable bending, such as precision power distribution equipment.

6101 Aluminum Busbar Electrical Properties

  • Electrical Conductivity: Typically around 55–60% IACS, allowing it to efficiently carry high currents while maintaining low losses.
  • Better than Copper: Lighter weight, lower cost, but equivalent current capacity may require a larger cross-sectional area.

6101 Aluminum Busbar Mechanical Properties

  • Mechanical Strength: Higher yield strength and better creep resistance compared to higher-purity aluminum alloys like 1350. This makes it more robust in structural and thermal cycling applications.
  • Ductility: 6101 has medium ductility, allowing it to be formed and shaped during installation.
  • Comparison: Conductivity is higher than 6061 aluminum, but mechanical strength is slightly lower.
  • Formability and Machinability: 6101 alloy is easy to extrude and machine, and can be formed into various shapes (flat, right angles, round or R corners) with a smooth surface and minimal edge burrs.
  • Weldability: Compatible with standard welding techniques like TIG and MIG, but heat input may affect local strength.
Alloy Temper Yield Strength Rp0.2(Mpa) Tensile Strength Rm(Mpa) Conductivity %IACS Bending
6101 T63 ≥150 ≥185 ≥56 90°1t
T64 ≥55 ≥105 ≥59.5 90°1t

6101 aluminum busbar Thermal Properties

  • Thermal Expansion: 23.6 µm/m·°C (higher than copper), thus thermal cycling must be considered in the design.
  • Melting Point: ~655°C, suitable for most electrical environments.
  • Heat Dissipation: Good thermal conductivity (~180 W/m·K) helps control heat buildup.

Customized 6101 aluminum busbar

6101 aluminum busbar Dimensions and Specifications

Item Specifications/Range
Thickness 2 - 20 mm
Width 30 - 130 mm
Length 3 m, 6 m, 12 m (custom cutting available)
Standard Compliance ASTM B317, IEC 60105, ISO 209-1, etc.
Design Options Right angle, rounded corners, R-corner busbar, smooth edges (no burrs), high dimensional accuracy

6101 aluminum busbar Surface Treatment

  • Anodizing or Powder Coating: Used to enhance corrosion resistance and provide a uniform, smooth surface.
  • Plating: Options include tin plating, silver plating, or nickel plating—this further improves surface oxidation resistance and helps reduce contact resistance.
Product Type Description
Tin-Plated 6101 Aluminum Busbar Tin-plated 6101 aluminum busbars offer excellent oxidation resistance and corrosion resistance, performing well in humid or harsh environments. The tin plating enhances the busbar's welding performance and improves connection reliability, making them widely used in switchgear, transformer connections, and power distribution systems to ensure long-term stable electrical performance.
Silver-Plated 6101 Aluminum Busbar Silver-plated 6101 aluminum busbars have extremely low contact resistance and excellent electrical conductivity, making them ideal for high-performance electrical applications. The silver plating improves the busbar's heat resistance and reduces energy losses, making them widely used in high-frequency electrical equipment, avionics, telecommunications, and precision electrical connections.
Nickel-Plated 6101 Aluminum Busbar Nickel-plated 6101 aluminum busbars have excellent corrosion resistance, high-temperature resistance, and mechanical strength, making them suitable for extreme environments and high-temperature electrical systems. The nickel plating provides good wear resistance and ensures reliable electrical contact under harsh conditions, commonly used in rail transport, marine power systems, and specialized industrial equipment.

6101 aluminum busbar Manufacturing and Processing

  • Extrusion and Rolling: Busbars are typically produced through extrusion or rolling, allowing for high-volume production of standard or custom sizes.
  • Processing and Finishing: Post-extrusion processes include cutting, bending, and surface finishing to meet precise design requirements.
  • Connection Methods: Welding (TIG/MIG), bolt connections, or clamps; using compatible connectors to avoid electrochemical corrosion.

6101 aluminum busbar Standards and Compliance

  • ASTM B317: Specifies the requirements for extruded aluminum busbars.
  • IEC 60439: Governs low-voltage switchgear components.
  • UL Certification: Usually required to ensure the safety of electrical systems.

6101 aluminum busbar Applications

6101 EC aluminum busbars have a wide range of uses and are suitable for various electrical and industrial applications:

Application Area Description
Distribution 6101 EC aluminum busbars are primarily used in switchgear, substations, and distribution panels as efficient conductive paths, providing stable power transmission for industrial and commercial facilities. Their excellent conductivity and corrosion resistance ensure long-term reliable operation, while reducing the overall system weight, improving ease of installation and maintenance.
Power Plants and Stations 6101 EC aluminum busbars serve as the main conductors for large current and high-power transmission, effectively reducing energy loss and improving the efficiency of power systems. Due to their superior conductivity and heat resistance, these busbars are widely used in thermal power plants, hydropower plants, nuclear power generation, and other high-power transmission scenarios.
Battery Systems and Electric Vehicle Charging 6101 EC aluminum busbars perform excellently in battery systems and electric vehicle charging due to their excellent mechanical properties and lightweight characteristics, making them an ideal choice for battery packs and electric vehicle charging stations. These busbars can withstand high current loads and provide efficient power transmission, ensuring the stable operation of battery management systems and charging infrastructure.
Industrial and Aerospace 6101 EC aluminum busbars are favored in the industrial and aerospace fields due to their excellent strength-to-weight ratio and good formability. They have wide applications in aerospace, electrical equipment manufacturing, and other engineering applications where weight is a concern. Their corrosion resistance and high conductivity make them an ideal material for aircraft power distribution systems, satellite components, and high-end industrial equipment.
Renewable Energy 6101 EC aluminum busbars play a key role in renewable energy applications, being widely used in solar power plants, wind turbines, and battery storage systems. Due to their high conductivity and resistance to environmental corrosion, these busbars ensure the efficient and stable operation of new energy systems, reducing energy transmission losses and improving overall energy utilization.

Advantages of 6101 Aluminum Busbar Over Other Materials

  • Cost-Effective: The material cost is lower than copper, and it is about 70% lighter than copper, reducing installation and transportation costs.
  • Lightweight: The density is approximately 1/3 that of copper, making installation and structural support easier.
  • Mechanical Properties: Enhanced yield strength and creep resistance compared to high-purity aluminum alloys (such as 1350) provide better performance under mechanical stress and thermal cycles.
  • Design Flexibility: 6101 busbars come in a variety of tempers and shapes, which can be customized according to specific electrical and mechanical design requirements.
  • Environmental and Economic Benefits: Aluminum is more cost-effective and recyclable, helping to reduce environmental impact.

6101 aluminum and copper current carrying capacity comparison table

Ampacity Conversion Chart Copper C110 30° C Rise 50° C Rise 65° C Rise Aluminum 6101 30° C Rise 50° C Rise 65° C Rise
Flat Bar Size in Inches Sq. In Circ Mils Thousands Weight Per Ft in Lb. DC Resistance at 20° C, Microhms/Ft 60 Hz Ampacity Amp* Weight Per Ft in Lb. DC Resistance at 20° C, Microhms/Ft 60 Hz Ampacity Amp**
1/16 x 1/2 0.0312 39.7 0.121 264 103 136 157 0.037 494 58 76 88
1/16 x 3/4 0.0469 59.7 0.181 175 145 193 225 0.055 327 81 108 126
1/16 x 1 0.0625 79.6 0.242 132 187 250 285 0.073 247 105 140 160
1/16 x 1 1/2 0.0938 119 0.362 87.7 270 355 410 0.110 164 151 199 230
1/16 x 2 0.125 159 0.483 65.8 345 460 530 0.146 123 193 258 297
1/8 x 1/2 0.0625 79.6 0.241 132 153 205 235 0.073 247 86 115 132
1/8 x 3/4 0.0938 119 0.362 87.7 215 285 325 0.110 164 120 160 182
1/8 x 1 0.125 159 0.483 65.8 270 360 415 0.146 123 151 202 232
1/8 x 1 1/2 0.188 239 0.726 43.8 385 510 590 0.220 82 216 286 330
1/8 x 2 0.25 318 0.966 32.9 495 660 760 0.293 62 277 370 426
1/8 x 2 1/2 0.312 397 1.210 26.4 600 800 920 0.365 49 336 448 515
1/8 x 3 0.375 477 1.450 21.9 710 940 1100 0.439 41 398 526 616
1/8 x 3 1/2 0.438 558 1.690 18.8 810 1100 1250 0.512 35 454 616 700
1/8 x 4 0.5 636 1.930 16.5 900 1200 1400 0.585 31 504 672 784
3/16 x 1/2 0.09375 119 0.362 87.7 195 260 300 0.110 164 109 146 168
3/16 x 3/4 0.141 179 0.545 58.4 270 360 415 0.165 109 151 202 232
3/16 x 1 0.188 239 0.726 43.8 340 455 520 0.220 82 190 255 291
3/16 x 1 1/2 0.281 358 1.090 29.3 480 630 730 0.329 55 269 353 409
3/16 x 2 0.375 477 1.450 21.9 610 810 940 0.439 41 342 454 526
3/16 x 2 1/2 0.469 597 1.810 17.5 740 980 1150 0.549 33 414 549 644
3/16 x 3 0.562 715 2.170 14.6 870 1150 1350 0.658 27 487 644 756
3/16 x 3 1/2 0.656 835 2.530 12.5 990 1300 1500 0.768 23 554 728 840
3/16 x 4 0.75 955 2.900 11 1100 1450 1700 0.878 21 616 812 952
1/4 x 1/2 0.125 159 0.483 65.8 240 315 360 0.146 123 134 176 202
1/4 x 3/4 0.188 239 0.726 43.8 320 425 490 0.220 82 179 238 274
1/4 x 1 0.25 318 0.966 32.9 400 530 620 0.293 62 224 297 347
1/4 x 1 1/2 0.375 477 1.450 21.9 560 740 880 0.439 41 314 414 482
1/4 x 2 0.5 637 1.930 16.5 710 940 1100 0.585 31 398 526 616
1/4 x 2 1/2 0.625 796 2.410 13.2 850 1150 1300 0.731 25 476 644 728
1/4 x 3 0.75 955 2.900 11 990 1300 1550 0.878 21 554 728 868
1/4 x 3 1/2 0.875 1110 3.380 9.4 1150 1500 1750 1.024 18 644 840 980
1/4 x 4 1 1270 3.860 8.23 1250 1700 1950 1.170 15 700 952 1092
1/4 x 5 1.25 1590 4.830 6.58 1500 2000 2350 1.463 12 840 1120 1316
1/4 x 6 1.5 1910 5.800 5.49 1750 2350 2700 1.755 10 980 1316 1512
3/8 x 3/4 0.281 368 1.090 29.3 415 550 630 0.329 55 232 308 353
3/8 x 1 0.375 477 1.450 21.9 510 680 790 0.439 41 286 381 442
3/8 x 1 1/2 0.562 715 2.170 14.6 710 940 1100 0.658 27 398 526 616
3/8 x 2 0.75 955 2.900 11 880 1150 1350 0.878 21 493 644 756
3/8 x 2 1/2 0.938 1190 3.620 8.77 1050 1400 1600 1.097 16 5.88 784 896
3/8 x 3 1.12 1430 4.350 7.35 1200 1600 1850 1.310 14 672 896 1036
3/8 x 3 1/2 1.31 1670 5.060 6.38 1350 1800 2100 1.533 12 756 1008 1176
3/8 x 4 1.5 1910 5.8 5.49 1500 2000 2350 1.755 10 840 1120 1316
3/8 x 5 1.88 2390 7.26 4.38 1800 2400 2800 2.2 8 1008 1344 1568
3/8 x 6 2.25 2860 8.69 3.66 2100 2800 3250 2.633 7 1176 1568 1820
1/2 x 1 0.5 637 1.93 16.5 620 820 940 0.585 31 347 459 526
1/2 x 1 1/2 0.75 955 2.9 11 830 1100 1250 0.878 21 465 616 700
1/2 x 2 1 1270 3.86 8.23 1000 1350 1550 1.17 15 560 756 868
1/2 x 2 1/2 1.25 1590 4.83 6.58 1200 1600 1850 1.463 12 672 896 1036
1/2 x 3 1.5 1910 5.8 5.49 1400 1850 2150 1.755 10 784 1036 1204
1/2 x 3 1/2 1.75 2230 6.76 4.7 1550 2100 2400 2.048 9 868 1176 1344
1/2 x 4 2 2550 7.73 4.11 1700 2300 2650 2.34 8 952 1288 1484
1/2 x 5 2.5 3180 9.66 3.29 2050 2750 3150 2.925 6 1148 1540 1764
1/2 x 6 3 3820 11.6 2.74 2400 3150 3650 3.51 5 1344 1764 2044
1/2 x 8 4 5090 15.5 2.06 3000 4000 4600 4.68 4 1680 2240 2576
  • **Source: Copper Development Organization https://www.copper.org/applications/electrical/busbar/bus_table1.html
  • **Source: Aluminum Association https://www.aluminum.org/sites/default/files/aecd13.pdf

Note: Ratings depend upon configuration, air flow, ambient temp, etc. The values depicted are an approximation. Controlled testing is always required to validate.

Other considerations:

  • Forming the busbar (aluminum has a tendacy to crack with very tight radius)
  • Electroplating the busbar (white rust on aluminum, oxidation is an issue with aluminum)
  • Configuration of the busbar (vertical or horizontal configuration)

HC Aluminum Common sizes of 6101 aluminum busbar

6101 Right Angle Aluminum Busbar

Thickness A (in) Width B (in) Estimated Weight per lb/ft
1/8 0.375 0.055
1/8 0.500 0.074
1/8 0.625 0.090
1/8 0.750 0.110
1/8 0.875 0.127
1/8 1.000 0.149
1/8 1.250 0.184
1/8 2.000 0.299
1/8 2.500 0.371
1/8 4.000 0.599
3/16 0.375 0.084
3/16 0.500 0.112
3/16 0.625 0.140
3/16 0.750 0.168
3/16 0.875 0.187
3/16 1.000 0.222
3/16 2.000 0.442
1/4 0.500 0.149
1/4 0.750 0.209
1/4 1.000 0.284
1/4 1.250 0.359
1/4 1.500 0.434
1/4 2.000 0.584
1/4 2.500 0.734
1/4 3.000 0.884
1/4 3.250 0.959
1/4 4.000 1.184
1/4 4.500 1.334
1/4 5.000 1.484
1/4 6.000 1.784
1/4 7.000 2.084
1/4 8.000 2.384
3/8 0.625 0.277
3/8 1.25 0.527
3/8 2 0.864
3/8 2.5 1.120
3/8 3 1.134
3/8 4 1.764
3/8 5 2.214
3/8 6 2.664
3/8 8 3.596
1/2 0.75 0.385
1/2 1.5 0.896
1/2 2 1.196
1/2 3 1.796
1/2 4 2.396
1/2 5 2.996
1/2 6 3.596
1/2 8 4.796
1/2 10 5.996
3/4 1 0.884
3/4 4 3.455
3/4 5 4.495
1 1.25 1.498
1 8 9.535
1 10 11.996
1 12 14.364

Rounded Corners 6101 Aluminum Busbar

Thickness A (in) Width B (in) Radius R (in) Estimated Weight per lb/ft
1/8 0.375 0.031 0.055
1/8 0.5 0.016 0.074
1/8 0.5 0.031 0.074
1/8 0.625 0.062 0.09
1/8 0.75 0.031 0.11
1/8 0.875 0.062 0.127
1/8 1 0.031 0.149
1/8 1.25 0.062 0.184
1/8 2 0.031 0.299
1/8 2.5 0.031 0.371
1/8 4 0.031 0.599
3/16 0.375 0.031 0.084
3/16 0.5 0.031 0.112
3/16 0.625 0.031 0.14
3/16 0.75 0.016 0.169
3/16 0.75 0.031 0.168
3/16 0.875 0.094 0.187
3/16 1 0.062 0.222
3/16 2 0.094 0.442
1/4 0.5 0.031 0.149
1/4 0.75 0.125 0.209
1/4 1 0.125 0.284
1/4 1.25 0.125 0.359
1/4 1.5 0.125 0.434
1/4 2 0.125 0.584
1/4 2.5 0.125 0.734
1/4 3 0.125 0.884
1/4 3.25 0.125 0.959
1/4 4 0.125 1.184
1/4 4.5 0.125 1.334
1/4 5 0.125 1.484
1/4 6 0.125 1.784
1/4 7 0.125 2.084
1/4 8 0.125 2.384
3/8 0.625 0.062 0.277
3/8 1.25 0.188 0.527
3/8 2 0.062 0.895
3/8 2 0.187 0.864
3/8 2.5 0.062 1.12
3/8 3 0.187 1.314
3/8 5 0.187 2.214
3/8 4 0.187 1.764
3/8 6 0.187 2.664
3/8 8 0.062 3.596
1/2 0.75 0.250 0.385
1/2 1.5 0.062 0.896
1/2 2 0.062 1.196
1/2 3 0.062 1.796
1/2 4 0.062 2.396
1/2 5 0.062 2.996
1/2 6 0.062 3.596
1/2 8 0.062 4.796
1/2 10 0.062 5.996
3/4 1 0.125 0.884
3/4 4 0.375 3.455
3/4 5 0.062 4.495
1/1 1.25 0.031 1.498
1/1 8 0.25 9.535
1/1 10 0.062 11.996
1/1 12 0.188 14.364

Usage Notes

  • Cross-sectional dimensions: Larger than copper under equivalent current, but the space/weight savings often justify this.
  • Thermal management: Ensure adequate spacing and ventilation to handle expansion.
  • Connector compatibility: Use anti-oxidation compounds or bimetallic strips when connecting to copper.

6101 EC aluminum busbars are a comprehensive conductor choice for modern electrical systems. By combining medium conductivity with excellent mechanical properties and outstanding formability, it meets the demanding requirements of high current and high reliability applications. Whether used in power distribution, battery systems, or industrial installations, its design flexibility and cost advantages make it a competitive alternative to copper and other aluminum alloys.

6101 EC aluminum busbars are a high-performance solution for modern electrical systems, offering the best balance of conductivity, strength, and cost-efficiency. Its use is particularly beneficial in large-scale and renewable energy projects where weight and sustainability are key factors. Proper design and installation practices ensure reliability and longevity in various operating environments.