6101 T6 T61 T64 Electrical Aluminum Busbar

6101 Aluminum alloy is a heat-treatable wrought alloy, known for its excellent electrical conductivity and moderate strength, making it particularly suitable for electrical applications such as busbars.

Chemical Composition: 6101 alloy is primarily composed of aluminum, including magnesium (0.35–0.8%) and silicon (0.3–0.7%), which enhance its mechanical strength without significantly compromising electrical conductivity.
Electrical Conductivity: Approximately 59% of the International Annealed Copper Standard (IACS), which is lower than pure copper, but sufficient to meet the requirements of many electrical applications.

6101 aluminum busbars are available in various specifications, including different cross-sectional shapes (such as rectangular, round, etc.) and sizes, to meet specific current-carrying capacities and installation requirements.

6101 electrical aluminum busbars are an efficient, economical, and practical solution suitable for a wide range of electrical applications.

6101 aluminum busbars are made from aluminum alloy, typically containing a certain proportion of magnesium and silicon, providing excellent electrical conductivity and mechanical strength. Compared to pure aluminum, aluminum alloys offer significant advantages in strength and corrosion resistance.

6101 aluminum busbars

HC Aluminum 6101 EC grade aluminum busbars comply with IEC 60105, ISO 209-1, 2, DIN EN 755-2, and DIN EN 755-5 standards. The 6101 aluminum busbars have a smooth surface with no burrs, exceptional conductivity, high strength, good corrosion resistance, and a lightweight design.

6101 Aluminum Busbar Specifications

The specifications of 6101 aluminum busbars are diverse, with common cross-sectional shapes including rectangular, round, and flat. The cross-sectional dimensions and lengths can be customized based on specific application requirements.

Dimension Name	Specification
Material	Aluminum
Shape	Bar-Rectangle
Alloy	6101
Temper	T61
Production Method	Extruded
Shape Type	Full Round Edge

6101 Aluminum Busbar Characteristics

Excellent conductivity: 6101 aluminum alloy has good electrical conductivity, approximately 61% IACS (International Annealed Copper Standard), making it highly efficient for electrical applications.
Corrosion resistance: The oxide layer that naturally forms on 6101 alloy in the air provides excellent corrosion resistance, making it suitable for various environments.
Mechanical strength: Although aluminum's strength is relatively low, the mechanical strength of 6101 alloy, after alloying and heat treatment, meets the structural requirements for electrical busbars.
Good machinability: 6101 aluminum alloy is easy to extrude, bend, and weld, making it suitable for producing various shapes of electrical busbars.
Lightweight: The low density of aluminum makes 6101 busbars lighter than copper busbars, helping to reduce installation costs and the load on supporting structures.

Chemical composition of HC Aluminum 6106 conductive aluminum busbar

Element	Composition (%)
Aluminum (Al)	Balance
Copper (Cu)	1.0 - 1.5
Iron (Fe)	0.5 max
Silicon (Si)	0.5 max
Manganese (Mn)	0.1 - 0.5
Magnesium (Mg)	0.15 max
Zinc (Zn)	0.1 max
Titanium (Ti)	0.1 max
Other Elements	0.05 each, 0.15 total max

Properties of HC Aluminum 6101 electrical aluminum busbar

emper	Yield Strength Rp0.2(Mpa)	Ultimate tensile strength Rm(Mpa)	Elongation	Conductivity %IACS
6101-T6	≥172	≥200	15	-
6101-T61	≥55	≥103	-	≥59%
6101-T63	≥150	≥185	-	≥56
6101-T64	≥55	≥105	-	≥59.5
6101-T65	-	-	-	≥58%

6101 Aluminum Busbar Mechanical Properties

Mechanical Properties
Property	Value
Ultimate Tensile Strength KSI	18
Density g/cm^3	3
Brinell Hardness 500 kg load	71
Yield Tensile Strength KSI	11
Rockwell Hardness B Scale	34
Elongation % in 2 in.	10
Melting Point °F	1150 - 1210
Electrical Conductivity % IACS	59

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

Advantages and Disadvantages of 6101 Aluminum Busbars

Category	Advantages	Disadvantages
Weight	6101 aluminum busbars are lighter than copper busbars, making them easier to install and handle, reducing the burden on support structures.	Although aluminum busbars are lightweight, additional support may be needed in certain high-load situations.
Conductivity	6101 aluminum busbars have good conductivity, making them suitable for most power transmission applications.	The conductivity of aluminum is approximately lower than that of copper.
Corrosion Resistance	The oxide film that forms on aluminum surfaces provides good corrosion protection, making it suitable for humid or corrosive environments.	In certain extreme environments, the corrosion resistance of aluminum may be insufficient, requiring additional protective measures.
Cost	The raw material cost of aluminum is typically lower than that of copper, making 6101 aluminum busbars more economical for large-scale applications.	Initial investment and installation technical requirements may lead to increased overall costs, especially in cases requiring high-precision connections.
Installation and Maintenance	The installation process is relatively straightforward, and aluminum busbars have low maintenance requirements, reducing long-term operating costs.	Connections require specialized skills to ensure good electrical contact and to avoid overheating and oxidation issues.

Applications of 6101 Aluminum Busbars

Application Area	Detailed Description
Power Distribution Systems	6101 aluminum busbars are widely used in equipment such as power distribution cabinets and substations as the main channel for power delivery, ensuring effective transmission of electricity from the power source to various loads.
Power Distribution	In distribution systems, 6101 aluminum busbars are used to connect transformers, switching devices, and other electrical equipment, providing efficient power transmission to meet the energy needs of different loads.
Industrial Applications	In factories and manufacturing, 6101 aluminum busbars are used for electrical wiring and power distribution, particularly suitable for heavy load or high current applications, capable of withstanding power demands under high load conditions.
Buildings and Infrastructure	In the electrical systems of large buildings (such as data centers, hospitals, and high-rise buildings), 6101 aluminum busbars provide stable power supply, ensuring the normal operation of critical equipment.
Transportation	In rail transit, subways, and electric vehicles, 6101 aluminum busbars serve as power transmission lines, ensuring safe and efficient power supply to support the normal operation of urban transportation.

Considerations

Although 6101 aluminum alloy offers several advantages, it is important to note that its electrical conductivity is lower than that of pure copper. Therefore, to achieve equivalent current-carrying capacity, a larger cross-sectional area is required. Additionally, aluminum's higher coefficient of thermal expansion compared to copper necessitates careful design to accommodate thermal stresses and prevent loosening of connections over time.

6101 aluminum alloy is a versatile material that balances electrical conductivity with mechanical strength, making it a preferred choice for various electrical applications, especially where weight and cost are significant considerations.