aluminum busbar | HC Aluminum

A conductive material made from aluminum, used to distribute electricity within electrical panels or systems. They provide a low-resistance path for electrical current and are commonly used in substations and switchgear.

aluminum busbar Supplied Forms

1050 aluminum flat bar busbar
1050 aluminum busbars (aluminum flat bars) are a type of high-purity aluminum alloy, typically containing at least 99.5% aluminum, classified as EC-grade aluminum (electrical conductivity grade aluminum).
1060 Electrical Aluminum Busbar
The 1060 aluminum busbar is a conductive busbar made primarily of 1060 aluminum alloy, commonly used in power systems and electrical equipment.
1070 Electrical Aluminum Busbar
The 1070 electrical aluminum busbar, with its excellent conductivity, lightweight, and corrosion resistance, has become an important component in power transmission and distribution systems, suitable for various electrical equipment and applications.
1350 Electrical Aluminum Busbar
1350 electrical aluminum busbar is a widely used aluminum alloy conductor in electrical engineering and distribution systems, featuring excellent electrical conductivity and mechanical properties.
6061 T4 T6 Electrical Aluminum Busbar
The 6061 aluminum busbar is a special type of electrical busbar made from 6061 aluminum alloy. Due to its excellent mechanical properties and corrosion resistance, it is widely used in electrical and structural applications.
6063 T4 T6 Electrical Aluminum Busbar
6063 aluminum busbars are electrical conductors made from 6063 aluminum alloy. Due to their lightweight and ability to effectively handle large currents, they are commonly used in power distribution systems.
6101 T6 T61 T64 Electrical Aluminum Busbar
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.
Tin-plated Aluminum Bus Bar
High quality tin-plated aluminum busbars are ideal for power generation, telecommunications, electric vehicles and transportation systems. Available in custom sizes and conforms to ASTM B545 standards.
Copper Clad Aluminum Busbar
Copper Clad Aluminum Busbar combines the high conductivity of copper with the lightweight advantages of aluminum, providing efficient and stable power transmission solutions for power distribution systems and other fields, reducing costs and weight.
Nickel-plated aluminum busbar
Nickel-plated aluminum busbars combine high conductivity, lightweight properties, and enhanced durability, making them the preferred choice for various electrical applications.
Flexible Aluminum Busbar
Flexible aluminum busbars can be bent and formed to fit a variety of configurations, making them ideal for installation in tight or complex spaces.
Aluminum Tubular Busbar
Aluminum tubular busbars are the ideal solution for modern electrical applications. Designed for efficiency and high performance, these busbars ensure stable power transmission while reducing weight and optimizing space in your system.

Aluminum busbars are metal strips or rods used for power distribution, conducting large currents in switchgear, substations, distribution boards, or industrial equipment. They act as central hubs that connect multiple circuits, ensuring efficient and reliable power transmission.

Aluminum busbars are used in electrical systems to achieve efficient conduction and distribution of power. These busbars are typically made from high-purity aluminum alloys, serving as central connection points that allow power to be collected from the input source and distributed to multiple circuits. Their design and material properties make them essential components in various electrical applications.

Aluminum Busbar

HC Aluminum - High-Quality Aluminum Busbar Supplier

HC Aluminum offers a comprehensive range of electrical busbar products, including aluminum busbars, copper busbars, and copper-clad aluminum busbars. Popular aluminum busbar products include 6101, 1060, 1100, 1350, 6061, 6063, etc., with a full range of specifications and competitive prices.

In addition to standard products, we can provide customized solutions for specialized applications within a short lead time.

Shape: Flat, angled, or custom-extruded profiles.
Surface treatment: Anodizing, plating, spraying, etc.; typically aluminum plated with silver, tin, or nickel.

Aluminum Busbar Standards and Compliance

Main standards: IEC 61439, ANSI C37.20, ASTM B317 (material specifications).
Testing: Temperature rise, short-circuit withstand, HIPOT testing, and corrosion resistance (e.g., salt spray test).

Aluminum Busbar Material Properties

Conductivity: The electrical conductivity of aluminum is about 61% of that of copper (37.7 MS/m vs. 58.0 MS/m). To match the current carrying capacity of copper, aluminum busbars need approximately 56% larger cross-sectional area.
Weight: With a density of 2.7 g/cm³ (compared to copper at 8.96 g/cm³), aluminum busbars are approximately 50-60% lighter for the same current capacity.
Corrosion resistance: Forms a protective oxide layer; optional coatings (anodizing, tin-plating/silver-plating) enhance durability.
Non-magnetic: Ideal for applications requiring minimal electromagnetic interference.
Thermal expansion: Higher than copper; design adjustments may be required to prevent mechanical stress.

Aluminum Busbar Design Considerations

Shape: Rectangular (most common for high surface area), round, or tubular (used to mitigate skin effect in high-frequency applications).
Rated current: Determined by the cross-sectional area, ambient temperature, and cooling conditions (e.g., a 100mm x 10mm rectangular busbar can carry ~1200A in a 35°C environment).
Temperature rise: Must comply with standards (e.g., IEC 61439) to prevent overheating. Aluminum has lower thermal conductivity than copper. To compensate for heat dissipation, we generally recommend increasing the surface area to improve heat exchange and enhance cooling efficiency.
Mechanical strength: The softness of aluminum may require thicker profiles or additional support to prevent sagging.
Surface treatment: Polishing, anodizing, or plating (tin/silver) to reduce oxidation and improve contact resistance.

Aluminum Busbar Features

Conductivity: Aluminum offers excellent conductivity, about 61% of copper’s, allowing for efficient power transmission with minimal energy loss.
Lightweight: Aluminum is much lighter than copper, making aluminum busbars easier to handle and install. The reduced weight can save on transportation and installation costs.
Corrosion resistance: Aluminum naturally forms a protective oxide layer, offering corrosion resistance and enhancing the durability of the busbar, especially in outdoor or harsh environments.
Cost-effectiveness: Generally, aluminum is more affordable than copper, making aluminum busbars a cost-effective choice for many applications.

High-Quality Aluminum Busbar

Aluminum Busbar Applications

Power distribution: Aluminum busbars are widely used in power distribution systems, including substations and distribution boards, to efficiently distribute power to various circuits.
Switchgear and control panels: They are essential components in switchgear and control panels, helping to safely and efficiently distribute power.
Renewable energy systems: Aluminum busbars are used in renewable energy installations, such as solar systems, to connect and distribute power from solar panels to inverters and other components.
Power distribution in substations, data centers, and industrial plants.
Electric vehicles (battery interconnections).
Busbar trunking systems in commercial buildings.

Advantages of Aluminum Busbars over Copper

Advantages: Lower cost (saving 30-50%), lighter weight, corrosion-resistant, recyclable.
Disadvantages: Larger size, lower conductivity, possible oxidation at joints.

Copper and Aluminum 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)

Conductive aluminum busbar size reference table

Aluminum Busbar - Sharp Corners (Standard)

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 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

Aluminum Busbar Manufacturing and Quality Control

Process: Extrusion of complex shapes, precision cutting, drilling, and surface treatment.
Quality control checks: Dimensional accuracy, conductivity testing, and coating adhesion.

Aluminum Busbar Environmental Considerations

Aluminum busbars provide a cost-effective and lightweight solution for modern electrical systems, striking a balance between performance and practical design considerations. Their versatility makes them an essential component in industries that prioritize efficiency and sustainability.

Outdoor use: Anodized or coated layers with UV/salt spray resistance.
Sustainability: Fully recyclable, reducing the environmental impact over the product’s lifecycle.

Common Issues and Solutions for Aluminum Busbars

Oxidation: Use of coatings or anti-oxidation paste.
Vibration loosening: Use of thread-locking adhesives or anti-vibration hardware.
Creep: Design joints to accommodate material flow under pressure.

Installation and Maintenance

Connections: Use of anti-oxidation compounds, stainless steel hardware, or bimetallic connectors to prevent electrochemical corrosion.
Thermal management: Leave expansion gaps; use torque specifications and lock washers to secure bolted connections.
Maintenance: Regular inspection for corrosion, joint tightening, and surface cleaning. Use of Belleville washers or re-tightening schedules to address loosening caused by creep.

Considerations

While aluminum busbars offer many advantages, it is important to ensure proper installation and maintenance to prevent issues such as oxidation at connection points, which can increase resistance and reduce efficiency. Regular inspections and appropriate protective measures help maintain optimal performance.

Aluminum busbars are crucial components in electrical systems, featuring high conductivity, lightweight, corrosion resistance, and cost-effectiveness, making them suitable for a wide range of applications.

Aluminum Busbar Purchasing Guide

Conductivity: Aluminum’s conductivity is about 61% of copper’s, but it is lighter and more cost-effective, making it suitable for most power transmission applications.
Current carrying capacity: The current carrying capacity of aluminum busbars varies depending on their size and shape.
Size: The size of aluminum busbars should be determined based on specific application requirements to ensure they meet current carrying capacity and installation space needs.
Alloy selection: Different aluminum alloys have varying mechanical properties and conductivity; choosing the right alloy is crucial to meet specific application needs.
Shape: Aluminum busbars can be flat, angled, or custom-extruded profiles, with the choice of shape depending on installation space and electrical connection requirements.
Surface treatment: Surface treatments such as polishing, anodizing, or plating (tin/silver) can reduce oxidation, improve contact resistance, and extend the lifespan of the busbar.

Factor	Details
Electrical Conductivity	Aluminum has about 61% the conductivity of copper. This means aluminum busbars need to be larger in cross-section for the same current-carrying capacity.
Current-Carrying Capacity	The ampacity depends on dimensions, material, and temperature. An approximate formula: I = 0.8 × Width (mm) × Thickness (mm) is used for sizing.
Dimensions	The size of the busbar must match the required current-carrying capacity and minimize resistance. Custom sizes may be required for specific applications.
Alloy Selection	Common alloys for busbars: 6061-T6 (good mechanical properties), 6063-T52 (excellent corrosion resistance), 1350 (high conductivity). Alloy choice affects strength and conductivity.
Shape	Busbars are available in flat, angled, or custom extruded profiles to meet specific installation needs. Custom shapes can optimize space and performance.
Surface Treatment	Various treatments like polishing (reduces resistance), anodizing (corrosion resistance), or electroplating (tin/silver, improves conductivity and reduces oxidation).
Mechanical Strength and Durability	Busbars must resist mechanical stresses, including thermal expansion. Alloy and temper affect strength and flexibility.
Corrosion Resistance	Aluminum’s natural oxide layer provides basic corrosion resistance. Anodizing further improves resistance, especially for harsh environments.
Thermal Expansion	Aluminum has a higher coefficient of thermal expansion compared to copper. This needs to be accounted for in design to avoid issues with temperature changes.
Weight	Aluminum is lighter than copper, making installation easier and reducing structural support requirements. This can lead to cost savings.
Cost	Aluminum is more cost-effective than copper, making it a good option for large-scale applications where budget is a concern.
Environmental Impact	Aluminum is highly recyclable and uses less energy in recycling than its production, making it an environmentally friendly choice.

By carefully evaluating these characteristics, customers can select the aluminum busbar that best meets their specific requirements, balancing performance, cost, and environmental factors.