Tuling Aluminum Busbar
Tuling aluminum busbar is designed for high amperage current distribution for AC and DC equipment. We use both aluminum 1xxx and 6xxx series for our busbar production.
On average, our aluminum bus bars have 0.8 Amp/mm2 current carrying capacity. Our low voltage bus bars can handle load over 600V.
We can make aluminum bus bars in all shapes (e.g, round, rectangle, square) and edges (round edge, square edge). Our advanced CNC precision machines, CAM and Solid work tooling technology enable us to provide a tight tolerance of 0.01 mm.
All our aluminum bus bars are produced following the industry standards: IEC 60105, ASTM B236, ASTM B317, ISO 209-1, 2, DIN EN 755-2, and EN 573-3.
Tuling Bus Bar Aluminum Products
Hollow aluminum busbar pipes are used in high frequency transmissions.
These busbars are well suited for high-shock and vibration equipment.
Insulation-sleeved aluminum bus bars are safe and can prevent electrical arcing.
These bus bars are widely used in the automotive and metallurgical sectors.
Tuling Aluminum Busbar Features
Pure aluminum bus bars have 56.5% of IACS conductivity.
An aluminum busbar can be up to 60% lighter than a copper busbar of the same size.
Our standard aluminum bus bars can handle over 4000 Amp current.
Tuling aluminum bus bars have excellent mechanical, fatigue, and corrosion resistance.
Tuling Aluminum Busbar Manufacturing Capabilities
At Tuling, we manufacture laminated aluminum bus bars by stacking thin aluminum sheets and joining them by diffusion bonding. Later, we employ machining and secondary operations to bring the desired bus bar shape. Take a look at our capabilities:
| Machining Capabilities | Bending, drilling, forming, milling, sawing, punching, tapping, etc. |
| Joining | Brazing, soldering, welding |
| Electroplating | Tin, silver, and nickel |
| Insulation | Heat shrink, thermal epoxy powder coating, immersive dip coating |
Aluminum Bus Bar Material Grades
At Tuling, we offer our clients the freedom to select aluminum grades as per their specifications. Our recommended aluminum grades are:
- Aluminum 1060 (T3, T4, T5, T6, T8)
- Aluminum 1350 (H14, H16, H19)
- Aluminum 6101 (T6, T61, T63, T64, T65)
- Aluminum 6060 (T4, T5, T6)
- Aluminum 6161 (T4, T6)
- Aluminum 6163 (T4, T5, T6, T52, T66)
- Aluminum 6182 (T3, T4, T5, T6)
Tuling Design Considerations for Aluminum Busbars
Dimensions: Tuling can manufacture bus bars from the smallest (e.g., 1/16″ x 1/2″) to the largest sizes (e.g., 1/2″ x 8″). We optimize the busbar dimension depending on the conductivity, voltage, and maximum temperature requirement.
Linear Expansion: We measure the aluminum busbar’s linear expansion at 40kN force to prevent failure due to thermal contraction and expansion.
Bend Radius: Tuling takes the bend radius in consideration to maintain the aluminum busbar structural integrity. For example, our 6101 aluminum bus bar allows up to 12mm bend radius for 1x thickness.
Thermal Conduction: We can achieve the same thermal conductivity of a copper busbar with aluminum by increasing the cross-section by 62%.
Ampacity: Tuling follows the ideal aluminum busbar ampacity chart to prevent any electrical progressive deterioration in the future.
Tuling Aluminum Busbar Applications
Our aluminum busbar fits a wide variety of applications, including:
- Power transmission system: Aluminum busbars are used in high-frequency and high-voltage transmission lines, power plants, substations, and distribution transformers.
- Building power room: Aluminum bus bars are suitable for power distribution in residential and commercial buildings.
- Power Storage: These bus bars can store generated energy and transmit it to the power grid.
- Automotive: Aluminum bus bars distribute power to the powertrain, facilitate charging, and provide reliable grounding and driving systems.
Copper bus bars are most frequently used due to high thermal and electrical conductivity. However, aluminum bus bars can be an excellent alternative. Aluminum is lighter, has excellent machining abilities, and costs less. As a result, aluminum bus bars are the top priority where weight and flexibility are needed.
The installation technique of Tuling aluminum bus bars varies depending on the end applications. We can use bolts, screws, rivets, and other fasteners to ensure a secure electrical connection. Moreover, welding can also establish a safe connection.
