China Copper-Aluminum Transition Bar for Motor Controller - Quality Suppliers & Factory Direct
Copper-Aluminum Transition Bar for Motor Controller
The technical specification for the bar:
| Item | Parameter Value | Test Standard |
|---|---|---|
| Material | Copper end: T2 oxygen-free copper (conductivity ≥ 98% IACS); Aluminum end: 1060 pure aluminum (conductivity ≥ 61% IACS) | GB/T 5231, GB/T 3190 |
| Bonding Process | Atomic diffusion welding (explosion welding / flash welding optional), interface shear strength ≥ 70MPa, no delamination | DL/T 247 |
| Contact Resistance | Transition interface resistance ≤ 0.05mΩ, overall resistance 30% better than industry average | GB/T 6145 |
| Rated Current | 300A ~ 3000A (customized by cross-sectional size: width 20–120mm, thickness 3–12mm) | GB/T 11022 |
| Operating Temperature | -40℃ ~ 125℃, short-term peak 150℃ | IEC 60068-2-14 |
| Surface Treatment | Copper end: tin-plated / nickel-plated (5–10μm, anti-oxidation); Aluminum end: chemical passivation / anodization (salt spray resistance ≥ 72h) | GB/T 13913 |
| Insulation Option | Heat shrinkable sleeve / epoxy coating available, withstanding voltage ≥ 2500V AC / 1min | GB/T 1408.1 |
| Mechanical Performance | No cracks after 90° bending; Vibration test meets automotive electronics standards (10–2000Hz, 10g) | IEC 60068-2-6 |
Application Scenarios for the bar:
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New Energy Vehicles
Motor controllers, high-voltage distribution units (PDU), OBC charging modules of passenger cars / commercial vehicles, and connection between battery packs and electronic controls.
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Industrial Automation
Servo motor controllers, frequency converters, robot joint electronic controls, and servo systems of injection molding machines.
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Rail Transit
Traction converters of subways / high-speed rails, and auxiliary power controllers of trains.
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Wind Power / Photovoltaics
Wind power converters, and motor-side output connections of photovoltaic inverters.
Product Advantages
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Metallurgical Bonding for High Reliability
Atomic-level fusion at the interface, no contact gap, no heating or loosening during long-term high-current operation; Avoids electrochemical corrosion problems of traditional crimping / brazing.
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Cost and Weight Reduction
56% lighter than pure copper bars, material cost reduced by more than 40%, facilitating the lightweight design of the controller.
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Precise Adaptation to Electronic Control Scenarios
Customizable length, bending angle, hole diameter / hole position according to the internal space of the controller; Supports single hole / double hole / slotted hole to meet bolt fastening requirements.
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Resistance to Harsh Working Conditions
Salt spray resistance, damp heat resistance and electromagnetic interference resistance, suitable for new energy vehicle outdoor and industrial servo vibration environments.
Specification Selection & Customization
5.1 Standard Specifications
- 50×5mm (rated current about 800A); 60×6mm (about 1000A); 80×8mm (about 1500A)
- Length: 50–300mm optional; Hole diameter: M6/M8/M10 standard threaded holes
5.2 Customization Services
- Size Customization: Arbitrary width / thickness / length, special-shaped bending, multi-section transition.
- Surface Treatment: Silver plating, gold plating (for high-frequency / high-corrosion scenarios).
- Insulation Treatment: Partial / overall heat shrinkable tube, dip coating, spray coating.
- Bulk Marking: Laser marking of model, batch number and rated current.
The Package & Shipment:
Frequently Asked Questions
Q
What is the difference between explosion welding and flash welding for the copper-aluminum transition bar?
Both processes achieve atomic-level metallurgical bonding at the copper-aluminum interface. Explosion welding is suitable for larger cross-sections and complex shapes, offering extremely high interface shear strength. Flash welding is preferred for high-volume production of standard-size bars due to its faster cycle time. Both methods meet the DL/T 247 standard with interface shear strength ≥ 70MPa and no delamination.
Q
What rated current range can the copper-aluminum transition bar support?
The standard current range is 300A to 3000A, determined by the cross-sectional dimensions. For example, a 50×5mm bar handles approximately 800A, a 60×6mm bar handles approximately 1000A, and an 80×8mm bar handles approximately 1500A. Custom cross-sections with widths from 20mm to 120mm and thicknesses from 3mm to 12mm are available to meet specific current requirements.
Q
Can the copper-aluminum transition bar be used in outdoor or high-humidity environments?
Yes. The aluminum end undergoes chemical passivation or anodization treatment, providing salt spray resistance of ≥ 72 hours. The copper end is tin-plated or nickel-plated (5–10μm) to prevent oxidation. Optional insulation coatings and heat shrinkable sleeves further enhance protection against moisture, damp heat, and electromagnetic interference, making it fully suitable for outdoor new energy vehicle and industrial servo environments.
Q
What customization options are available for special controller designs?
We offer comprehensive customization including arbitrary width, thickness, and length dimensions; special-shaped bending and multi-section transitions; custom hole configurations (single hole, double hole, or slotted holes in M6/M8/M10 sizes); surface treatments such as silver or gold plating for high-frequency or high-corrosion scenarios; partial or full insulation via heat shrinkable tube, dip coating, or spray coating; and laser marking of model numbers, batch numbers, and rated current for bulk orders.
Q
How does the copper-aluminum transition bar reduce costs compared to pure copper busbars?
By replacing the aluminum section with pure copper, the overall weight is reduced by approximately 56% compared to a full copper bar. Material costs are reduced by more than 40% since aluminum is significantly less expensive than copper. This weight and cost reduction directly supports the lightweight design goals of motor controllers in new energy vehicles and industrial equipment, without compromising electrical conductivity or mechanical reliability.
Q
What quality and safety certifications does the copper-aluminum transition bar comply with?
The product is manufactured and tested in accordance with multiple standards including GB/T 5231 and GB/T 3190 for material quality, DL/T 247 for bonding process, GB/T 6145 for contact resistance, GB/T 11022 for rated current, IEC 60068-2-14 for temperature performance, GB/T 13913 for surface treatment, GB/T 1408.1 for insulation voltage withstand, and IEC 60068-2-6 for vibration and mechanical performance. These ensure full compliance with automotive electronics, industrial automation, and rail transit application requirements.