China Copper-Aluminum Transition Busbar Factory - Reliable Suppliers for Efficient Busway Systems
Copper-Aluminum Transition Busbar for Busway
The Description for Copper-Aluminum Transition Busbar
The bar is made of high-quality T2 oxygen-free copper and 1060 pure aluminum as base materials, and adopts advanced atomic diffusion welding or explosion welding technology to achieve metallurgical bonding, with no solder, no false welding and no delamination at the interface. The copper end is perfectly matched with the copper busbar of the busway and the copper terminal of the power distribution equipment, and the aluminum end is connected with the aluminum busbar of the busway and the aluminum power cable.
It is mainly used for the transition connection of power input and output of busway trunking, branch busway, busway junction box and distribution cabinet, and is suitable for low-voltage, medium-voltage and high-current busway systems.
Technical Specifications for the Busbar
| 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 optional), interface shear strength ≥ 75MPa, no delamination or cracks | DL/T 247, GB/T 13148 |
| Contact Resistance | Transition interface resistance ≤ 0.04mΩ, overall resistance 35% better than industry average | GB/T 6145 |
| Rated Current | 500A ~ 5000A (customized by cross-sectional size: width 30–150mm, thickness 4–15mm) | GB/T 11022, GB/T 29520 |
| Operating Temperature | -40℃ ~ 130℃, short-term peak 160℃ | IEC 60068-2-14 |
| Surface Treatment | Copper end: tin-plated / nickel-plated (8–12μm, anti-oxidation and anti-corrosion); Aluminum end: chemical passivation / anodization (salt spray resistance ≥ 96h) | GB/T 13913 |
| Insulation Option | Heat shrinkable sleeve / epoxy coating / silicone insulation layer, withstanding voltage ≥ 3000V AC / 1min | GB/T 1408.1 |
| Mechanical Performance | No cracks after 90° bending; Tensile strength ≥ 180MPa, suitable for busway installation and fixing | IEC 60068-2-6, GB/T 228.1 |
Application Scenarios
🏭 Industrial Power Distribution
Busway systems in factories, workshops, industrial parks, including trunk busway, branch busway, and transition connection between busway and distribution cabinets, transformers.
⚡ Power Industry
Busway transition connection in power plants, substations, power distribution rooms, and connection between busway and generators, transformers, switchgear.
Customization Services
- Size Customization: Arbitrary cross-sectional width and thickness, length, special-shaped bending, multi-section transition, to adapt to different busway installation spaces and connection angles.
- Surface Treatment: Silver plating, gold plating (for high-frequency, high-corrosion and high-precision power distribution scenarios), and thickened tin plating for strong anti-oxidation requirements.
- Insulation Treatment: Partial or overall insulation treatment, customized insulation thickness and material, to meet the insulation requirements of different voltage levels.
- Bulk Marking: Laser marking of product model, batch number, rated current, production date, etc., to facilitate project management and traceability.
Package & Shipment
Frequently Asked Questions
What is a copper-aluminum transition busbar and why is it needed?
A copper-aluminum transition busbar is a bimetallic connector that enables reliable electrical connection between copper and aluminum busbars. It is needed because direct contact between copper and aluminum causes galvanic corrosion and increased contact resistance. The transition busbar uses metallurgical bonding to eliminate these issues and ensure stable, low-resistance connections.
What bonding process is used to join the copper and aluminum ends?
The copper and aluminum ends are joined using atomic diffusion welding or explosion welding technology. These advanced processes achieve true metallurgical bonding at the interface, with an interface shear strength ≥ 75MPa, ensuring no delamination, no cracks, and no false welding throughout the product's service life.
What current ratings are available for the copper-aluminum transition busbar?
The standard rated current range is 500A to 5000A. The actual current capacity is determined by the cross-sectional dimensions, with width options from 30mm to 150mm and thickness from 4mm to 15mm. Custom sizes are available to meet specific project requirements and busway installation conditions.
What surface treatment options are available for the copper and aluminum ends?
The copper end can be treated with tin plating or nickel plating (8–12μm thickness) to provide anti-oxidation and anti-corrosion protection. The aluminum end can undergo chemical passivation or anodization with salt spray resistance ≥ 96 hours. For special applications, silver plating and gold plating are also available as customization options.
Can the busbar be customized for special installation requirements?
Yes, comprehensive customization services are available. This includes custom cross-sectional dimensions, lengths, special-shaped bending, multi-section transitions, various surface treatment options, partial or full insulation treatment, and laser marking with product model, batch number, rated current, and production date for project traceability.
What industry standards does the copper-aluminum transition busbar comply with?
The product complies with multiple national and international standards, including GB/T 5231 and GB/T 3190 for materials, DL/T 247 and GB/T 13148 for bonding process, GB/T 6145 for contact resistance, IEC 60068-2-14 for operating temperature, GB/T 1408.1 for insulation performance, and IEC 60068-2-6 and GB/T 228.1 for mechanical performance testing.