China Cu To Al Busbar Suppliers - High-Performance Factory Solutions for Copper-Aluminum Connections
Construction & Material
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Copper End T2 Red Copper (C11000), conductivity ≥ 98% IACS, good electrical conductivity and corrosion resistance.
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Aluminum End 1060 Pure Aluminum, conductivity ≥ 55% IACS, lightweight and cost-effective.
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Bonding Process Friction Welding / Diffusion Welding / Laser Welding, no pores or false welding at the interface, high bonding strength.
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Surface Treatment Optional Nickel-plated, Tin-plated or Bare. Nickel-plated and tin-plated can effectively improve oxidation resistance and corrosion resistance, extending product service life.
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Insulation Protection Optional PVC/EVA/PE heat shrink tube or dip coating insulation, suitable for different insulation requirements of working environments.
Technical Specifications
| Parameter | Value |
|---|---|
| Material | T2 Copper + 1060 Aluminum |
| Resistivity | Copper ≤ 0.0177 Ω·mm²/m | Aluminum ≤ 0.0282 Ω·mm²/m | Interface ≤ 0.005 Ω·mm²/m |
| Current Rating | 85% of solid copper with the same cross-section |
| Density | ≈ 5.8 g/cm³ (average value) |
| Thickness | 3 / 5 / 6 / 8 / 10 / 12 mm (Customizable) |
| Width | 20–200 mm (Customizable) |
| Length | 100–6000 mm (Customizable) |
| Cu/Al Ratio | 1:1 or Customizable according to requirements |
| Working Temperature | -40℃ ~ +120℃ |
| Standards | GB/T 30586-2014, DL/T 247-2012, IEC 60439 |
Applications
New Energy Energy Storage
Energy storage cabinets, battery clusters, BMS connection busbars, energy storage converters.
Photovoltaic & Wind Power
Box transformers, combiner boxes, inverters, copper-aluminum docking of power generation equipment.
Low & High Voltage Switchgear
GGD, MCC, medium-voltage switchgear, interconnection of copper and aluminum equipment in power distribution systems.
Data Centers
Bus ducts, header cabinets, high-current power distribution systems, server cabinet power supply connections.
New Energy Vehicles
Motor controllers, PDU (Power Distribution Unit), high-voltage box connections, battery pack connections.
Industrial Equipment
Heavy-duty machinery, power stations, petrochemical equipment, high-current conductive connections.
Packaging & Delivery
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Packaging Moisture-proof film + hard carton + wooden pallet, which can effectively prevent collision, oxidation and moisture during transportation.
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Minimum Order Quantity (MOQ) 10 pieces for standard sizes; 5 pieces for customized sizes (negotiable).
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Lead Time 3–7 working days for standard products; 7–15 working days for customized products (depending on order quantity and customization requirements).
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Shipping By sea, air or express (DHL, FedEx, UPS, TNT), according to customer requirements. We will choose the most cost-effective and fastest shipping method.
Why Choose Us
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Professional Manufacturer 10+ years of experience in copper-aluminum composite conductors, focusing on R&D, production and sales of Cu To Al Busbar. We have advanced production equipment and a professional technical team.
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Strict Quality Control Each product undergoes strict quality testing, including metallographic analysis, resistance testing, tensile testing, salt spray testing and temperature rise testing, to ensure product qualification rate 100%.
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Strong Customization Capacity We can provide one-stop customization services, including size, hole position, surface treatment, insulation protection, etc., according to customer drawings or requirements.
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Competitive Price Direct factory sales, no middlemen, providing customers with high-quality products at competitive prices. We support bulk purchase with preferential policies.
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Perfect After-Sales Service Professional after-sales team provides 24-hour online service. If you have any questions about product use, installation or quality, we will reply and solve them in time.
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Global Export Experience Our products have been exported to more than 30 countries and regions, including Europe, America, Southeast Asia, the Middle East, etc., and have won a good reputation among customers.
Frequently Asked Questions
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What is a Cu To Al Busbar and why is it needed?
A Cu To Al Busbar (copper-to-aluminum transition busbar) is a bimetallic conductor that joins copper and aluminum sections through advanced welding processes such as friction welding or diffusion welding. It is needed to safely connect copper-based equipment to aluminum busbars or cables, preventing galvanic corrosion and overheating at the connection point while maintaining excellent electrical conductivity.
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What welding methods are used to bond the copper and aluminum sections?
We use three main bonding processes: Friction Welding, Diffusion Welding, and Laser Welding. All methods produce a metallurgically bonded interface with no pores, voids, or false welding, ensuring high bonding strength, low interface resistivity (≤ 0.005 Ω·mm²/m), and long-term reliability in demanding electrical environments.
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Can the Cu To Al Busbar be customized to specific dimensions and configurations?
Yes. We offer full customization services including thickness (3–12 mm), width (20–200 mm), length (100–6000 mm), Cu/Al ratio, hole positions, surface treatment (nickel-plated, tin-plated, or bare), and insulation protection (PVC/EVA/PE heat shrink or dip coating). Customers are welcome to provide drawings or specifications for tailored solutions.
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What surface treatment options are available, and which is recommended?
We offer three surface treatment options: Bare (no coating), Tin-plated, and Nickel-plated. For applications in humid, corrosive, or high-temperature environments, nickel-plating is recommended as it provides superior oxidation resistance and extends the product service life significantly. Tin-plating is a cost-effective alternative that also improves corrosion resistance and solderability.
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What is the minimum order quantity (MOQ) and lead time?
The MOQ is 10 pieces for standard sizes and 5 pieces for customized sizes (negotiable based on specific requirements). Lead time is 3–7 working days for standard products and 7–15 working days for customized products, depending on order quantity and complexity of customization.
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Which international standards does your Cu To Al Busbar comply with?
Our Cu To Al Busbars are manufactured in compliance with GB/T 30586-2014, DL/T 247-2012, and IEC 60439. Each product undergoes comprehensive quality testing including metallographic analysis, resistance testing, tensile testing, salt spray testing, and temperature rise testing to ensure a 100% product qualification rate before delivery.