High Current Copper Aluminium Transition Connector Bus Bar

Our High Current Copper Aluminium Transition Connector Bus Bar is a bimetallic power connector engineered to solve galvanic corrosion and overheating issues when connecting copper and aluminum conductors. It integrates high‑conductivity copper and lightweight aluminum via friction welding/explosion welding, creating a molecular‑bonded transition zone with ultra‑low contact resistance.

Designed for 100–1500A high‑current applications, it delivers stable electrical performance, reduces system weight by ~30% vs. pure copper, and cuts material costs by 30–60%. Ideal for switchgears, transformers, energy storage, and new energy vehicles.

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Product Details

Key Features

High‑Current Capacity: Rated 100A–1500A (customizable); handles short‑circuit currents up to 65–105kA.
Premium Bimetallic Bond: Friction‑welded interface (IEC 61238‑1 compliant) eliminates loose connections and corrosion.
Dual‑Material Advantages:
- Copper end (T2/C11000): ≥98% IACS conductivity, tin‑plated for corrosion resistance.
- Aluminum end (1060/6061‑T6): Lightweight, excellent heat dissipation.
Extreme Durability: Withstands ‑40°C to +125°C; 5000+ thermal cycles without performance loss.
Customizable Design: Tailored width, length, hole positions, and plating (tin/nickel/silver).
Cost & Weight Savings: ~30% lighter and 30–60% cheaper than pure copper busbars.

Technical Specifications：

Parameter	Details
Materials	Copper: T2/C11000; Aluminum: 1060/6061‑T6
Welding Process	Friction Welding / Explosion Welding
Current Rating	100A–1500A (customizable)
Conductivity	≥62% IACS (composite); Copper ≥98% IACS
Operating Temperature	‑40°C ~ +125°C
Dimensions	Width: 20–300mm; Thickness: 3–20mm; Length: 500–6000mm (custom)
Surface Treatment	Tin‑plated (standard), Nickel/Silver‑plated (optional)
Insulation (Optional)	PVC/PE/Epoxy; Withstand Voltage: ≥3.5kV AC
Mechanical Strength	Tensile Strength: ≥76MPa (bond area)
Certifications	IEC 61238‑1, IEC 61439, RoHS, REACH

Applications

Power Distribution: Low‑voltage switchgears, distribution boxes, transformer bushings.
New Energy: EV battery packs, motor controllers, charging stations, solar inverters.
Energy Storage: Battery energy storage systems (BESS), high‑current interconnects.
Industrial: Heavy‑duty machinery, welding equipment, high‑power UPS.

Customization & Services

OEM/ODM: Custom drawings, dimensions, hole patterns, and plating options.
Samples: Available for testing before bulk orders.
Lead Time: 7–15 days for standard orders; 15–25 days for custom designs.
Packaging: Anti‑corrosion film + wooden boxes; labeled with specs and certifications