High-Performance Cu to Al Busbar from China Suppliers | Reliable Factory Connection Solutions
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 the 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 used?
A Cu To Al Busbar (Copper-to-Aluminum Transition Busbar) is a bimetallic conductor that joins a copper end and an aluminum end through advanced welding techniques such as friction welding, diffusion welding, or laser welding. It is used to reliably connect copper and aluminum conductors in electrical systems, eliminating galvanic corrosion risks at the interface while maintaining excellent conductivity and reducing overall system weight and cost.
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What materials are used in the Cu To Al Busbar?
The copper end is made from T2 Red Copper (C11000) with conductivity ≥ 98% IACS, offering excellent electrical conductivity and corrosion resistance. The aluminum end uses 1060 Pure Aluminum with conductivity ≥ 55% IACS, which is lightweight and cost-effective. The two materials are metallurgically bonded at the interface with an interface resistivity ≤ 0.005 Ω·mm²/m.
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Can the Cu To Al Busbar be customized to specific dimensions?
Yes. We offer full customization services. Thickness can range from 3 mm to 12 mm, width from 20 mm to 200 mm, and length from 100 mm to 6000 mm. The Cu/Al ratio can also be adjusted per your requirements. Additional customizations include hole positions, surface treatments (nickel-plated, tin-plated, or bare), and insulation protection (PVC/EVA/PE heat shrink tube or dip coating). Please provide your drawings or specifications for a tailored solution.
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What surface treatment options are available and which is recommended?
Three surface treatment options are available: Bare (no coating), Nickel-plated, and Tin-plated. For environments with high humidity, salt spray, or aggressive chemicals, nickel-plated or tin-plated finishes are strongly recommended, as they significantly improve oxidation resistance and corrosion resistance, extending the product's service life. For standard indoor applications, bare finish may be sufficient.
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What is the minimum order quantity and lead time?
The minimum order quantity (MOQ) is 10 pieces for standard sizes and 5 pieces for customized sizes (negotiable depending on specifications). Lead time for standard products is 3–7 working days, while customized products typically require 7–15 working days depending on the order quantity and complexity of the customization requirements.
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Which industries and applications are Cu To Al Busbars suitable for?
Cu To Al Busbars are widely used across multiple industries including new energy energy storage systems (battery clusters, BMS connections), photovoltaic and wind power installations (inverters, combiner boxes), low and high voltage switchgear (GGD, MCC), data centers (bus ducts, high-current distribution), new energy vehicles (motor controllers, PDU, battery packs), and industrial equipment (power stations, petrochemical facilities). They are ideal wherever a reliable copper-to-aluminum electrical transition is required.