Products

Copper-aluminum composite panel

Classification:

Copper-Aluminum Eutectic Composite Series

Copper and aluminum are both good conductive materials, and their conductivity is better than other common metal materials. The copper-aluminum composite ground nut is designed so that it can be in close contact with the ground wire, thereby reducing the contact resistance and improving the conductive efficiency. In addition, the copper-aluminum composite material also has good corrosion resistance, which can effectively resist corrosion and oxidation, and ensure the long-term stable operation of the grounding system. The copper-aluminum composite ground nut is a component used in the grounding system. It is usually composed of two metal materials, copper and aluminum. This kind of nut has excellent electrical conductivity and corrosion resistance, so it is widely used in grounding system.

Telephone

86-15382428966

E-mail

pindi@cnsm.cn

Online consultation

Traditional manufacturing process for copper-aluminum composite busbars

The primary principle of the rolling-bonding method is that, under the pressure of the rolling mill, the composite metals undergo substantial plastic deformation, bringing their fresh surfaces into intimate contact and interlocking. Subsequent annealing promotes mutual diffusion between the two metals, thereby achieving metallurgical bonding. However, the interfacial bond strength of the clad plate remains relatively low.

The explosive bonding method utilizes the enormous impact force generated instantaneously by explosive detonation to induce collision and plastic deformation in the metals to be bonded, thereby achieving interfacial bonding. However, this method suffers from significant limitations in terms of the maximum thickness of the composite plate, as well as issues such as high noise levels and relatively high safety risks.

We employ a unique cast-rolling composite forming technology in which solid copper sheets are simultaneously introduced into the molten aluminum during the liquid-to-solid phase transition. Under the high temperature and high pressure of the cast-rolling rolls, atoms at the interface between the two metals mutually diffuse and crystallize, followed by cold rolling and annealing, ultimately yielding a copper–aluminum eutectic material with a distinctive processing route.

Advantages of our company’s copper-aluminum eutectic busbar process:

Leveraging our established expertise in aluminum strip production and employing a unique solid–liquid cast-rolling composite process, the copper–aluminum eutectic busbar we produce delivers groundbreaking improvements over conventional copper–aluminum composite busbars in terms of peel strength, tensile strength, shear strength, current-carrying capacity, and electrical conductivity.

Copper-aluminum eutectic array

• Tensile strength: 140–190 MPa

• Interface peel strength > 80–220 N/mm

• Shear strength > 63.6 N/mm

• Post-fracture elongation > 15%

• 90° bending with no cracks

• DC resistivity ≤ 0.0235–0.0256 Ω·mm ²/m

• Eutectic layer thickness: 300–500 nm

Our company’s copper–aluminum eutectic busbar features an average copper–aluminum interface layer thickness of 380 nm, with the eutectic phase composition being Al₂Cu and Al₄Cu₉. This design not only achieves metallurgical bonding between copper and aluminum but also effectively ensures strong bond strength, thereby resolving the issue of excessively high resistivity in the transition layer. The overall performance is excellent, eliminating common defects such as burring, delamination, and peeling that typically occur during bending, drilling, and punching in conventional copper-clad aluminum busbars.

Technical Benchmarking

	Industry standards, national standards	Ride a horse
Product	Copper-aluminum composite busbar (copper-clad aluminum busbar)	Copper-aluminum eutectic array
Tensile strength (Room temperature, 20% copper)	Tensile strength ≥ 110 MPa	Tensile strength: 140–190 MPa
Interface peel strength	Interface peel strength > 12 N/mm	Interface peel strength > 80–220 N/mm
Shear strength	Shear strength > 35 N/mm	Shear strength > 63.6 N/mm
Bend	After the wide-edge bending test, the copper-aluminum composite busbar exhibits bending. The low-magnification microstructure near the part interface is free of porosity, and the product shall not Cracking and blistering occur.	90° bending angle with no cracks
20°C DC resistivity	DC resistivity ≤ 0.02606 Ω·mm²/m	DC resistivity ≤ 0.02350 Ω·mm²/m
Elongation at break	Elongation at break ≥11%	Elongation > 15%
Data Source	DL/T 217—2012 Copper-Clad Aluminum Busbars for Power Transmission and Transformation Equipment GB/T 32468—2015 Copper-Aluminum Composite Plate Strip	Shanghai Electrical Equipment Testing Co., Ltd. Tianjin Tianchuan Electrical Control Equipment Testing Co., Ltd. (National Quality Inspection and Testing Center for Electrical Control and Distribution Equipment) Testing Center, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences

Current-Carrying Capacity Table for Copper-Aluminum Eutectic Alloys

Measured Permissible Current-Carrying Capacity of Rectangular Busbars in the Laboratory

Serial Number	Busbar specification		Copper-Aluminum Eutectic Array			Width > 60	Weight per meter	Note
	Grid size		Continuous Current (A)			≥>60	Quantity in kg
	Width	Thickness	5.0 K temperature rise	6.0 K temperature rise	7.0 K temperature rise	At 92%	(Density 3.94)
1	15	3				0	0.177
2	20	3				0	0.236
3	25	3				0	0.296
4	30	3	342	370	398	366	0.355	Self-test
5	40	3	403	438	468	431	0.473	Heavenly Transmission Institute
6	25	4	345	381	421	387	0.394	Self-test
7	30	4	352	391	418	385	0.473	Self-test
8	40	4	468	513	550	506	0.630	Self-test
9	50	4	581	642	695	639	0.788	Self-test
10	20	5	322	356	382	351	0.394	Self-test
11	25	5	405	438	465	428	0.493	Self-test
12	30	5	437	491	541	498	0.591	Self-test
13	40	C	599	665	705	649	0.788	Heavenly Transmission Institute
14	50	5	635	681	757	696	0.985	Self-test
15	60	5	714	812	889	818	1.182	Self-test
16	80	5	981	1066	1193	1098	1.576	Self-test
17	100	5	1155	1274	1363	1254	1.970	Self-test
18	25	6	410	451	498	458	0.591	Self-test
19	30	6	452	482	535	492	0.709	Self-test
20	40	6	586	640	681	627	0.946	Self-test
21	50	6	694	757	830	764	1.182	Self-test
22	60	6	903	988	1052	968	1.418	Heavenly Transmission Institute
23	80	6	1081	1204	1327	1221	1.891	Shangke Electric
24	100	6	1264	1387	1483	1364	2.364	Self-test
25	120	6	1525	1682	1815	1670	2.837	Self-test
26	25	8	540	591	612	563	0.788	Self-test
27	30	8	611	673	712	655	0.946	Self-test
28	40	8	731	792	858	789	1.261	Self-test
29	50	8	865	958	1038	955	1.576	Self-test
30	60	8	1055	1153	1262	1161	1.891	Shangke Electric
31	80	8	1351	1425	1630	1500	2.522	Heavenly Transmission Institute
32	100	8	1565	1796	1862	1713	3.152	Heavenly Transmission Institute
33	100	8	1602	1825	1953	1797	3.152	Shangke Electric
34	120	8	1783	1927	2105	1937	3.782	Self-test
35	25	10	600	661	715	658	0.985	Self-test
36	30	10	670	744	805	741	1.182	Self-test
37	40	10	897	945	984	905	1.576	Self-test
38	50	10	978	1073	1156	1064	1.970	Self-test
39	60	10	1116	1251	1317	1212	2.364	Self-test
40	80	10	1458	1576	1703	1567	3.152	Heavenly Transmission Institute
41	100	10	1800	1923	2075	1909	3.940	Heavenly Transmission Institute
42	120	10	2126	2214	2485	2286	4.728	Shangke Electric
43	125	10	2180	2330	2535	2332	4.925	Self-test
44	30	12	752	848	900	828	1.418	Self-test
45	40	12	890	980	1062	977	1.891	Self-test
46	50	12	1120	1225	1285	1182	2.364	Self-test
47	60	12	1260	1367	1448	1332	2.837	Self-test
48	80	12	1685	1820	2135	1964	3.782	Self-test
49	100	12	1920	2000	2170	1996	4.728	Self-test
50	120	12	2300	2470	2680	2466	5.674	Self-test
51	125	12	2330	2505	2750	2530	5.910	Self-test