Aluminum Bus Bars
Aluminum bus bars are often used as electrical conductors in power distribution systems, where heat can easily be dissipated. Because of the low value of the metal, it can be the best economic option for the application.
If requested, the moment a question or quote request comes to Storm Power, our engineering design team employs a process designed to make sure that each customer makes the right choice in metal, design and fabrication. If you need to create custom aluminum or copper bus bar, we work side-by-side with your engineers with the shared goal of making your part work from inception to completion.
Contact us to discuss your requirements of Aluminium Busbar. Our experienced sales team can help you identify the options that best suit your needs.
Here are the factors Storm Power employs in determining use of aluminum bus and electrical components:
Temperature Rise - Aluminum conducts at a lower level than copper. To compensate for heat dissipation, we will often recommend creating a larger surface area. This leads to better heat exchange for more efficient thermal dissipation.
Available Space - In tight enclosures - like cabinets, switchgear and panelboards - using a larger, thicker bus bar may seem an unlikely alternative, however, while dimensionally larger, the most commonly used aluminum alloy offers slightly more than half the conductivity (56%) at half the weight of copper. Installation is less of a burden when the aluminum bus is custom designed for a precise fit.
How and Where to Install - Industry standards provided by the Institute of Electrical and Electronics Engineers (IEEE), Underwriters Laboratory (UL) and the National Electrical Manufactures Association (NEMA) are applied by Storm Power to help to determine the feasibility of using aluminum connectors and bus systems. Experience and product knowledge are also applied by Storm's design engineers when recommending how and where to install aluminum.
Maintenance - Corrosion and regular expansion/contraction are the most common concerns for aluminum electrical connectors. In either case, periodic maintenance is necessary, as described below. Regular inspection and a torque schedule for bus bar fasteners is highly recommended. Environmental corrosion affects both copper and aluminum, especially in areas where hydrogen sulfide or extreme temperatures occur. At a microscopic perspective, these metals appear far different from the smooth surfaced bus bar seen by the human eye. Over time, corrosion can increase the severity of the imperfect surface, causing higher peaks and valleys. Silver or tin electroplating is a solution to this problem, and available in-house at Storm Power.
Options - While aluminum bus bar and electrical connectors can be plated for protection from environmental effects, dielectric finishing like epoxy powder coating may also present an option. Aluminum offers many possibilities, including laminated bus, and insulated bus bar connectors. To learn more, please contact Storm's engineering team by calling 800-394-.
Because aluminum has this imperfect surface, and is also subject to thermal expansion and contraction (which is 42% higher than copper) there is a greater risk that mechanical fasteners between bus bars will become loose. Storm can provide specifications that help prevent deformation problems with information on torquing sequence and specifications on connection washers, bolts and other options.
For more information check out this pdf document from Aluminum.org.
There is some debate regarding which material is better for use for busbars&#;aluminum or copper. Both materials have been used with success, but which is better? Or is one better than the other? Which is best for your project?
Busbars have evolved over the last 50 years. That evolution has allowed the use of busbars to surpass the use of hard-wired power distribution. Recent innovations have led to a shift from the demand for copper applications to aluminum ones. The trend seems to be to move back and forth from aluminum to copper.
There are misconceptions regarding the value of aluminum in busbar manufacturing. However, despite arguments that copper is a better choice, either material meets demand when manufactured to industry and environmental standards and installed correctly.
Let&#;s compare copper to aluminum so that you can make an informed decision regarding your next busbar application.
Copper
Copper is the most common conductive metal other than silver and is therefore considered the international standard for conductivity. It&#;s one of the oldest known materials and, as such, has been used in applications where ductility and conductivity were essential requirements. Early experimenters like Benjamin Franklin used copper when conducting experiments with electricity.
In , the International Annealed Copper Standard (IACS) was adopted so the conductivity of other metals could be compared to that of copper. Based on this standard, pure annealed copper has a 100 percent conductivity rating. Since processing technology has changed and improved since the standard was created, today&#;s commercially pure copper can have a higher IACS conductivity value.
Another benefit to using copper is its tensile strength as well as its thermal expansion and thermal conductivity properties. Copper is resistant to corrosion caused by most organic chemicals. The green patina that can form after being exposed to the atmosphere for long periods of time is a protective surface that doesn&#;t change how copper performs.
Are you interested in learning more about Aluminium Bus Bar Price? Contact us today to secure an expert consultation!
Additional reading:
Is extruded aluminum stronger than steel? - Exlabesa
Everything You Need To Know To Find The Best Aluminum Products Purchasing Service
Aluminum
The strength of aluminum varies depending upon the alloying agents used. It can be extremely soft, or it can be a mild steel-like strength. The conductivity of aluminum also depends on the alloy as well as the temper. The conductivity of pure aluminum rates at approximately 62 percent of that of copper.
In the s and s, a specific grade of aluminum was popular for use with household wiring. However, poor workmanship in combination with physical property differences between aluminum and copper caused fire hazards. The industry responded by adjusting aluminum alloys to have properties that are more like those of copper.
Aluminum can be much lighter than copper&#;up to 70 percent more lightweight. Even if a significantly larger aluminum component is required, the resulting weight will still be less than a copper system of the same conductivity rating. The reduced weight of aluminum helps to save costs in a variety of areas. Aluminum requires fewer supports to secure the busbar; transportation costs for aluminum are reduced, and fewer people are required to install aluminum.
Aluminum does require more surface area for conductivity than copper does. That means that aluminum components are larger. So much larger, in fact, that the overall dimensions may restrict the use of aluminum in certain applications. For example, small buildings or underfloor applications may be prevented by the sheer size of the aluminum busbar system.
Comparisons Between Copper and Aluminum
It&#;s essential to understand how the individual metals compare when it comes to factors like price, electrical ratings, environmental sustainability, and connectivity. Depending on the project, these factors may tip the scale toward one or the other of the metals.
Ratings
When it comes to electrical ratings, copper takes the win when compared by volume to aluminum. Copper has lower power loss, voltage drop, electrical resistance, and a higher ampacity compared to its aluminum counterpart. All of these contribute to the efficiency of the busbar system.
However, if the comparison is based on weight, aluminum is more efficient. If sizing isn&#;t an issue, then aluminum is the less-dense, efficient choice.
Price
There is a significant cost difference between copper and aluminum, with the price of copper being much higher than aluminum. Both materials are influenced greatly by political and economic factors as well as consumer demand. The resulting price volatility can affect the accuracy of cost estimates for busbar production. In the past, aluminum was less affected by outside factors allowing for more stable and accurate pricing, but that is no longer the case.
Environmental Factors
Both copper and aluminum are recyclable metals. However, their environmental sustainability is affected by the way each one is recycled and how they are mined.
Of the two metals, aluminum is the most recycled. Approximately 75 percent of all aluminum that has been produced is still being used. Copper falls a little shy of that at 65 percent still being used or available to be used.
The recycling process for aluminum vs that of copper also presents a slight edge in favor of aluminum. The process for recycling aluminum uses approximately 5 percent of the energy required for initial production. Meanwhile, the same amount of copper uses 15 percent of the mining and extraction energy in the recycling process. What does that mean? Aluminum is arguably the more environmentally sustainable of the two metals.
Connectors
Choosing to use aluminum means that the connectors that are used must be rated for aluminum. Those rated for aluminum can often be used with copper, but the reverse isn&#;t always the case. Connectors that are rated for both will be marked to indicate that rating. Should the application require soldering, copper is more easily soldered and therefore is preferred to aluminum.
Current Applications
Copper is still used more often than aluminum for building wire, electronic cables, or other products that require high conductivity. It&#;s also more commonly used than aluminum for conductors in power generation and distribution as well as in automotive applications.
Aluminum is more commonly used when the lightweight property of the metal is essential. Aircraft commonly use aluminum, and so do overhead utility transmission lines.
Large coaxial cables can take advantage of the properties in both. How? They can be constructed from copper-clad aluminum wire, which allows for the conductivity advantages of copper combined with the lightweight properties of aluminum.
Final Thoughts
The debate between copper and aluminum for use in busbar construction is ongoing. Both metals have attributes that are beneficial to the application. Copper typically has a higher conductivity rating, while aluminum is more lightweight and less costly.
It would seem that either metal is appropriate for use with busbars. The question then becomes which properties are beneficial to the particular project at hand. Learn more about Kenmode's busbar offering.
For more information, please visit Aluminium Chequered Sheet.
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