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Aluminum Wire for High Thermal Conductivity

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Intro

Aluminum filler metals specifically chosen for their high electrical and thermal conductivity, essential for welding heat sinks, electrical bus bars, and other energy transfer components.

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Introduction

Applications like electrical bus bars and cooling systems require filler metals that maintain the high thermal and electrical conductivity of the parent material. This niche requires high-purity aluminum alloys, primarily from the 1XXX series (like ER1100), which have the lowest alloy content and thus the highest conductivity. The wire must be manufactured to the highest cleanliness standards, as impurities directly degrade both electrical and thermal performance of the joint, leading to inefficient heat dissipation and potential electrical failure.

Specification

Key PropertyMaximized electrical and thermal conductivity (high % IACS)
Material FocusER1100, ER1070, and other high-purity (low-alloy) 1XXX series
Purity ControlStrict control over iron (Fe) and silicon (Si) impurities
Joint QualityLow resistance joint to minimize heat loss
TestingOften tested to verify conductivity post-weld

Applications

  • Joining aluminum bus bars in power distribution and electrical substations.

  • Welding of heat sinks, cooling plates, and thermal management devices.

  • Fabrication of components for high-current transfer and specialized battery technology.

  • General purpose joining where pure aluminum properties are required.

FAQ

  • Q: Which aluminum alloy filler metal offers the highest thermal conductivity?
  • A: Pure aluminum filler metals, such as ER1100 (99% pure Al), offer the highest thermal and electrical conductivity because alloying elements typically decrease these properties.
  • Q: What impact does a slightly impure weld have on a bus bar connection?
  • A: Impurities increase the electrical resistance in the joint. This resistance causes localized heating ("hot spots"), which can lead to increased power loss, component degradation, and potential failure of the connection under high current load.

Advantages

  • Maximized Efficiency: High-purity weld metal maintains the efficiency of the thermal/electrical pathway, preventing hot spots and energy loss.

  • Low Resistance: Produces weld joints with minimal electrical resistance, which is critical for high-current applications (e.g., battery connections).

  • Purity Guarantee: Strict QC ensures the weld metal’s chemical purity translates directly into superior physical performance.

  • Stable Arc: High conductivity filler metal ensures a stable arc that facilitates high-quality, high-speed welding of pure aluminum.

Payment and Shipping

  • Technical Data: Provision of specific conductivity data and test results for filler metals.

  • Packaging: Materials are handled and packaged to prevent surface oxidation, which is a major detriment to electrical conductivity.

  • Bulk Supply: Available in high-volume, continuous supply to meet the demands of electrical component manufacturers.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aluminum Wire for High Thermal Conductivity Manufacturers and Wholesale Aluminum Wire for High Thermal Conductivity OEM/ODM Suppliers. We are located in the industrial zone of Puyang Town, Xiaoshan District, Hangzhou, Zhejiang Province. It is a high-technology enterprise specializing in the research, development and manufacturing of high-performance. The company has more than 20 years of aluminum alloy wire production experience, with international advanced manufacturing equipment, complete testing equipment,stable production process and strict quality control system.
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