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Aluminum Wire for High-Purity Electrical Conductors

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Product Description

Extremely high-purity aluminum filler metals, predominantly ER1100 or specialized high-purity ER4043 variants, specifically manufactured for welding electrical conductor components. The critical parameter is electrical conductivity, which is highly sensitive to impurity elements. Iron (Fe) and Silicon (Si) are minimized to the lowest possible levels as they dramatically reduce conductivity by scattering electrons in the aluminum lattice. The filler metal is selected to ensure the weld deposit's conductivity approaches that of the pure aluminum base material (typically 1000 series or EC-grade conductors), minimizing resistive losses at the joint.

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20+ Years Experience

Over two decades of aluminum alloy wire production expertise

International Certifications

DB, CE, ABS, DNV, CCS and other authoritative certifications

200MT Monthly Capacity

Large-scale production with consistent quality

Global Export

Exporting to over 30 countries worldwide

Introduction

The electrical power and distribution industry relies heavily on aluminum for high-voltage transmission lines and busbars due to its high conductivity-to-weight ratio. Welding these components requires a filler metal that maintains the system's low electrical resistance. Our high-purity conductor wires guarantee the minimal introduction of conductivity-reducing elements (Fe, Cu, Zn). We provide certified conductivity data for our weld deposits, ensuring that the joint remains cool and efficient under high current loads, preventing premature failure due to excessive Joule heating.

Specification

Base Metal Focus1XXX Series (e.g., 1050, 1100), EC-grade conductors
Filler AlloyER1100 (Highest Purity), Low-Fe/Si ER4043
Key PropertyMaximum Electrical Conductivity (%IACS)
Impurity LimitsFe and Si must be minimized (Fe+Si≪0.10%)
MeasurementElectrical Resistivity measured in microohm-centimeters (μΩ⋅cm)

Applications and Solutions

  • High-Voltage Transmission Lines: Welding splices, terminals, and repair of overhead conductors (ACSR, AAC, AAAC).

  • Electrical Busbars: Fabrication of conductor bars used in switchgear, power stations, and industrial electrolysis plants (e.g., aluminum smelting).

  • Transformer Windings: Welding connections in large power transformers and inductor coils where resistive heat generation must be strictly controlled.

  • Battery Trays and Connectors: Welding thick aluminum connections in high-power battery packs for electric vehicles and energy storage systems.

FAQ

  • Q: Why does adding elements like Si or Mg reduce conductivity?A: Alloying elements dissolve in the aluminum lattice, acting as impurities that scatter free electrons, increasing electrical resistance. The total concentration of alloying elements must be kept extremely low to maintain high conductivity.
  • Q: What is IACS and what conductivity should I aim for?A: IACS stands for International Annealed Copper Standard. High-purity aluminum conductors typically have conductivity >60%IACS. The filler should aim for the highest possible value, typically ∼50% to 55%IACS in the weld deposit.
  • Q: Is ER5356 ever used for electrical conductors?A: No. ER5356 contains ∼5%Mg, which severely reduces conductivity to unacceptable levels for power transmission applications. Only 1XXX and certain high-purity 4XXX fillers are suitable.

Advantages and Core Features

  • Maximized Conductivity: Low impurity content ensures the weld metal's electrical resistance is only marginally higher than the base conductor material, minimizing I2R losses.

  • Minimized Thermal Runaway: Low resistance prevents excessive heat generation at the joint, reducing the risk of thermal runaway and premature failure under load.

  • High Ductility (ER1100): Pure aluminum fillers retain excellent ductility, which is beneficial for joints that may experience thermal expansion cycling or mechanical stress.

  • Consistent Purity: The manufacturing process is dedicated to preventing cross-contamination from high-conductivity-reducing elements.

Material Selection Guide

For welding electrical conductors, prioritize purity: ER1100 is the standard for maximum conductivity. If the base metal is a 1050 or 1100 alloy, ER1100 provides the best match. Only use ER4043 if the base metal is also a 4XXX alloy, and ensure it is a low-Fe/Si variant to minimize conductivity loss.

About Us

Coming From China, Marketing To The World.

Hangzhou Kunli welding materials Co., Ltd. is China Aluminum Wire for High-Purity Electrical Conductors Manufacturers and Wholesale Aluminum Wire for High-Purity Electrical Conductors 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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