6101 T6 T61 Electrical Aluminum Busbar Supplier

Why choose Chalco Aluminum 6101 electrical busbar

Chalco 6101 EC grade aluminum busbar conforms to IEC 60105, ISO 209-1, 2, DIN EN 755-2, DIN EN 755-5 standards. The 6101 aluminum busbar has excellent conductivity, high strength, good corrosion resistance, and lightweight design.

Chalco Aluminum supplies 1050, 1060, 1070, 1100, 1350, 6060, 6082, 6101 etc. conductive aluminum busbar product. The products have been widely exported to Hitachi, ABB, Siemens, Legrand, Toshiba etc. companies, and enjoy good reputation from them.

Chalco aluminum busbar partner

Specification of Chalco Aluminum 6101 electrical aluminum busbar

Tempers: T6, T61, T63, T64, T65

Equivalent Names: UNS A96101, AA6101-T61, Al6101-T61, AA6101-T65, Al6101-T65

Specification compliance: ASTM B317/B317M, ASTM B236, ASTM B241, ASTM B429, IEC 60105, ISO 209-1/2, DIN EN 755-2, DIN EN 755-5:2008-06

Testing & quality control: Conductivity Test/Temperature Rise Test/Bending Test

Surface Treatment & Processing

Surface Requirements: Smooth, burr-free, clean, oil-free, with a dense, uniform oxide layer for superior corrosion resistance.
Anodizing – Enhances oxidation resistance and durability.
Tin Plating & Electroplating – Improves conductivity and corrosion resistance (available in silver, tin, nickel).
Insulation Coating & Sleeves – Powder coating, epoxy resin coating, insulation paint, PVC, heat shrink tubing, silicone rubber for electrical insulation and enhanced safety.
Protective spraying – Additional surface protection for extended service life.
Edge processing: Right angle, rounded corner, R-rounded corner – tailored for different structural and assembly needs.
Machining & Fabrication: Cutting, Drilling, Bending, Stamping

For detailed production and processing capacity, check the [Capacity Part].

Stock Sizes

Thickness: 0.08"-9.8" (2-250mm)
Width: 0.2"-11.8" (5-300mm)
Length: Customizable up to project specifications.

Dimensions and tolerance
Length	Maximum 6m [Click for size table]
Width	10mm - 200mm
Width tolerance [mm]	b≤35.50		±0.40
	35.50		±0.80
	6>100.00		±1.20
Thickness	0.15mm - 40mm
Thickness tolerance [mm]	a≤6.30	±0.15
	6.30	±0.20
	a>12.50	±0.30
Minimum Bend Radius [mm]	1x thickness (up to 12mm) 2x thickness (>12mm)

Note: In the above table,

a=thickness, i.e. narrow edge size;

b=width refers to the size of the wide edge.

Product types of Chalco 6101 electrical aluminum busbar

6101 EC Grade Flat Busbar

A key choice for power transmission, switchgear, and enclosures, with excellent conductivity, lightweight design, and corrosion resistance for high-current use.
Extruded 6101 Aluminum Busbar

Produced with high-precision extrusion for uniform dimensions, enhanced strength, and superior finish, ideal for demanding structural and electrical applications.
6101 busbar coil strip

Provide high conductivity, flexibility, and corrosion resistance, ideal for compact power distribution and flexible connections.
6101 busbar by plate sawing

Precision-cut for accurate dimensions, perfect for precision equipment and applications requiring exact specifications.
Flexible 6101 Aluminum Busbar

Composed of multiple thin layers of 6101 aluminum, laminated or braided together to provide high flexibility, reduced stress fatigue, and improved vibration resistance.
Laminated 6101 Aluminum Busbar

Consist of multiple conductive layers separated by insulating materials, significantly reducing electromagnetic interference (EMI) and improving power efficiency.
Round Edge 6101 Aluminum Busbar

Feature smooth, rounded corners to minimize stress concentration, reducing the risk of electrical discharge and improving safety in high-voltage applications.
Insulated 6101 Aluminum Busbar

Feature protective coatings or insulating sleeves to enhance dielectric strength, safety, and corrosion resistance. Ideal for high-voltage systems where electrical isolation is necessary.

Properties of Chalco Aluminum 6101 electrical aluminum busbar

Chalco 6101 aluminum busbar has outstanding performance advantages in terms of conductivity and current carrying capacity. According to different busbar sizes, Chalco conductive aluminum bus bars can handle currents up to 4000A.

For specific requirements, please clickQuick Quoteto contact our customer service personnel. The following table is a reference table for the performance parameters of Chalco 6101 conductive aluminum busbar.

Temper	Yield Strength Rp0.2(Mpa)	Ultimate tensile strength Rm(Mpa)	Elongation	Conductivity %IACS
6101-T6	≥172	≥200	15	-
6101-T61	≥55	≥103	-	≥59%
6101-T63	≥150	≥185	-	≥56
6101-T64	≥55	≥105	-	≥59.5
6101-T65	-	-	-	≥58%

Manufacturing Processing and Customization capabilities

Chalco Aluminum is a leading manufacturer of high-performance aluminum busbars, offering comprehensive processing, customization, and manufacturing capabilities to meet diverse industrial and electrical applications. Our state-of-the-art facilities ensure precision machining, advanced material cladding, and high-quality surface treatments to enhance performance, durability, and reliability.

Surface treatment for enhanced performance

To improve the durability, conductivity, and corrosion resistance of our aluminum busbars, we offer the following surface treatments:

Anodizing – Forms a dense oxide layer for enhanced corrosion resistance.
Electroplating – Silver, tin, or nickel plating to increase electrical conductivity and oxidation resistance.
Protective Spraying – Ensures long-term performance in harsh environments.

Customization & quality assurance

We support custom orders based on specific electrical and mechanical requirements, including:

Custom dimensions – Thickness 0.15mm - 40mm, Width 10mm - 200mm, Length up to 6m.
Special bending and forming – Tailored to fit unique electrical layouts.
Stringent testing procedures – Including conductivity tests, temperature rise tests, and bending tests to guarantee optimal performance.

Precision machining & fabrication

We provide advanced machining services to achieve precise dimensions and structural integrity for various applications:

Cutting – Custom length adjustments for different installations.
Drilling – Precision hole placement for electrical connections.
Bending – Tailored shaping to fit complex assembly requirements.
Stamping – High-efficiency mass production for uniform busbar components.

Copper cladding & insulation coating

Our specialized cladding and insulation techniques enhance conductivity, corrosion resistance, and electrical safety:

Copper-Clad Aluminum (CCA) Processing – Utilizing explosive welding, rolling cladding, and hot-dip cladding to form a high-strength copper-aluminum composite layer, improving conductivity and mechanical performance.
Insulation Coatings – Powder coating, epoxy resin coating to prevent electrical leakage and corrosion.
Insulation Sleeves – Options include PVC, heat shrink tubing, and silicone rubber, ensuring additional protection in high-voltage applications.

At Chalco Aluminum, we combine high-precision manufacturing with advanced processing technologies, ensuring reliable, high-quality aluminum and copper-clad busbars for global industrial and electrical applications.

For further inquiries or customized solutions, contact us today for a quick quote!Quick Quote

Advantage of Chalco Aluminum 6101 electrical aluminum busbar

Chalco can provide complete design, including machining, forming, and brazing. Cutting, stamping, bending, drilling and other processing can be completed according to the specific requirements of customers for current capacity and bending degree.

Chalco can provide surface coating and insulation processing for conductive aluminum busbars according to customer requirements to improve product corrosion resistance, aesthetics, and avoid short circuits and other issues.

High conductivity: the 6101 conductive aluminum busbar is lighter than ordinary copper wires, but its conductivity is equivalent to that of copper.

Lightweight: due to its lightweight, it is often used in weight sensitive applications such as aerospace and automotive to achieve lightweight design.

Good thermal stability: 6101 conductive aluminum busbar is able to work for long periods of time in high temperature environments and not easily melt or deform.

Processability: it can perform machining operations such as cutting, punching, and bending to meet the needs of different applications.

Good corrosion resistance: 6101 conductive aluminum busbar can resist moisture, acid, alkali, and most corrosive media.

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Advantage of Chalco Aluminum 6101 electrical aluminum busbar

Application of Chalco Aluminum 6101 electrical aluminum busbar

Power transmission and distribution system: power substations, power transmission lines, switchgear, distribution cabinets, etc.

Industrial equipment and machinery: such as machine control cabinets, electrical panels, generators, transformers, and other equipment.

Transportation: power transmission and control systems such as electric vehicles, rail transit systems (such as subways, high-speed trains), and ships and aircraft.

Metallurgy and mining: such as electrolytic cells, electric furnaces, electrolytic aluminum production, and other high current applications.

Other fields: power transmission, electrical connection and distribution in areas such as renewable energy, electronic equipment, communication equipment, electrical systems of buildings and buildings, lighting systems, etc.

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Application of Chalco Aluminum 6101 electrical aluminum busbar

6101 aluminum busbar or copper aluminum busbar

6101 aluminum busbar is the most commonly used aluminum busbar, frequently compared with or used as a substitute for copper busbars. Due to its lightweight and cost-effectiveness, 6101 aluminum is a popular choice in many applications. Below is a comparison of the current-carrying capacity between 6101 aluminum busbars and copper busbars.

Converting Copper to Aluminum using an Ampacity Chart
Ampacity Conversion Chart			Copper C110		30° C Rise	50° C Rise	65° C Rise	Aluminum 6101		30° C Rise	50° C Rise	65° C Rise
Flat Bar Size in Inches	Sq. In	Circ Mils Thousands	Weight Per Ft in Lb.	DC Resistance at 20° C, Microhms/Ft	60 Hz Ampacity Amp*			Weight Per Ft in Lb.	DC Resistance at 20° C, Microhms/Ft	60 Hz Ampacity Amp**
1/2*1	0.5	637	1.93	16.5	620	820	940	0.585	31	347	459	526
1/2*1 1/2	0.75	955	2.9	11	830	1100	1250	0.878	21	465	616	700
1/2*2	1	1270	3.86	8.23	1000	1350	1550	1.17	15	560	756	868
1/2*2 1/2	1.25	1590	4.83	6.58	1200	1600	1850	1.463	12	672	896	1036
1/2*3	1.5	1910	5.8	5.49	1400	1850	2150	1.755	10	784	1036	1204
1/2*3 1/2	1.75	2230	6.76	4.7	1550	2100	2400	2.048	9	868	1176	1344
1/2*4	2	2550	7.73	4.11	1700	2300	2650	2.34	8	952	1288	1484
1/2*5	2.5	3180	9.66	3.29	2050	2750	3150	2.925	6	1148	1540	1764
1/2*6	3	3820	11.6	2.74	2400	3150	3650	3.51	5	1344	1764	2044
1/2*8	4	5090	15.5	2.06	3000	4000	4600	4.68	4	1680	2240	2576

1/4*1/2	0.125	159	0.483	65.8	240	315	360	0.146	123	134	176	202
1/4*3/4	0.188	239	0.726	43.8	320	425	490	0.220	82	179	238	274
1/4*1	0.25	318	0.966	32.9	400	530	620	0.293	62	224	297	347
1/4*1 1/2	0.375	477	1.450	21.9	560	740	880	0.439	41	314	414	482
1/4*2	0.5	637	1.930	16.5	710	940	1100	0.585	31	398	526	616
1/4*2 1/2	0.625	796	2.410	13.2	850	1150	1300	0.731	25	476	644	728
1/4*3	0.75	955	2.900	11	990	1300	1550	0.878	21	554	728	868
1/4*3 1/2	0.875	1110	3.380	9.4	1150	1500	1750	1.024	18	644	840	980
1/4*4	1	1270	3.860	8.23	1250	1700	1950	1.170	15	700	952	1092
1/4*5	1.25	1590	4.830	6.58	1500	2000	2350	1.463	12	840	1120	1316
1/4*6	1.5	1910	5.800	5.49	1750	2350	2700	1.755	10	980	1316	1512

1/8*1/2	0.0625	79.6	0.241	132	153	205	235	0.073	247	86	115	132
1/8*3/4	0.0938	119	0.362	87.7	215	285	325	0.110	164	120	160	182
1/8*1	0.125	159	0.483	65.8	270	360	415	0.146	123	151	202	232
1/8*1 1/2	0.188	239	0.726	43.8	385	510	590	0.220	82	216	286	330
1/8*2	0.25	318	0.966	32.9	495	660	760	0.293	62	277	370	426
1/8*2 1/2	0.312	397	1.210	26.4	600	800	920	0.365	49	336	448	515
1/8*3	0.375	477	1.450	21.9	710	940	1100	0.439	41	398	526	616
1/8*3 1/2	0.438	558	1.690	18.8	810	1100	1250	0.512	35	454	616	700
1/8*4	0.5	636	1.930	16.5	900	1200	1400	0.585	31	504	672	784

1/16*1/2	0.0312	39.7	0.121	264	103	136	157	0.037	494	58	76	88
1/16*3/4	0.0469	59.7	0.181	175	145	193	225	0.055	327	81	108	126
1/16*1	0.0625	79.6	0.242	132	187	250	285	0.073	247	105	140	160
1/16*1 1/2	0.0938	119	0.362	87.7	270	355	410	0.110	164	151	199	230
1/16*2	0.125	159	0.483	65.8	345	460	530	0.146	123	193	258	297
Source: Copper Development Organization; Aluminum Association
Note: Ratings depend upon configuration, air flow, ambient temp, etc. The values depicted are an approximation. Controlled testing is always required to validate.
Other considerations Forming the busbar (aluminum has a tendency to crack with very tight radius) Electroplating the busbar (white rust on aluminum, oxidation is an issue with aluminum) Configuration of the busbar (vertical or horizontal configuration)

In practical applications, there are two common methods to convert copper busbar dimensions to aluminum busbar dimensions to achieve the same temperature rise:

1. Increase the width of the aluminum bar by 27%. For example, to achieve the same temperature rise, a 5-inch x 1/4-inch aluminum bar is equivalent to a 4-inch x 1/4-inch copper bar.

2. Increase the thickness of the aluminum bar by about 50%. For example, to achieve the same temperature rise, a 4-inch x 3/8-inch aluminum bar is equivalent to a 4-inch x 1/4-inch copper bar.

Increasing the width of the aluminum busbar to enlarge the cross-sectional area not only reduces resistive heating but also significantly increases the surface area for heat dissipation. Changes in the thickness of rectangular bars do not notably affect the exposed surface area.

For instance, increasing the width from 4 inches to 8 inches for a 1/4-inch bar increases the capacity by about 87%, whereas increasing the thickness of a 4-inch bar from 1/4 inch to 1/2 inch only increases the capacity by about 45%. While both examples double the cross-sectional area, the current-carrying capacity difference between these two examples is 42%.

If you have electrical project needs or require technical support, feel free to contact Chalco. We will provide you with comprehensive solutions and professional services. Quick Quote

More electrical aluminum busbar products in Chalco

1060 EC aluminum busbar T3, T4, T5, T6, T8

It is usually formed by extrusion or rolling, and has good processing performance.

High conductivity Corrosion resistance
1350 EC aluminum busbar H14, H16, H19

The minimum weight percentage is 99.5%, which is the material used for battery busbars.

Conductivity Thermal conductivity
6060 EC aluminum busbar T4, T5, T6

It can effectively transmit and distribute electricity, reducing energy loss and line power loss.

Lightweight Processability
6082 EC aluminum busbar T3, T4, T5, T6

It has high strength and hardness, while maintaining good conductivity.

Machinability High strength and rigidity
6061 EC aluminum busbar T4

6061 aluminum busbar has strong conductivity and is a universal material for most processing technologies.

Smooth surface Strong moisture resistance
6063 EC aluminum busbar T4, T5, T6, T52, T66

In high-power applications, it can help effectively dissipate heat, and reduce the risk of equipment overheating.

Strong plasticity Excellent heat dissipation
Copper clad aluminum bus bar

CCA bus or bimetallic conductive bus, it is the third generation of "new energy-saving conductor materials".

Conductivity Scalability Reliability

More electrical aluminum products in Chalco

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Common sizes of Chalco aluminum electrical aluminum busbar

Square angle aluminum bar
2mm	2*30	2*40	2*67	2*70	2.5* 25
3mm	3*10	3*15	3*20	3*25	3*30	3*40	3*50	3*60	3*67	3*75
3mm	3*110
4mm	4*10	4*15	4*20	4*25	4*30	4*40	4*45	4*50	4*60	4.6*60
4mm	4.8*9.8
5mm	5*15	5*20	5*25	5*30	5*35	5*40	5*50	5*60	5*80	5*100
6mm	6*20	6*25	6*30	6*40	6*50	6*54	6*55	6*60	6*65	6*70
6mm	6*75	6*80	6*100	6*120	6*150	6*160
6.3mm	6.3*50	6.3*63	6.3*63.5	6.3*80	6.35*50.8	6.35*76.2
7mm	7.6*80	7*150	7420*4
8mm	8*11	8*30	8*40	8*50	8*51	8*60	8*63	8*63.5	8*65	8*70
8mm	8*80	8*90	8*100	8*120	8*125	8.8*28.6
9mm	9*170	9*125	9. 2*64
10mm	10*20	10*25	10*30	10*40	10*45	10*50	10*60	10*63	10*65	10*70
10mm	10*80	10*90	10*100	10*110	10*114	10*120	10*125	10*140	10*150	10*160
12mm	12*30	12*40	12*45	12*50	12*60	12*70	12*76	12*80	12*100	12*120
12mm	12*125	12*130	12*140	12*150	12*160
12.5mm	12.5*90	12.5*100	12.5*125	12.5*127	12.7*101.6	12.7*160
13mm	13*125	13*130	13*160
14mm	14*100	14*120	14.5*80
15mm	15*30	15*35	15*50	15*60	15*80	15*100	15*120	15*125	15*150
16mm	16*30	16*90	16*100	16*110	16*125	16*130	16*140	16*150	16*160
20mm	20*76	20*100	20*120	20*130
Square bar	19*19	30*45	15*15
Round bar	Φ6	Φ8	Φ10	Φ11	Φ12	Φ14	Φ15	Φ15.6	Φ16	Φ18
	Φ20	Φ21	Φ22	Φ23	Φ25	Φ27	Φ28	Φ30	Φ32	Φ35
	Φ38	Φ40	Φ45	Φ50	Φ55	Φ60

Round angle aluminum bar
2mm	R2*20	R2.5* 50
3mm	R3*30	R3*40	R3*50	R3*60	R3*80	R3*100	R3*120	R3*160
4mm	R4*25	R4*30	R4*35	R4*40	R4*50	R4*60	R4.1*44.1	R4.7*151
5mm	R5*30	R5*35	R5*40	R5*45	R5*50	R5*60	R5*70	R5*75	R5*80
5mm	R5*90	R5*100	R5*120
6mm	R6*40	R6*50	R6*60	R6*70	R6*80	R6*100	R6*120	R6*140	R6*160
6mm	R6.3*63	R6.35*76.5
7mm	R7*70
8mm	R8*40	R8*50	R8*60	R8*80	R8*100	RS*120
10mm	R10*20	R10*40	R10*50	R10*60	R10*75	R10*80	R10*100	R10*120	R10*125
10mm	R10*150	R10*160	R10*170	R10.4*25
12mm	R12*80	R12*100	R12*110	R12*120	R12*125	R12*150	R12*160
12.5mm	R12.5*80	R12.5*125	R12.7*90	R12.7*127
13mm	R13*120	R13*125
14mm	R14*100	R14*120	R14*150
15mm	R15*100	R15*120	R15*130	R15*150
16mm	R16*150	R16*160
19mm	R19.05*101.6	R19.05*127
20mm	R20*80	R20*120	R20*130
Special-shaped hypotenuse	450	550	560	640	650	660	680	860	880
	8100	8120	1040	1080	10100	10120	1280	12100	12120
	15120	20130	2860