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6101 T6 T61 T64 Electrical Aluminum Busbar
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6101 T6 T61 T64 Electrical Aluminum Busbar

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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

EC 6101 aluminum busbar specification
Equivalent name UNS A96101, AA6101-T61, Al6101-T61, AA6101-T65, Al6101-T65
Temper T6, T61, T63, T64, T65
Requirements for surface quality Smooth surface without defects such as burrs and spots; The surface is clean, dust-free, oil-free, and free of other impurities; The oxide layer is uniform, dense, and has good corrosion resistance;
Surface treatment Anodizing, electroplating, spraying, etc. Usually aluminum plating includes: silver, tin, nickel
Insulation treatment Insulation coating: powder coating, epoxy resin coating or insulation paint coating, etc. Insulating sleeve: polyvinyl chloride (PVC), heat shrink tubing, or silicone rubber, etc.
Product packaging When delivering according to length, it should be packaged in bundles and boxes, and when delivering according to quality, it should be packaged in discs, circles, or bundles.
Test Conductivity test, temperature rise test, bending test, etc.
Standard ASTM B317/B317M, ASTM B236, B241, and B 429 IEC 60105, ISO 209-1, 2, DIN EN 755-2, DIN EN 755-5:2008-06
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.

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%

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 aluminum busbar
    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 aluminum busbar
    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 aluminum busbar
    6060 EC aluminum busbar T4, T5, T6

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

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

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

    Machinability High strength and rigidity
  • 6061 aluminum busbar
    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 aluminum busbar
    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 busbar
    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
3*110
4mm 4*10 4*15 4*20 4*25 4*30 4*40 4*45 4*50 4*60 4.6*60
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
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 7*4*20*4
8mm 8*11 8*30 8*40 8*50 8*51 8*60 8*63 8*63.5 8*65 8*70
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
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
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
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
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
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 *4*50 *5*50 *5*60 *6*40 *6*50 *6*60 *6*80 *8*60 *8*80
*8*100 *8*120 *10*40 *10*80 *10*100 *10*120 *12*80 *12*100 *12*120
*15*120 *20*130 *28*60
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