Aluminum busbar

Tubular conductors are hollow-core conductors with a low skin-effect coefficient, which helps to increase the corona inception voltage. When used in outdoor switchgear, tubular conductors offer advantages such as a small footprint, a simple structure, and clear arrangement.

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Product Description

1. Implementation Standard: YS/T454-2003 Aluminum and Aluminum Alloy Conductors

2 Product Grades: 3A21, 6063, 6R05, 1060

3 Product Status: H18 T10 T6 T6511

4. Physical and Mechanical Properties at Room Temperature

5 Commonly Used Calculation Data for Aluminum Busbars

6. Current-carrying capacity of aluminum busbar (reference ambient temperature +25℃)

7. Deflection Calculation Data (taking 6063T6 as an example)

8 Installation and Usage Instructions

Tubular conductors are typically installed overhead after welding, using specialized busbar fittings for secure fixation. Since the strength of the joint is reduced after welding—approximately 65% of the base material’s strength—it is essential to reinforce the interior of the joint with a liner pipe to prevent bending during operation once the conductor is installed overhead. The number of welded joints between two overhead support structures (or suspension points) should not exceed two. The commonly used welding methods for aluminum and aluminum alloy tubes are as follows:

Argon arc welding is a welding process conducted under argon gas protection, using a DC power source. A welding wire (or electrode rod) serves as the electrode, generating an electric arc between the electrode and the workpiece. The weld is formed at the interface between the welding wire (or electrode rod) and the workpiece. This method offers several advantages: it concentrates heat effectively, ensures a stable arc, and allows the molten metal to benefit from excellent protection by the argon gas, thereby preventing oxidation. Moreover, the argon arc can easily remove the oxide film from the surface of the molten metal. As a result, this process produces high-quality welds that are not only free of defects but also exceptionally pure. Additionally, the technique is relatively easy to master, and it enables welding in all positions.

1 Requirements for Argon Gas

The purity of argon must be maintained at 99.9% or higher, with impurity levels below: oxygen less than 0.005%, hydrogen less than 0.005%, water content less than 0.02 mg/L, and nitrogen less than 0.015%. An increase in either oxygen or nitrogen will degrade the cathode atomization effect. When oxygen exceeds 0.3%, tungsten electrode burn-off will intensify; when oxygen exceeds 0.1%, the weld surface will lose its luster or turn black. When nitrogen exceeds 0.05%, the fluidity of the molten pool will deteriorate, resulting in poor weld bead formation.

2 Joint Type

Joint geometry and dimensions

3 Welding Requirements

To ensure the tubular conductor is securely fixed and to minimize deformation, the welding sequence should begin with spot welding to stabilize the main pipe and reduce bending at the joint. It is advisable to perform spot welding in a symmetrical manner. The argon gas flow rate typically ranges from 30 to 50 L/min.

4. Composition of welding wire (or electrode)

5 Joint Strength Coefficient

Insulated copper busbar

Enclosed insulated busbar

Insulated copper busbar

Enclosed insulated busbar

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Hubei Bailian New Energy Technology Co., Ltd. Enterprise Code

Hubei Lianhua Power Busbar Manufacturing Co., Ltd. Enterprise Code