Custom Conductive Aluminum Tubular Busbar

When choosing bus conductors, several key aspects should be evaluated. Consider the nature of the electrical current, the required ampacity, system frequency, and the operating voltage. It’s also essential to assess permissible voltage drop, potential short-circuit levels, and the physical space available for installation. The number and type of taps and connections must be planned to ensure reliable operation. For installations handling large currents, prioritizing appropriate current density is vital. Outdoor substations require special attention to environmental and weather-related factors. In industrial settings, careful analysis of allowable temperature rise, load capacity, and energy losses will ensure safe and efficient system performance.

The choice between aluminum tubular busbars and copper bars depends on your specific project requirements. Aluminum tubular busbars are lightweight, cost-effective, and easy to install. With proper design and surface treatment, they offer good conductivity and corrosion resistance, making them ideal for long spans, high-current transmission, and budget-sensitive projects. Copper bars provide higher conductivity and are better suited for spaces with limited room or extremely high current density needs. Overall, aluminum tubular busbars are increasingly popular in modern applications due to their excellent balance of performance and cost.

The heat treatment of aluminum extrusions determines their mechanical properties, strength, and suitability for specific applications. Among the various heat treatment methods, T5, T6, and T66 are the most commonly used. Here’s an in-depth look:

Other Heat Treatment States 

• T4: Solution heat-treated and naturally aged. Used in applications requiring intermediate strength and enhanced formability.
• T7: Overaged for better stress-corrosion resistance, often used for aerospace and marine purposes.
• O (Annealed): Very soft condition suitable for extensive forming or bending requirements.
• F (As-Fabricated): No heat treatment applied, used in non-critical applications with low strength requirements.

. Anodizing (Oxidation)

• Common Colors:
  Natural silver
  Black
  Champagne
  Light bronze
  Dark bronze
  Gold

2. Electrophoresis Coating (E-Coating)

• Common Colors:
  Black
  Champagne
  Light bronze
  Dark bronze
  Custom metallic colors

3. Powder Coating

• Colors:
  Can match any color based on the RAL color chart.
  Offers textures like matte, gloss, satin, and custom finishes.

4. PVDF Coating (Polyvinylidene Fluoride)

• Colors:
  Also customizable using the RAL color chart.
  High-end finishes with matte or glossy effects.

5. Wood Grain Transfer Printing

• Colors and Patterns:
  Mimics various wood types (e.g., oak, walnut, teak, mahogany).
  Custom patterns available based on provided samples.

6. Film Lamination

• Colors and Patterns:
  Includes textures like marble, leather, and solid colors.
  Custom finishes and patterns based on provided samples.

Pre-Treatment Options (Impact on Final Color)

• Brushing/Polishing: Produces smooth or reflective metallic surfaces.
• Sandblasting: Adds a rough, matte texture before the final surface treatment.

Mold fees are an essential part of the custom aluminum extrusion process. Since every order requires a uniquely designed mold tailored to specific requirements, these molds cannot be used for other products. Therefore, the mold fee is necessary and non-negotiable.

We require 100% upfront payment of the mold fee before mold development begins to ensure timely production. However, as a token of appreciation for your support, we offer a refund of the mold fee or equivalent discounts once the order reaches a certain production volume. Specific policies can be discussed based on your order volume and collaboration details.

Our minimum order quantity (MOQ) varies depending on the size of the product. For smaller-sized products, the MOQ is typically 500kg, while for larger-sized products, it is 2 tons.

We will specify the exact MOQ requirements during the quotation process. If your order quantity does not meet the MOQ, we can still arrange production, but an additional fee will be applied to cover mold preheating and production setup time. Rest assured, this extra fee will be reasonable, and we aim to keep it as minimal as possible to ensure smooth cooperation.

Packaging can be customized according to your needs. Options include using protective film or paper to separate and protect the surface, or foam film for additional surface protection. Products can be palletized or packed into cartons, and the quantity per pallet or carton can be specified by the customer.

The standard packaging involves bundling several pieces together with plastic wrap and then securing them onto pallets. Any packaging requirements beyond the standard will be accommodated, and the associated costs will be clearly provided to the customer.

Mold production typically takes 7 days. After the sample is confirmed, producing a full container load of 26 tons generally requires 14 days for extrusion alone. If surface treatment is required, an additional 3 days will be needed. For machining, extra time will be required depending on the complexity and volume of the machining work. The exact additional time for machining will be determined based on the specific processing requirements.

Aluminum profiles are naturally corrosion-resistant due to the formation of a thin, protective oxide layer when exposed to air or water. This oxide layer is stable and self-repairing, meaning that even if the surface is scratched or cut (such as at exposed ends or during processing), the aluminum will not rust or corrode like iron or steel. Instead, the exposed areas will quickly form a new oxide layer, providing continuous protection against further oxidation.

With proper design, installation, and maintenance, aluminum profiles can last for decades, even in challenging environments. For example, untreated aluminum can easily withstand 20-30 years in outdoor applications, while profiles with surface treatments like anodizing or powder coating can last even longer, often exceeding 50 years. This makes aluminum an excellent choice for applications where durability and long-term performance are essential.

The price of aluminum profiles consists of several components: raw material costs, extrusion processing fees, surface treatment fees, machining costs, and additional packaging fees. Among these, the cost of aluminum as a raw material tends to fluctuate frequently, while other fees remain relatively stable. Due to these fluctuations, our quotations are typically valid for 7 days.

Pricing can be structured in different ways depending on the product and requirements. It can be calculated by weight (e.g., cost per ton), by length (e.g., cost per meter), or by piece (e.g., cost per unit). For products involving extensive machining, such as heat sinks, pricing is generally calculated on a per-piece basis to accurately reflect the additional processing costs. This flexible pricing approach ensures the quote is tailored to the specific needs of the customer.

We can manufacture aluminum profiles in compliance with technical requirements that meet European standards (EN), American standards (ASTM/AA), or other standards as specified by the customer. Custom production is tailored to ensure that the profiles meet the specific standard requirements requested.

Our production equipment is designed for the metric system. If the drawings provided are in the imperial system, we will convert them into metric units for production to ensure accuracy.

It is important to note that while we can machine imperial-threaded holes for fasteners, if you require us to supply matching imperial fasteners, they may not always be available in stock. Custom orders for imperial fasteners typically require a large volume for production. Please consider this when planning your project.