High-Conductivity Copper-Inlaid Aluminum Busbars

Short Description:

Product Specifications
Name： Copper-Inlaid Aluminum Busbar (Hybrid Copper Clad Aluminum Busbar)
Standard： ASTM B187 / B152 (Copper Layer), GB/T 5585 (Aluminum Base), RoHS Compliant, REACH Compliant
Material： High-Purity Aluminum Base with Embedded C11000 Pure Copper Strip
Surface： Mill Finish or Tin-Plated, Optional Pre-Drilled Holes
Width： 20mm – 300mm
Thickness： 3mm – 20mm
Length： 1000mm – 6000mm (custom cut-to-length available)
Product Features:
Combines aluminum’s lightweight advantage with copper’s superior conductivity · Excellent corrosion resistance and long-term reliability · High mechanical strength with good flexibility · Low contact resistance and efficient heat dissipation · Cost-effective alternative to full copper busbars · Easy to bend and install in compact spaces · Stable performance under vibration and thermal cycling
Application Field:
New energy vehicle battery packs and power distribution, Industrial switchgear and control panels, Renewable energy inverters and storage systems, Data center power rails, High-current electrical connections, Transformer and generator bus systems, Marine and offshore electrical equipment

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Copper-Inlaid Aluminum Busbar – Process & Quality Assurance Statement
Our copper-inlaid aluminum busbars are engineered to deliver the optimal balance of conductivity, weight, and cost for modern high-current electrical systems.

Key process features

Production integrates advanced cladding technology with precision fabrication:

●Base Material Preparation: High-purity aluminum bars are selected and machined to create precise grooves for copper inlay.
●Copper Inlay Insertion: High-conductivity C11000 copper strips are press-fitted or explosion-bonded into the aluminum base, ensuring a strong metallurgical bond.
●Hot Rolling / Cladding: Controlled rolling consolidates the interface for excellent electrical and mechanical integrity.
●Annealing: Protective atmosphere annealing relieves stresses and optimizes conductivity without compromising the bond.
●Precision Finishing: CNC cutting, drilling, and edge chamfering are performed to customer specifications.
●Surface Treatment: Optional tin plating or protective coating is applied for enhanced corrosion resistance and solderability.
●Final Cleaning & Packaging: Bars are thoroughly cleaned and securely bundled with protective interleaving to prevent damage during global shipping.

Quality control system

● Full traceability from raw aluminum and copper materials to finished busbar
● Material test reports including conductivity, bond strength, and dimensional data provided with every shipment
● Sample retention ≥3 years for third-party verification (SGS, BV, TÜV, etc.)
● 100% inspection of essential parameters:
• Chemical composition and purity of both layers (spectrometric analysis)
• Bond integrity (ultrasonic and shear testing)
• Dimensional accuracy (laser measurement; typical tolerance ±0.2mm)
• Surface quality and plating thickness (where applicable)
• Electrical conductivity (eddy current testing)
● Internal standards exceed ASTM B187 and industry cladding requirements. Typical performance:
Conductivity approaching pure copper at contact surfaces while maintaining aluminum’s weight advantage, Excellent thermal transfer, Strong metallurgical bond with no delamination under thermal cycling.
● ISO 9001:2015 certified production ensures every copper-inlaid aluminum busbar delivers consistent quality, reliability, and performance for your critical power systems.