Technological Path for Synergistic Enhancement of Strength and Conductivity of 6101 Aluminum Flat Busbar for Extrusion Molding

The extrusion process is to uniformly coat the insulating material on the surface of Bus Bar Aluminum to form a dense protective layer. This characteristic determines that the aluminum bar must meet strict requirements in four dimensions: mechanics, surface, structure, and composition. In terms of mechanical strength, the in vehicle scenario needs to cope with continuous vibration and assembly stress. The 1 series aluminum busbar needs to meet the H24 state standard, which means the tensile strength should not be less than 150MPa and the yield strength should not be less than 135MPa. In terms of surface quality, the surface of aluminum bars must be smooth and flat, with no burrs or protrusions on the edges, otherwise it is easy to puncture the insulation layer during the extrusion process, causing potential leakage hazards. In terms of structural design, to avoid cracking of the insulation layer at sharp corners due to stress concentration, the four corners of the Aluminum Flat Busbar for Switchgear need to be designed with smooth R-angles of 0.45 to 0.50mm, and the overall dimensional tolerance should be strictly controlled. In terms of composition control, to ensure excellent conductivity, the alloy composition needs to be accurately proportioned, the impurity content should be strictly limited, and the hydrogen content of the melt should be strictly controlled to avoid internal porosity defects affecting subsequent processing and performance.

At present, the traditional processes for preparing 1370 Flexible Aluminum Connections in the industry are mainly divided into rolling heat treatment and direct extrusion, both of which have inherent limitations in balancing performance and quality. The combination of rolling and low-temperature heat treatment process is achieved by forming wide aluminum coils through rolling and then subjecting them to heat treatment, which can meet the strength requirements of H24 state. But this process requires obtaining the target width through subsequent slitting processes, and the slitting edges inevitably produce burrs, which can directly damage the extruded insulation layer. The direct extrusion process utilizes a mold for one-time molding, which can completely eliminate burrs and accurately control the R-angle shape through mold design. The 6101 Aluminum Flat Busbar has significant advantages in surface quality. However, the temperature during the extrusion process is usually higher than the recrystallization temperature of the aluminum alloy, resulting in the formed aluminum strip being in the H112 state with a tensile strength of only 120 to 130 MPa, which cannot meet the mechanical performance requirements of the H24 state and is difficult to adapt to the harsh working conditions of new energy vehicles.

In response to the limitations of traditional processes, the innovative composite process route of "aluminum rod preparation continuous extrusion forming cold rolling strengthening" effectively solves the problem of balancing strength and surface quality of Aluminum Busbar Electrical Power Connector. Firstly, in the aluminum rod preparation stage, the alloy is melted using continuous casting and rolling technology, with strict control of the composition ratio. The silicon content is 0.04% -0.07%, the iron content is 0.14% -0.16%, the individual impurity content does not exceed 0.02%, the total impurity content does not exceed 0.10%, and the aluminum content is guaranteed to be above 99.70%, ensuring conductivity from the source; At the same time, strict control of the hydrogen content in the melt is achieved through online degassing and other processes to eliminate internal porosity defects in Customized Aluminum Busbars. Secondly, in the continuous extrusion molding stage, a continuous operation mode of unwinding, straightening, cleaning, extrusion, cooling, and winding is adopted to control the extrusion speed at 20-25m/min, ensuring molding efficiency and quality; The cooling process adopts a combination of 20-30 ℃ water cooling and 5-8m/s air cooling to rapidly cool down and suppress the recrystallization process, laying the structural foundation for subsequent strengthening processes.

Cold rolling strengthening is the core process for achieving the strength standard of Aluminum Flexible Connections, while also considering the R-angle shape and elongation rate. Therefore, controlling the process parameters is crucial. Roll the extruded busbar through a cold rolling mill, strictly controlling the cold rolling reduction to 7% -12% of the thickness. If the reduction is too low, the strength improvement will be insufficient and it will not meet the H24 state requirements; If the compression amount is too high, it will cause R-angle deformation and damage the extrusion compatibility. To further balance the mechanical strength and material elongation, 6061 Aluminum Busbar needs to undergo low-temperature annealing treatment after cold rolling, and be kept at a temperature of 250-300 ℃ for 1 to 2 hours. This process not only eliminates the internal stress generated during the cold rolling process, but also optimizes the microstructure of the material, ultimately achieving the mechanical performance standard of H24 state while maintaining high conductivity of 1370 aluminum alloy extruded aluminum, perfectly solving the industry pain point that traditional processes cannot balance surface quality and strength.

If you have any process consultation, performance adaptation, or customization needs for 6101 Aluminum Flat Busbar for extrusion, please feel free to contact us at any time. We will provide professional technical support and accurate inquiry quotations based on your specific working conditions, helping you solve product performance problems.