Choosing the right aluminum alloy for busbars is crucial to achieving the desired balance of conductivity, mechanical properties, and cost. Xinyi recommends E91E aluminum as a next-generation alternative to traditional 6101 and EC-grade aluminum, especially in high-performance electrical systems. Here's how these alloys compare.

Conductivity Performance

Conductivity is the most important factor in busbar selection. While EC-grade aluminum (like 1350) has a high conductivity rating of 61% IACS, E91E matches or slightly exceeds this, offering ≥ 61.5% IACS. 6101, on the other hand, typically provides around 57–58% IACS, making it less suitable for critical low-loss systems.

• E91E: ≥ 61.5% IACS
• EC Grade (1350): ~61% IACS
• 6101: ~57–58% IACS

Mechanical Strength and Ductility

While EC-grade aluminum offers excellent conductivity, it is relatively soft and lacks strength under mechanical load. E91E is engineered to enhance strength without sacrificing conductivity. Compared to 6101-T6, which is stronger but less conductive, E91E offers a superior balance of mechanical and electrical properties.

• E91E: Moderate strength, high formability
• EC Grade: Low strength, poor mechanical durability
• 6101: High strength, but lower conductivity

Thermal Stability and Processing

In busbar applications, the ability to withstand thermal cycling and retain form during punching or bending is essential. E91E offers good dimensional stability and can be easily processed into complex shapes without cracking—unlike EC-grade aluminum, which is more prone to tearing during fabrication.

Cost and Supply Chain Considerations

E91E provides a cost-effective alternative to copper busbars