What is the advantage of the Copper-Aluminum Transition Bar for Charging Piles?

The Core Advantages are following:

• Galvanic Corrosion Prevention: Adopts advanced metallurgical bonding technology (explosion bonding/hot rolling), achieving seamless combination between copper and aluminum surfaces. It completely eliminates gaps that cause electrolyte penetration, fundamentally avoiding galvanic cell reaction and ensuring no corrosion even in outdoor humid environments or high-temperature charging scenarios, which is the key to solving the oxidation problem of direct copper-aluminum connection in charging piles. The composite layer is formed by mutual diffusion of copper and aluminum, realizing true metallurgical bonding with high bonding strength.

• Stable Conductivity & Low Energy Loss: The copper end (tinned) ensures excellent electrical conductivity (resistivity ≤ 0.0172Ω·mm²/m), and the aluminum end (resistivity ≤ 0.0282Ω·mm²/m) guarantees efficient current transmission. The contact resistance is stable and ≤ 1.1 times that of the same-section aluminum bar, effectively reducing energy loss and overheating risks—critical for DC fast charging piles with high current (up to 218A for 120kW piles, and up to 400A+ for 800V high-voltage platform piles). Especially in 800V high-voltage systems, our product maintains stable resistance even after repeated fast charging cycles, with a resistance increase of less than 5% after 300 cycles, far lower than pure aluminum conductors.

• Lightweight & High Strength: The density is only 44% of pure copper (3.94g/cm³), which greatly reduces the load of charging pile internal components and simplifies installation, while reducing logistics costs. The tensile strength is ≥ 180MPa (≥ 90MPa for soft state, ≥ 110MPa for hard state), the interface shear strength between copper and aluminum is ≥ 35MPa, which can withstand the vibration during transportation and installation, as well as the temperature difference caused by frequent charging and stopping, ensuring structural stability and avoiding loose connections. It also has good ductility and bendability, adapting to the internal layout of charging piles.

• Cost-Effective Solution: The price is about 50% of pure copper bars, while the current-carrying capacity reaches 85%-90% of pure copper (conductivity up to 85% IACS, 86% in standard state), which is in line with the “copper saving with aluminum” strategy. Choosing a slightly larger specification can fully achieve the same current-carrying capacity as pure copper bars. It can significantly reduce the overall cost of charging pile production without compromising performance, bringing greater economic benefits to customers, especially for large-scale charging station construction.

• Long Service Life & Low Maintenance: With tin plating (10-15μm) on the copper end to prevent oxidation, and excellent corrosion resistance (salt spray resistance ≥ 5000h), the service life in outdoor environments is ≥ 20 years. It is maintenance-free during operation, reducing the later operation and maintenance costs of charging piles and charging stations. The surface is as bright and smooth as pure copper, with strong oxidation resistance and corrosion resistance.

• Compliant with International Standards: Fully meets the requirements of IEC 61238, IEEE 837, GB/T 36103, DL/T 247-2012, GB/T 30586-2014 and other international and industry standards. The copper layer is made of T2 copper (copper content ≥ 99.90%) and the aluminum core is made of 1070 aluminum (aluminum content ≥ 99.70%), which has passed strict quality testing, ensuring compatibility with global charging pile systems (AC/DC, different power levels) and smooth customs clearance.

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Company Name: Xi’an Zipeng Machinery Technology Co., Ltd
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Country: China
Website: https://www.zpbusbar.com/