ALUMINIUM
Conductors
TABLE OF CONTENTS
The • ALUMINIUM AND ALUMINIUM ALLOYS WIRES
technical data ■ Aluminium wires..........................................................................................p 3
in this catalog • Hard aluminium
are given for • _hard aluminium
information • Other states
purposes and ■ Aluminium alloys wires for electrical uses.......................................................p 3
imply absolutely • Material composition
no commitment • Properties of the material
on our part, ■ Aluminium alloys wires for mechanical uses ...................................................p 6
• Material composition
except under • Properties of the material
the terms ■ The aluminium conductors for the overhead lines ............................................p 8
of a specific • The pure aluminium conductors (ACC)
agreement. • The bi-metallic conductors in aluminium and zinc coated steel (ACSR)
• The bi-metallic conductors in aluminium and aluminium clad steel (ACSR/AW)
• The conductors in aluminium alloy (AAAC)
• The bi-metallic conductors in aluminium alloy and zing coated steel (AACSR)
• The conductors in aluminium with aluminium alloy core (ACAR)
■ The aluminium conductors for insulated cables ...............................................p 8
■ The aluminium alloy conductors for insulated cables........................................p 9
■ Fine wires in aluminium alloy for flexible cables ...........................................p 10
• Material composition
• Properties of the material
2
ALUMINIUMCONDUCTORS
ALUMINIUM WIRES
They are at the root of many types of bare conductors for overhead lines and
conductors for insulated cables. According to the final product, several levels
of characteristics are proposed as :
• hard aluminium
• 3/4 hard aluminium
• aluminium under other states
Hard aluminium
Use of the bare conductors for the overhead lines. The main characteristics
required in the standards are given below :
Nominal diameter
over
(mm)
1,25
1,50
1,75
2,00
2,25
2,50
3,00
3,50
Minimum tensile stress
Maximum resistivity
at 20° C
(MPa)
200
195
190
185
180
175
170
165
160
(nΩ.m)
up to and including
(mm)
1,25
1,50
1,75
2,00
2,25
2,50
3,00
3,50
5,00
28,264
Main characteristics ( according EN et CEI 60889)
3/4 hard aluminium
It is the basic material for the usual insulated cables.The characteristics of this
intermediate state allow to perform on the conductor a compaction operation.
The mean characteristics extracted from the NF C31-122 are given for information purpose, the other specifications, national or international, are very
close.
Nominal diameter d
(mm)
1,06 ≤ d ≤ 1,32
1,40 ≤ d ≤ 1,60
1,70 ≤ d ≤ 2,00
2,12 ≤ d ≤ 2,50
2,65 ≤ d ≤ 3,00
3,15 ≤ d ≤ 3,55
3,75 ≤ d ≤ 4,00
4,25 ≤ d ≤ 5,00
Minimum
elongation on
200 mm
(%)
1
1,2
1,5
1,75
2
2,25
2,75
3,25
Tensile Stress
R
(MPa)
Maximum
resistivity at
20° C
(nΩ.m)
120 ≤ R ≤ 180
28,264
Main charactéristics according C31-122
Other states
Other metallurgical states ( full annealed, half hard, F9, F13, H14, H24 ...),
with intermediate properties for some specific applications, could be supplied
on request.
3
ALUMINIUM ALLOYS WIRES FOR ELECTRICAL USES
They are at the root of many types of bare conductors for overhead lines, messengers of insulated cables and armouring for optical ground wires. The use
established the designations : 6201, 6101, AGS, Almelec™ and Aldrey™.
The properties can differ slightly from one standard to another but remain, on
the whole, very close.
Material Composition
The types given below are extracted from EN 1715-2 Standard and from
EN 573-3 Standard with regard to the chemical composition :
Numerical
designation
Symbolic
designation
Content in main elements
(%)
Si
Fe
Mg Others
EN AW-6101
EN AW-EA1 MgSi
EN AW-6201
EN AW-EA1 Mg0,7Si
0,30
0,7
0,50
0,9
0,50
0,50
0,35
0,8
0,6
0,9
To see
EN 573-3
To see
EN 573-3
Composition of alloys (extract of EN 573-3)
Properties of the material
The material properties appear in the EN 50183 in which 6 types of alloys
(AL2 to AL7) are defined.
Type
Nominal
conductivity
(% IACS)
In order to
give optimal
properties, all
these alloys
are submitted
to a final
aging.
Depending
upon the final
use of the
alloy, it is possible to improve the electrical conductivity or the
mechanical
resistance .
AL2
52,5
AL3*
AL4
53,0
52,9
AL5
AL6
55,25
55,6
AU
57,5
Nominal
Minimum
Maximum
diameter
tensile stress
resistivity
over up to and of individual mean of of individual mean of
including wires
a lot
wires
a lot
2
2
(mm)
(mm) (N/mm ) (N/mm ) (nΩ.m)
(nΩ.m)
1,50
3,50
1,50
1,50
3,50
1,50
1,50
3,50
1,50
2,50
3,00
3,50
4,00
3,50
5,00
5,00
3,50
5,00
5,00
3,50
5,00
2,50
3,00
3,50
4,00
5,00
325
315
295
325
315
295
314
304
300
290
275
265
255
342
330
32,84
32,84
32,53
32,9
32,9
32,2
31,5
31,5
30,5
30,5
30,5
30,5
30,5
32,6
32,6
31,2
31,0
31,0
30,0
30,0
30,0
30,0
30,0
Extract of EN 50183
*Contrary to other alloys which require a wrapping test of 8 turns without
break around a mandrel of diameter equal to the wire diameter, this type of
alloy requires a wrapping test of 8 turns around a mandrel having the same
diameter as that of the wire. Six of these turns shall be wound off and then
wound on again. The wire shall not break.
Aldrey™ is a trade mark of Aluminium Suisse
Almelec™ is a trade mark of Aluminium Pechiney
4
ALUMINIUM ALLOYS WIRES FOR MECHANICAL USES
They are at the root of many uses in the field of the cold heading, armor devices for overhead conductors etc...
The properties can differ slightly from one standard to another but remain, on
the whole very close.
Material Composition
The types given below are extracted from EN 1301-2 Standard and EN 573-3 Standard with
regard to the chemical composition:
In order to give
optimal properties, all these
alloys are submitted to a final
aging.
Depending
upon the final
use of the alloy,
it is possible to
adjust the
mechanical
characteristics
of the alloy in
order to
improve, for
instance, the
behaviour
during the cold
working..
Numerical
designation
Symbolic
designation
Content in main elements
(%)
Si
Fe
Mg Others
EN AW-6060
EN AW-A1 MgSi
EN AW-6063
EN AW-A1 Mg0,7Si
0,30
0,6
0,20
0,6
0,10
0,30
0,35
0,35
0,6
0,45
0,9
To see
EN 573-3
To see
EN 573-3
Composition of alloys (Extract of EN 573-3)
Properties of the material
The material properties appear in the EN 1301-2 in which are shown some metallurgical conditions : T39, T4, T6, T89. The wires are produced only in the T89 condition, therefore an heat
treatment followed by a quenching, then a cold working and finally an aging.
Type
Minimum tensile stress
EN AW-6060
EN AW-6063
MPa
260
270
Extract ofe
EN 1301-2
5
THE ALUMINIUM CONDUCTORS FOR THE
OVERHEAD LINES
The conductors form the basic part of an overhead line because they have to carry the electrical
current. The lightness and the good conductivity of the aluminium imposed this metal as the basic
material.The physical and human geography promoted either of the main options : the homogeneous or the bi-metallic. Then the utility generally confirmed, by care of homogeneity, the initial
choice during the expansions of its networks.
The conductors for the bare overhead lines of the distribution and transport
networks are classified in six main families :
• the homogeneous conductors in pure aluminium (AAC)
• the bi-metallic conductors in aluminium and zinc coated steel (ACSR)
• the bi-metallic conductors in aluminium and aluminium-clad steel
(ACSR/AW)
• the homogeneous conductors in aluminium alloy (AAAC)
• the bi-metallic conductors in aluminium alloy and zinc coated steel
(AACSR)
• The bi-metallic conductor in aluminium and aluminium alloy (ACAR)
The pure aluminium conductors (AAC)
They are generally used in small sizes (section) because their mechanical characteristics are not so good for bigger sizes except for the bus-bars and the
straps.
These conductors are standardized in the main countries and by the main
organizations as :
International
Standard CEI 61089
Europe
UK
Germany
prEN50182* BS 215 Part1
USA
DIN48203 T5 ASTM B231
Canada
CSA C49.4
The bi-metallic conductors in aluminium and zinc coated steel (ACSR)
These bi-metallic conductors are used worldwide. The option to change the steel/aluminium ratio
allows for various applications. These conductors are standardized in the main countries and by
the main organizations as :
International Europe
Standard CEI 61089
UK
prEN50182* BS 215 Part 2
Germany
USA
Canada
DIN 48204 ASTM B232 CSA 49.1M87 C 34-120
The bi-metallic conductors in aluminium and aluminium-clad steel
(ACSR/AW)
The aluminium cladding of the steel wires provides a first-rate protection
against corrosion whilst allowing an improvement in the electrical conductivity
of these wires. These conductors are standardized in the main countries and
by the main organizations as :
International
Standard
CEI 61089
Europe
prEN50182*
*PrEN50182 : Draft in discussion at european level.
6
France
USA
ASTM B549
The conductors in aluminium alloy (AAAC)
These homogeneous conductors in aluminium alloy show many advantages i.e lightness, high
breaking load allowing long spans, simplificity of the accessories and lastly easy recycling. These
conductors are suitable for the long spans network. These conductors are standardized in the
main countries and by the main organizations as :
International Europe
Standard CEI 61089
UK
prEN50182* BS 3242
Germany
USA
Canada
France
DIN 48203 T6 ASTM B399 CSA 49.1M87 C 34-125
The bi-metallic conductors in aluminium alloy and zinc coated
steel (AACSR)
These bi-metallic conductors are recommended in the hard climatic environments or for river crossings. These conductors are standardized in the main
countries and by the main organizations as :
Standard
International
Europe
Germany
CEI 61089
prEN50182* DIN 48206
USA
ASTM B711
Canada
CSA 49.1M87 C 34-125
The conductors in aluminium with aluminium alloy core
(ACAR)
These conductors combine the properties of the aluminium with those of the
aluminium alloy. In changing the relative ratio of the two materials, it is possible to reach a lot of designs.These conductors, not so popular as the previous
ones, are standardized in the countries as following :
The conductors
range is substantial and
International Europe
USA
Canada
Nexans is able
to propose the Standard CEI 61089 prEN50182* ASTM B524 CSA 49.1M87
suitable way. *PrEN50182 : Draft in discussion at european level.
7
France
THE ALUMINIUM CONDUCTORS FOR INSULATED CABLES
The lightness and good conductivity of the aluminium imposed this metal as
the basic material, specially in the field of overhead insulated cables.
These conductors for the cables are standardized in the main countries and by
the main organizations as :
Standard
International
CEI 228
France
UK
NFC32-013 BS 6360
Germany
DIN VDE 0295
Spain
UNE 21022
The cores can be delivered compacted or noncompacted, circular or sectoral.
The compacting operation allows for a smooth surface conductor, to reduce
the outer diameter and therefore to decrease the insulating material quantity.
The table below, from the IEC228, gives the sizes of the most usual of the
stranded cores of class 2.
Minimum number
Nominal section of strands of the conductor
(mm2)
circular
circular
noncompacted compacted
16
25
35
50
70
95
120
150
185
240
300
400
500
630
800
1000
7
7
7
19
19
19
37
37
37
61
61
61
61
91
91
91
6
6
6
6
12
15
15
15
30
30
30
53
53
53
53
53
The sizes 95,150
and 240 mm2
can be delivered
as sectoral
stranded form.
For other sizes,
please *given for information
contact us. Main characteristics of conductors from IEC228.
Max resistance
at 20°C
(Ω/km)
Linear mass of the
compacted conductor*
(kg/km)
1,91
1,20
0,868
0,641
0,443
0,320
0,253
0,206
0,164
0,125
0,100
0,0778
0,0605
0,0469
0,0367
0,0291
41
64
89
121
174
245
300
385
475
645
790
1030
1300
1690
2170
2700
THE ALUMINIUM ALLOY CONDUCTORS FOR
INSULATED CABLES
The lightness and mechanical resistance of the aluminium alloy imposed this
material, specially for the messenger, in the field of overhead insulated cables.
The cores are standardized in the countries using this technology as:
Standard
France
Belgium
Spain
NF C33-209
NBN C33-321
UNE 21030
The conductors are generally delivered cicular, compacted. The table below, from
The technical C33-209, gives the most usual sizes of the stranded cores, circular and compacted.
services of
Nexans are able
Nominal
Number of
Max. resistance of
Min.breaking
section
strands of the core
the core at 20°C
load
to propose other
2
(mm )
(Ω/km)
(daN)
sizes, not included in these
54,6
7
0,63
1660
70
7
0,50
2050
mentionned
95
19
0,343
2750
standards.
Main characteristics of the core from C33-209
9
FINE WIRES IN ALUMINIUM ALLOY FOR
FLEXIBLES CABLES
They are at the root of cores of flexible cables for energy and soldering purposes. The use established the old designation: A4-G/L for the aluminium alloy
Material composition
The composition given below is given for information only because this alloy is
not standardized at the European level.
The usual
diameter is
0,51 mm, but
other
diameters
could be
produced on
request.
This alloy is
the basic
material of the
nickel plated
aluminium
alloy for
transport
applications.
Symbolic
designation
A4-G/L
Content in main elements
(%)
Si
Fe
Mg
Others
0,50
0,08
according to
0,10
0,80
0,25
specific standard
Properties of the material
The material properties are linked to the transformation process.
The following characteristics are given for a 0.50 mm wire diameter which the
elongation at fracture is equal to 10 % .
Tensile
stress
maximum
resistivity
(N/mm2)
(nΩ.m)
140/160
28,20
10
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Conductors
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