Hydro manufactures extruded aluminium busbars, tubular conductors, and flat wire profiles for OEMs and panel builders. Aluminium offers strong electrical conductivity at roughly half the weight of copper, with built-in corrosion resistance and full recyclability.
Hydro supplies aluminium conductor solutions for OEMs, panel builders and electrical equipment manufacturers, including busbars, tubular conductors and flat wire.
Specifications can be configured around alloy and temper, conductivity targets measured in % IACS, dimensions, delivery lengths, surface finish, tolerances and packaging. Hydro can also support cutting, drilling, punching, bending, machining and assembly to simplify installation.
Many conductor solutions are based on extruded aluminium profiles, allowing electrical performance and mechanical function to be designed together. An extruded busbar or tubular conductor can be adapted to the geometry, surface area and connection points of the equipment.
Hydro manufactures busbars and aluminium conductor profiles across multiple countries, in both Europe and North America.
For many busbar and conductor applications, aluminium offers a practical alternative to copper. The decision to substitute depends on current requirements, connection design, available space, and total cost of ownership. Hydro helps OEMs and panel builders evaluate the switch and design aluminium conductor solutions that meet their electrical and mechanical targets.
| Point to evaluate | What to consider |
|---|---|
| Electrical sizing | Aluminium is less conductive than copper by volume, so an aluminium busbar normally needs a larger cross-section for the same current rating. This should be checked early in space-constrained cabinets, switchgear and enclosures. |
| Weight | Even with a larger cross-section, aluminium conductors are typically much lighter than copper equivalents. This can reduce load on support structures and simplify handling and installation. |
| Thermal performance | Aluminium conducts heat efficiently, helping temperature differences equalize across the profile. Hollow or extruded busbar designs can also increase surface area and support heat dissipation in enclosed spaces. |
| Connection design | Aluminium-to-aluminium and aluminium-to-copper joints require correct surface preparation, hardware and torque values. This is often the most important engineering point in substitution projects, and Hydro can advise on joint design. |
| Fabrication | Aluminium busbars and conductor profiles can be cut, drilled, punched, machined, bent and supplied in customer-specific lengths or kits. Bending and forming depend on the right alloy, temper and bend radius. |
| Corrosion resistance | Aluminium forms a natural oxide layer that protects the surface in many indoor electrical environments. For outdoor or more demanding environments, surface treatment or coatings may be specified. |
| Cost | Aluminium is typically less expensive per kilogram than copper, but the final business case depends on the full system design, including profile size, joints, supports, fabrication and installation. |
| Recyclability | Aluminium is fully recyclable without loss of material properties, supporting circular material flows and lower-carbon product design. |
Aluminium is not a direct like-for-like replacement for copper in every design. The right choice depends on available space, current rating, connection design, installation requirements and total system cost.
...when weight reduction is a priority, the application allows a larger cross-section, you want to reduce exposure to copper price volatility, or your sustainability targets favor recyclable materials.
...when space is severely constrained and the larger aluminium cross-section will not fit, or when your assembly process and joint design are already optimized for copper and the cost of re-engineering outweighs the material savings.
...when the trade-offs are not clear for your specific application. We can help model the sizing, review connection design, and recommend suitable alloys and tempers.
Aluminium busbars, tubular conductors and flat wire are used in electrical systems where current carrying capacity, weight, thermal performance and efficient assembly are important design factors.
Alloy selection is important for aluminium busbars, tubular conductors and other extruded electrical conductor profiles. The right alloy depends on the required balance between electrical conductivity, mechanical strength, formability, contact performance and extrusion efficiency.
High-purity 1xxx aluminium alloys, such as EN AW-1050 and EN AW-1370, are used where electrical conductivity and low weight are the main priorities. These alloys offer high aluminium purity and good corrosion resistance, and can be extruded into profiles, rods, bars and tubes for conductor applications.
For applications that also require higher strength or improved contact performance, EN AW-6101A/B can be a good option. This Al-Mg-Si alloy has slightly lower conductivity than 1xxx alloys, but offers a stronger balance of conductivity, mechanical performance and manufacturability.
Compared with Cu-ETP R220 copper, aluminium conductor alloys have lower conductivity by volume but much lower density. In practice, this means an aluminium busbar usually needs a larger cross-section than copper for the same current rating, but the finished conductor can be significantly lighter.
| Alloy / material | Typical role in conductor applications |
|---|---|
| EN AW-1370-H112 | High-conductivity aluminium alloy for busbars and conductor profiles |
| EN AW-6101-T7 | Balanced conductivity, strength and contact properties |
| EN AW-6101-T6 | Higher strength option where mechanical performance is important |
| Cu-ETP R220 | Copper reference material with high conductivity but higher density |
Hydro can help select the right aluminium conductor alloy and temper based on conductivity targets, profile geometry, mechanical requirements and production needs.
An aluminium busbar is an extruded conductor profile used to distribute electrical current in switchgear, distribution boards, and power systems. Busbars are available as solid bars, tubular conductors, or flat wire profiles.
Busbars are commonly made from copper or aluminium. Aluminium busbars offer roughly half the weight of copper at equivalent conductivity, with strong corrosion resistance and full recyclability. Common aluminium alloys for busbars include those in the 1xxx series (high conductivity) and 6xxx series (higher strength).
In many applications, yes. Aluminium busbars are widely used in switchgear, panels, and power distribution as a lighter, cost-effective alternative to copper. The busbar cross-section is typically larger, but weight and material cost are lower. Joint design and surface preparation need to be adapted for aluminium. Hydro can help you evaluate whether substitution fits your application.
Aluminium reduces weight by roughly 50%, is fully recyclable, and is typically more cost-stable than copper. Extruded aluminium profiles can be optimized for thermal performance in enclosed spaces. Final sizing depends on current rating, temperature rise, and connection method.
Yes. With the right alloy and temper, aluminium busbars can be bent without cracking. See our guide to the best aluminium alloys for bending.
Yes. Alloy, temper, dimensions, and delivery length are specified per project. Share your requirements and we will confirm availability and options.
A tubular busbar is a hollow aluminium conductor profile that offers improved stiffness-to-weight and heat dissipation compared to solid bars. Tubular conductors are used where mechanical layout or thermal requirements favor a hollow cross-section.
