ALUMINIUM. Conductors

ALUMINIUM

TABLE OF CONTENTS

•

ALUMINIUM AND ALUMINIUM ALLOYS WIRES

■Aluminium wires...p 3 • Hard aluminium

• _hard aluminium • Other states

■Aluminium alloys wires for electrical uses...p 3 • Material composition

• Properties of the material

■Aluminium alloys wires for mechanical uses ...p 6 • Material composition

• Properties of the material

■The aluminium conductors for the overhead lines ...p 8 • The pure aluminium conductors (ACC)

• 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

The

technical data

in this catalog

are given for

information

purposes and

imply absolutely

no commitment

on our part,

except under

the terms

of a specific

agreement.

ALUMINIUM

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 Minimum tensile stress Maximum resistivity at 20° C over up to and including

(mm) (mm) (MPa) (nΩ.m) - 1,25 200 1,25 1,50 195 1,50 1,75 190 1,75 2,00 185 28,264 2,00 2,25 180 2,25 2,50 175 2,50 3,00 170 3,00 3,50 165 3,50 5,00 160

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 infor-mation purpose, the other specifications, national or international, are very close.

Minimum Tensile Stress Maximum Nominal diameter d elongation on R resistivity at

200 mm (MPa) 20° C (mm) (%) (nΩ.m) 1,06≤ d ≤1,32 1 1,40≤ d ≤1,60 1,2 1,70≤ d ≤2,00 1,5 2,12≤ d ≤2,50 1,75 120 ≤R ≤180 28,264 2,65≤ d ≤3,00 2 3,15≤ d ≤3,55 2,25 3,75≤ d ≤4,00 2,75 4,25≤ d ≤5,00 3,25 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.

ALUMINIUM ALLOYS WIRES FOR ELECTRICAL USES

They are at the root of many types of bare conductors for overhead lines, mes-sengers 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

Symbolic

Content in main elements

designation designation

(%)

Si

Fe

Mg

Others

EN AW-6101 EN AW-EA1 MgSi 0,30 0,35 To see 0,7 0,50 0,8 EN 573-3 EN AW-6201 EN AW-EA1 Mg0,7Si 0,50 0,6 To see

0,9 0,50 0,9 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.

Nominal Nominal Minimum Maximum Type conducti- diameter tensile stress resistivity

vity over up to and of individual mean of of individual mean of including wires a lot wires a lot (% IACS) (mm) (mm) (N/mm2_{) (N/mm}2_{) (nΩ.m) (nΩ.m)} AL2 52,5 1,50 3,50 325 32,84 3,50 5,00 315 32,84 AL3* 53,0 1,50 5,00 295 32,53 AL4 52,9 1,50 3,50 325 342 32,9 32,6 3,50 5,00 315 330 32,9 32,6 AL5 55,25 1,50 5,00 295 32,2 31,2 AL6 55,6 1,50 3,50 314 31,5 31,0 3,50 5,00 304 31,5 31,0 AU 57,5 1,50 2,50 300 30,5 30,0 2,50 3,00 290 30,5 30,0 3,00 3,50 275 30,5 30,0 3,50 4,00 265 30,5 30,0 4,00 5,00 255 30,5 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

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

pos-sible to

impro-ve the

electri-cal

conductivi-ty or the

mechanical

resistance .

ALUMINIUM ALLOYS WIRES FOR MECHANICAL USES

They are at the root of many uses in the field of the cold heading, armor devi-ces 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:

Numerical Symbolic Content in main elements

designation designation (%)

Si Fe Mg Others EN AW-6060 EN AW-A1 MgSi 0,30 0,10 0,35 To see

0,6 0,30 0,6 EN 573-3 EN AW-6063 EN AW-A1 Mg0,7Si 0,20 0,45 To see

0,6 0,35 0,9 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 condi-tions : 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 MPa EN AW-6060 260 EN AW-6063 270 Extract ofe EN 1301-2

In order to give

optimal

proper-ties, all these

alloys are

sub-mitted 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..

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 homoge-neous 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 cha-racteristics 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 Europe U K Germany USA Canada Standard CEI 61089 prEN50182* BS 215 Part1 DIN48203 T5 ASTM B231 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 UK Germany USA Canada France Standard CEI 61089 prEN50182* BS 215 Part 2 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 Europe USA

Standard CEI 61089 prEN50182* ASTM B549 *PrEN50182 : Draft in discussion at european level.

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 UK Germany USA Canada France Standard CEI 61089 prEN50182* BS 3242 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 environ-ments or for river crossings. These conductors are standardized in the main countries and by the main organizations as :

International Europe Germany USA Canada France Standard CEI 61089 prEN50182* DIN 48206 ASTM B711 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 possi-ble to reach a lot of designs.These conductors, not so popular as the previous ones, are standardized in the countries as following :

International Europe USA Canada Standard CEI 61089 prEN50182* ASTM B524 CSA 49.1M87 *PrEN50182 : Draft in discussion at european level.

The conductors

range is

sub-stantial and

Nexans is able

to propose the

suitable way.

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 :

International

France

UK

Germany Spain

Standard

CEI 228

NFC32-013 BS 6360

DIN VDE 0295 UNE 21022

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 Max resistance Linear mass of the Nominal section of strands of the conductor at 20°C compacted conductor*

(mm2_{) circular circular (}Ω_{/km) (kg/km)} noncompacted compacted 16 7 6 1,91 41 25 7 6 1,20 64 35 7 6 0,868 89 50 19 6 0,641 121 70 19 12 0,443 174 95 19 15 0,320 245 120 37 15 0,253 300 150 37 15 0,206 385 185 37 30 0,164 475 240 61 30 0,125 645 300 61 30 0,100 790 400 61 53 0,0778 1030 500 61 53 0,0605 1300 630 91 53 0,0469 1690 800 91 53 0,0367 2170 1000 91 53 0,0291 2700

*given for information

Main characteristics of conductors from IEC228.

The sizes 95,150

and 240 mm

can be delivered

as sectoral

stranded form.

For other sizes,

please

contact us.

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:

France Belgium Spain

Standard NF C33-209 NBN C33-321 UNE 21030

The conductors are generally delivered cicular, compacted. The table below, from C33-209, gives the most usual sizes of the stranded cores, circular and compacted.

Nominal Number of Max. resistance of Min.breaking section strands of the core the core at 20°C load

(mm2₎

₍

₍

54,6 7 0,63 1660

70 7 0,50 2050

95 19 0,343 2750

Main characteristics of the core from C33-209

The technical

services of

Nexans are able

to propose other

sizes, not

inclu-ded in these

mentionned

standards.

FINE WIRES IN ALUMINIUM ALLOY FOR

FLEXIBLES CABLES

They are at the root of cores of flexible cables for energy and soldering purpo-ses. 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.

Symbolic

Content in main elements

designation

(%)

Si

Fe

Mg

Others

A4-G/L - 0,50 0,08

according to

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 maximum

stress

resistivity

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.

édit photo : Digital Stock.

Conductors

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