Choosing the right aluminium strip for transformer windings is essential for ensuring the efficiency, longevity, and safety of your transformer. The right strip helps maintain electrical conductivity, prevents insulation damage, and ensures smooth, trouble-free winding. In this guide, we’ll explain the key factors you need to consider when selecting aluminium strip for your transformer project.

 Determine the Aluminium Alloy

The most commonly used aluminium alloys for transformer winding are:

• 1060-O – Standard, soft aluminium with excellent conductivity (≥61% IACS). Ideal for low-to-medium voltage applications.
• 1350-O – Higher purity aluminium, offering improved electrical conductivity, suitable for high-efficiency transformers.

For most transformer applications, 1060-O and 1350-O alloys are optimal, offering a balance between cost, performance, and availability.

 Choose the Right Thickness

The thickness of the aluminium strip directly impacts its electrical and mechanical properties. The strip needs to be thick enough to handle the electrical load but not so thick as to cause inefficiencies. Common thicknesses for transformer aluminium strips range from:

• 0.2 mm to 2.0 mm for distribution transformers
• 2.0 mm to 3.0 mm for power transformers

Be sure to choose a thickness that aligns with the transformer's voltage class and capacity. Our aluminium strip is available in precise thickness tolerances to match your project needs.

Decide on the Edge Type

The edge of the aluminium strip plays a crucial role in transformer winding efficiency and insulation protection. Choose from the following edge types:

• Deburred Edges – Smooth, sharp-edge removal, preventing damage to insulation paper during winding and ensuring better handling.
• Round Edges – Rolled edges for smoother winding and extra insulation protection, preventing short circuits.
• Flat Edges – Suitable for certain secondary applications, often requiring further processing.

Deburred and rounded edges are often preferred for safety and efficiency in winding processes.

 Select the Insulation Type

Choosing the right insulation for your aluminium strip ensures safe and efficient operation of the transformer. Common insulation options include:

• Kraft Paper – Low-cost, natural cellulose-based insulation, offering basic heat resistance up to 105°C.
• NOMEX® – High-performance aramid paper insulation for Class H (180°C) applications, providing superior thermal and electrical performance.
• Epoxy Coating – Provides enhanced insulation for dry-type transformers, offering moisture resistance and stronger adhesion.

We offer these insulation options depending on your transformer type, voltage class, and environmental conditions. Choose insulation that matches your project’s temperature class and durability requirements.

 Consider Winding Machine Compatibility

Ensure that the aluminium strip you select is compatible with your winding machines. Different machines may have specific requirements regarding strip thickness, edge type, and flexibility. Our aluminium strip is designed to work seamlessly with both manual and automatic winding machines, offering consistent quality and ease of use.

 Quantity and Customization

Many projects require custom widths and lengths of aluminium strip. Our aluminium strips are available in a wide range of custom sizes to suit your specific winding requirements. Whether you need small batches for prototype transformers or large-scale orders for mass production, we can accommodate your needs with flexible MOQ and timely delivery.

Conclusion: Choosing the Right Aluminium Strip

When choosing aluminium strip for your transformer project, it's essential to consider alloy type, thickness, edge type, insulation, and machine compatibility. By selecting the right materials, you can optimize transformer efficiency and reliability.