Choosing the right conductor material for power distribution systems is crucial for ensuring long-term efficiency and reliability. While copper has traditionally dominated the busbar market, advanced aluminum alloys such as E91E aluminum busbar offer a compelling alternative. Supplied by Xinyi, E91E aluminum busbars combine high conductivity with cost-effectiveness, making them increasingly popular across industries.

Electrical Conductivity: Narrowing the Gap

Copper is widely known for its excellent conductivity, with a standard value of 100% IACS. E91E aluminum achieves ≥61.5% IACS, making it a high-performance aluminum conductor. While slightly lower than copper in raw conductivity, E91E's larger cross-sectional area can compensate for this difference in practical applications.

Weight Advantages in Large Installations

Copper is heavy and adds significant load to electrical enclosures, supports, and transport logistics. E91E aluminum weighs roughly one-third as much, which reduces overall system weight, improves installation flexibility, and lowers transportation costs—especially in high-volume or elevated installations.

Cost Comparison: Aluminum’s Strong Advantage

The global price of copper remains significantly higher than aluminum. E91E offers a more economical solution, especially when large quantities of busbar material are required. Even when larger dimensions are needed to match copper’s conductivity, the total cost—including material, processing, and logistics—is generally 30–50% lower with E91E.

Mechanical and Thermal Performance

E91E aluminum busbars provide excellent thermal conductivity and are highly resistant to deformation under electrical load. With proper surface treatment such as tin plating, their contact resistance is minimized, making them suitable even for demanding applications like switchgear, transformers, and EV battery systems.

Corrosion Protection and Surface Finishing

Xinyi supplies E91E busbars with optional coatings including anodizing, tin plating, and PVDF film. These treatments protect against corrosion and oxidation while improving contact reliability—giving aluminum busbars longevity comparable to copper in controlled environments.

Eco-Friendly and Sustainable

Aluminum has a smaller environmental footprint than copper, both in mining and recycling. E91E busbars are fully recyclable and align with green energy goals, making them ideal for solar, wind, and EV infrastructure projects where sustainability matters.

 A Smarter Choice with Xinyi

While copper still has its place in some high-performance applications, E91E aluminum busbars from Xinyi offer a lighter, more economical, and environmentally friendly alternative. For projects seeking performance without overspending, E91E delivers proven value backed by Xinyi’s rigorous quality standards.