Enameled Aluminum Wire
E91E vs 6061 & 1350 Busbar
Choosing the right aluminum alloy for electrical busbars is critical to ensure long-term performance, efficiency, and cost-effectiveness. Among available options, E91E aluminum busbars produced by Xinyi offer a high-conductivity, mechanically stable, and application-ready solution. How does E91E compare with well-known grades like 6061 and 1350? This article breaks down the key differences to help you make an informed decision.
Overview of the Three Grades
- E91E: High-conductivity aluminum alloy designed specifically for busbars. IACS conductivity ≥ 61.5%, with good mechanical formability and stable structure.
- 6061: A structural aluminum alloy with excellent mechanical strength, commonly used in construction and mechanical parts. IACS conductivity around 40-43%.
- 1350: A commercially pure aluminum grade, typically ≥ 61% IACS conductivity, used for overhead lines and electrical conductors. Softer and less durable than E91E.
Conductivity Comparison
For applications where current carrying capacity is a priority, conductivity is a decisive factor. Here's how the grades stack up:
| Alloy | Conductivity (% IACS) | Typical Use |
|---|---|---|
| E91E | ≥ 61.5% | Power systems, switchgear, transformers |
| 6061 | ~43% | Structures, frames, mechanical support |
| 1350 | ≥ 61% | Overhead conductors, simple busbars |
Mechanical Strength and Processing
While 6061 is the strongest mechanically, E91E strikes a balance by offering sufficient yield strength while maintaining excellent conductivity. 1350 is softer, which can be a limitation in structural or bolted busbar systems.
- 6061: Very strong and machinable, but poor conductivity
- E91E: Moderate strength, good punching and bending performance
- 1350: Ductile but low in mechanical integrity, prone to deformation
Application Suitability
When it comes to electrical systems integration, E91E offers the best all-around performance for applications such as:
- Low and medium voltage switchgear
- EV battery connections and BESS
- Cast resin transformers
- Solar inverter and combiner box assemblies
1350 may still be viable for simple overhead transmission or budget-focused busbar installations. 6061, while strong, lacks the electrical efficiency required for most high-current paths.
Why Choose E91E from Xinyi?
Xinyi's E91E aluminum busbars are engineered to meet the dual demands of high conductivity and manageable mechanical strength. With tighter dimensional tolerances, surface finishing options, and custom fabrication, they provide an ideal alternative to older grades for modern power solutions.
Request a Comparison Sample Today
Still deciding between E91E and other alloys? Contact Xinyi to request technical datasheets, cost comparisons, or physical samples of our busbar products. Our team is ready to help you specify the right material for your system.
