Product Overview
Enameled flat aluminum wire is a lightweight, cost-effective alternative to copper magnet wire, manufactured by coating high-purity electrical aluminum (JIS C3003/1350/E-Al99.7) flat conductor with 5–13 layers of insulating varnish, cured at 350–420℃. It offers excellent electrical conductivity, thermal stability and mechanical strength at only 1/3 the weight of copper, making it ideal for cost-sensitive applications such as distribution transformers, compressor motors, traction motors and high-voltage coils.
JWHK has over 30 years of experience in aluminum magnet wire production, with advanced eddy current inspection technology ensuring zero internal defects.
Complete Product Specifications
|
Grade |
Temperature Index |
Size Range |
Core Properties |
Primary Applications |
Compliance Standards |
|
PVF Flat Aluminum Wire |
Class 120 (E) |
Thickness: 1.80–5.60mm |
Excellent transformer oil resistance, scratch resistance, flexibility and hydrolysis resistance |
Oil-immersed distribution transformers, general industrial motors |
IEC 60317, NEMA MW1000, JIS C3202, GB/T7095 |
|
EIW Flat Aluminum Wire |
Class 180 (H) |
Same as above |
Superior heat resistance, solvent resistance and thermal shock resistance |
H-class motors, dry-type transformers |
IEC 60317 |
|
EI/AIW Flat Aluminum Wire |
Class 200 (C) |
Same as above |
Outstanding refrigerant, solvent and radiation resistance |
Sealed refrigeration compressors, high-temperature coils |
IEC 60317 |
Key Technical Indicators:
- Aluminum purity: ≥99.7%
- Conductivity: ≥61% IACS
- Insulation breakdown voltage: ≥4kV/0.1mm
- Bend radius: ≥8× wire thickness (no cracking)
- Batch CPK: ≥1.30
Core Advantages
1. Lightweight & Cost-Effective
- Weight: Only 30% of copper wire with the same conductivity
- Cost: 30–50% lower than copper wire (fluctuates with LME prices)
- Application Benefit: Reduces equipment overall weight and transportation cost, especially for large transformers and motors
2. Full Customization Options
- Size: Custom thickness, width and cross-section area within the production range
- Surface Finish: Glossy or frosted
- Insulation Color: Red, green, blue, black and other custom colors
- Temper: Soft or half-hard according to your requirements
3. Advanced Eddy Current Defect Detection
- Real-time monitoring of internal and surface defects (cracks, scratches, burrs)
- Automatic alarm and shutdown when defects are detected
- Closed-loop control from detection to repair, ensuring zero defective products
- Water-soluble lubricants and diamond dies reduce false alarms and improve detection stability
Advanced Manufacturing Process (Full Quantified Version)
Stage 1: Bare Flat Aluminum Wire Preparation
1. Raw Material Preparation
￮ Material Grade: JIS C3003, 1350, E-Al99.7 high-purity electrical aluminum
￮ Quality Control: Chemical composition and mechanical property testing per batch; unqualified ingots are rejected
2. Extrusion Process
￮ Core Equipment: 800-ton aluminum extruder
￮ Key Parameters: Heating temperature 400–500℃, extrusion pressure 500–800MPa, water/air forced cooling
￮ Quality Control: Uniform surface quality and stable mechanical properties via precise temperature control
3. Multi-Stage Wire Drawing Process
￮ Core Equipment: 6-block aluminum wire drawing machine (equipped with tungsten carbide dies)
￮ Key Parameters: Single-pass reduction rate 10–20%, drawing speed 150–400m/min
￮ Process Details: Water-soluble lubricant to reduce friction and surface defects; online diameter measurement ±1μm accuracy
4. Annealing Process (Critical for Aluminum Wire)
￮ Core Equipment: Continuous annealing furnace
￮ Key Parameters: Annealing temperature 360–400℃, holding time 3–5 seconds, controlled cooling rate
￮ Performance Benefit: Releases internal stress, improves flexibility; bend radius ≥8× wire thickness (no cracking)
Stage 2: Eddy Current Defect Detection System (Exclusive for Aluminum Wire)
￮ Core Principle: Eddy current probe continuously excites and monitors signal changes; defects cause signal imbalance
￮ Detectable Defects: Internal cracks, surface scratches, dirt, burrs and inclusions
￮ Three-Layer Control:
Real-time monitoring and automatic shutdown when defects are detected
Process optimization: Water-soluble lubricants + diamond dies to reduce false alarms
Closed-loop control: Detection → Alarm → Shutdown → Repair → Automatic resumption
￮ Quality Guarantee: Zero internal defects in finished products
Stage 3: Enameling Process (Austrian MAG Aluminum-Specific Line)
￮ Key Parameters: 5–13 varnish coats, curing temperature 320–380℃ (lower than copper to avoid oxidation), line speed 80–250m/min
￮ Environmental Advantage: Effective control of waste gas, water and solid waste emissions; meets ISO 14001 standards
￮ Quality Control: Insulation flexibility and breakdown voltage testing every 20 minutes
Stage 4: Final Testing & Packaging
￮ Full performance testing per batch
￮ Anti-static reels + moisture-proof packaging for export
Order Fulfillment Timeline (MOQ=1 Ton)
|
Stage |
Duration |
|
Order Confirmation |
1 Business Day |
|
Raw Material Preparation |
3–4 Business Days |
|
Production |
10–14 Business Days |
|
Quality Inspection |
2 Business Days |
|
Packaging |
1 Business Day |
|
Logistics |
3–30 Business Days |
- Total Lead Time: 2–4 weeks for standard orders.
Packing & Shipping
- Spools: Anti-static reels, wooden spools
- Outer Packaging: Moisture-proof plastic film + cushioning foam + IPPC wooden pallets/crates
- Shipping: Sea, air, land; global delivery
Frequently Asked Questions
Q: What is your MOQ?
A: Standard MOQ is 1 ton.
Q: Can aluminum wire replace copper wire in all applications?
A: Aluminum wire is ideal for cost-sensitive, low-to-medium power applications where weight is a concern. For high-efficiency, high-power density applications (such as EV motors), copper wire is still recommended. Our engineers can help you choose the right material based on your specific requirements.
Q: What is the shelf life of enameled aluminum wire?
A: 12 months when stored in a dry, cool environment.
Q: Do you provide OEM service?
A: Yes, we can customize labels, packaging and spool sizes according to your requirements.
Contact Us
Tianjin Jingwei Power Technology Co., Ltd.
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