ALUMINIUM. Conductors

ALUMINIUM Conductors

TABLE OF CONTENTS The ALUMINIUM AND ALUMINIUM ALLOYS WIRES technical data Aluminium wires...p 3 in this catalog Hard aluminium are given for _hard aluminium information Other states purposes and Aluminium alloys wires for electrical uses...p 3 imply absolutely Material composition Properties of the material no commitment on our part, Aluminium alloys wires for mechanical uses...p 6 Material composition except under Properties of the material the terms The aluminium conductors for the overhead lines...p 8 of a specific The pure aluminium conductors (ACC) agreement. 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 2

ALUMINIUM CONDUCTORS 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 information 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. 3

ALUMINIUM ALLOYS WIRES FOR ELECTRICAL USES They are at the root of many types of bare conductors for overhead lines, messengers 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. 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 possible to improve the electrical conductivity or the mechanical resistance. 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/mm 2 ) (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 4

ALUMINIUM ALLOYS WIRES FOR MECHANICAL USES They are at the root of many uses in the field of the cold heading, armor devices 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: 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 possible to adjust the mechanical characteristics of the alloy in order to improve, for instance, the behaviour during the cold working.. 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 conditions : 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 5

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 homogeneous 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 characteristics 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. 6

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 environments 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 range is substantial and Nexans is able to propose the suitable way. 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 possible 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. 7

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 cores can be delivered compacted or noncompacted, circular or sectoral. 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. The sizes 95,150 and 240 mm 2 can be delivered as sectoral stranded form. For other sizes, please contact us. Minimum number Max resistance Linear mass of the Nominal section of strands of the conductor at 20 C compacted conductor* (mm 2 ) 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 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 technical services of Nexans are able to propose other sizes, not included in these mentionned standards. 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 (mm 2 ) (Ω/km) (dan) 54,6 7 0,63 1660 70 7 0,50 2050 95 19 0,343 2750 Main characteristics of the core from C33-209 9

FINE WIRES IN ALUMINIUM ALLOY FOR FLEXIBLES CABLES 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. They are at the root of cores of flexible cables for energy and soldering purposes. 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 0,10 0,80 0,25 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 stress (N/mm 2 ) maximum resistivity (nω.m) 140/160 28,20 10

Conductors 72, avenue de la Liberté F-92723 NANTERRE CEDEX Tel.: 01 55 51 51 51 - Fax: 01 55 51 55 51 Chauny 128, avenue Jean Jaurès F-02300 CHAUNY Tel.: 03 23 38 69 00 - Fax: 03 23 38 69 50 Lens 36, rue de Londres - BP 29 - F-62301 LENS CEDEX Tel.: 03 21 77 30 30 - Fax: 03 21 28 82 75 Bramsche Engterstraße 34 D-49565 Bramsche Tel.: (0) 54 61/8 00-0 - Fax: (0) 54 61/30 17 Neunburg Äußere Neukirchner Straße 1 D-92431 Neunburg vorm Wald Tel.: (0) 96 72/5 09-0 - Fax: (0) 96 72/5 09 26 Normanton Good Hope Close, Normanton Industrial Estate, Normanton, West Yorkshire WF6 1TR England. Tel.: 01924 223744 - Fax: 01924 220098 RC Nanterre 321165052 - March 2000 - crédit photo : Digital Stock.