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#Automotive
AMAG TopConduct for High-Performance Busbars
Electrification is transforming mobility and infrastructure, creating unprecedented demand for advanced power distribution solutions. Applications such as charging infrastructure, battery and energy storage systems, data centres, and electric vehicles require reliable, high-performance electrical distribution. Busbars play a central role as key components in power distribution: they must reliably carry high currents, ensure long-term performance and reliability and meet increasingly stringent cost and design requirements.
AMAG Austria Metall AG combines extensive materials expertise with advanced manufacturing capabilities to develop and produce high-quality aluminium solutions for demanding applications. With AMAG TopConduct, AMAG develops and produces rolled aluminium semi-finished products for high-performance busbars that are precisely tailored to the specific requirements of modern power distribution applications.
Advantages of AMAG TopConduct
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AMAG TopConduct vs. Copper
Copper has traditionally been the reference material for electrical applications. However, in many high-current applications, it has already been successfully replaced by aluminium, particularly where weight, cost, and sustainability are key deciding factors.
Significant weight reduction of aluminium compared to copper: Despite lower electrical conductivity, AMAG TopConduct achieves comparable current-carrying capacity through larger cross-sections. Due to the significantly lower density, this results in a weight reduction of around 50% compared to copper
Significant cost reduction of aluminium compared to copper: In addition, the significant price difference between copper and aluminium that has existed for years results in a substantial cost benefit. Taking the weight savings into account, AMAG TopConduct offers a significantly higher effective cost advantage – making it an attractive choice for cost-sensitive, high-volume industrial applications.
AMAG TopConduct vs. Extruded Solutions
AMAG aluminium for busbars is produced exclusively by rolling technology. Compared to extruded solutions, this creates a homogeneous microstructure throughout the entire cross-section while ensuring tight, reproducible dimensional tolerances. This results in consistent electrical properties, high dimensional accuracy, and reliable downstream processing. The surface-tovolume ratio of rolled busbars also supports efficient heat dissipation during operation, which can have a positive impact on electrical performance and contribute to longer component service life, especially at high current densities.
AMAG continuously develops optimized thermomechanical process routes to further increase conductivity and strength.
AMAG Alloy Design – Consistent Perfomrance Advantages
The performance of AMAG TopConduct is significantly influenced by alloy design and precisely controlled metallurgical process parameters.
AMAG utilizes selected alloys from the 6xxx series, with chemical compositions specifically developed for electrical applications. For example, EN AW-6101 achieves conductivities of more than 57% IACS (International Annealed Copper Standard). Through carefully coordinated heat treatment, the electrical properties are set reproducibly without compromising forming and bending properties.
This combination is particularly important for complex busbar layouts and industrial series applications, ensuring that AMAG TopConduct maintains stable electrical and mechanical properties even under demanding operating conditions.
AMAG TopConduct Portfolio for Highest Demands
AMAG supplies TopConduct as rolled products in alloys EN AW-6101 and EN AW-6101B for high-performance busbars, meeting the requirements of leading OEMs in demanding applications:
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AMAG offers EN AW-6101 and EN AW-6101B in various heat-treatment conditions:
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Typical minimum values:
All tempers offer very good bendability up to at least 90° with a tight bending radius, for example with a bend factor of 1 in temper T63.
Temper | Rm [MPa] | Conductivity [MS/m] | Conductivity [%IACS] |
T6 | ≥ 220 | ≥ 30 | ≥ 52 |
T63 | ≥ 190 | ≥ 32 | ≥ 55 |
T7 | ≥ 170 | ≥ 32 | ≥ 55 |
Please note: The minimum order quantity is 6 tonnes.
Future-Proof Busbar Solutions with AMAG TopConduct
With AMAG TopConduct, AMAG offers a purpose-designed portfolio of rolled aluminium solutions enabling efficient, sustainable, and competitive electrical infrastructure in energy, mobility, and industry. Interested? Please send us an enquiry via our contact form. We look forward to hearing from you!