CCA BUSBAR may encounter some specific technical and quality problems during the production process, as it involves the cladding and joining of two different metals (copper and aluminium). Some of the most common problems encountered in the production of CCA BUSBAR and their causes are analysed below:
- Poor adhesion of the copper plating
Problem Description: Poor adhesion between the copper cladding and the aluminium core, resulting in the copper cladding peeling off.
Cause analysis:
Improper surface treatment: the oxide layer on the surface of the aluminium core is not thoroughly removed, resulting in the copper layer not forming a strong metallurgical bond with the aluminium.
Poor control of the plating process: Inappropriate temperature, pressure and plating speed during the plating process can result in a weak bond between the copper layer and the aluminium core.
Soldering problem: During the soldering process of CCA BUSBAR, the soldering temperature is too high or too low, resulting in poor contact between the copper layer and the aluminium layer.
- Uneven thickness of the copper layer
Problem description: Uneven thickness of the copper layer resulting in unstable conductivity or even localised over-thinning leading to exposed copper layer.
Cause Analysis:
Unstable rolling process: Incorrect adjustment of equipment during the rolling process, or uneven friction between the copper layer and the aluminium core, resulting in changes in the thickness of the copper layer.
Uneven cooling: CCA BUSBAR may not be cooled evenly after rolling, resulting in uneven shrinkage of the copper layer, causing thickness variations.
Uneven material: Differences in the quality of the copper and aluminium materials, or uneven flow of the copper layer during cladding with the aluminium core.
- CCA BUSBAR breaks or pulls off
Problem description: CCA BUSBAR breaks or pulls off during production or subsequent use, affecting the performance of the product.
Cause analysis:
Improper drawing process: drawing speed is too fast or drawing temperature is too high, which will easily cause CCA BUSBAR to fracture, especially if the aluminum core is brittle.
Problems with alloy composition: The quality of the aluminum or the uneven alloy composition of the copper layer may lead to brittle fracture of CCA BUSBAR during the drawing process.
Excessive tensile stress: During the fabrication of CCA BUSBAR, if the tensile stress exceeds the material’s tolerance, it may also easily lead to fracture.
- Copper layer oxidation
Problem description: Oxidation of the copper layer occurs during fabrication or storage, affecting its electrical conductivity and leading to performance degradation.
Cause analysis:
Humid manufacturing environment: An environment with excessive humidity may cause oxidation of the copper layer when it is exposed to air.
Exposure to air during processing: If CCA BUSBAR is exposed to air during the rolling process and is not protected in time, oxidation is likely to occur.
Improper Packaging: If effective anti-oxidation measures are not taken during packaging and storage (e.g. using anti-oxidation film or nitrogen protection), the copper layer is susceptible to oxidation.
- CCA BUSBAR surface defects
Problem description: scratches, cracks, pits, or other physical defects on the surface of the CCA BUSBAR that affect aesthetics and performance.
Cause Analysis:
Processing equipment inaccuracy: Insufficient precision of rolling equipment or drawing equipment during the production process results in damage to the surface of CCA BUSBAR.
Material defects: There are quality problems with the copper or aluminum raw materials themselves, such as defects in the material surface.
Improper operation: Excessive stretching or squeezing of CCA BUSBAR during operation, resulting in surface damage.
- CCA BUSBAR Bending or Deformation
Problem description: CCA BUSBAR is prone to bending or deformation during use, especially after prolonged use.
Cause Analysis:
Improper control during the drawing process: Inappropriate tension control of CCA BUSBAR during the drawing process may lead to stress concentration and eventual bending of the wire after drawing.
Temperature control problem: If the temperature is not suitable during the wrapping process, it may lead to deformation of the surface of CCA BUSBAR with stress concentration.
Improper storage environment: If CCA BUSBAR is stored in a humid or pressurized environment, it may lead to bending or deformation of the wire.
- Poor Conductivity
Problem Description: The conductivity of CCA BUSBAR is not up to the required level, affecting subsequent electrical performance.
Cause Analysis:
Insufficient Copper Layer Thickness: The copper layer of CCA BUSBAR is too thin, resulting in a decrease in its electrical conductivity.
Uneven cladding: The copper layer is unevenly clad, and the local copper layer is thin or missing, resulting in impaired electrical conductivity.
Aluminum core quality problem: Poor quality or high impurity content of the aluminum core may lead to unstable conductivity, which in turn affects the performance of the whole CCA BUSBAR.
- Inconsistent expansion of different metals
Problem description: Due to the different coefficients of expansion of copper and aluminum, the bonding between the copper layer and the aluminum core is unstable under certain temperature conditions.
Cause Analysis:
Inconsistent material expansion: The expansion coefficients of copper and aluminum are quite different, and the degree of expansion of the two is different when the temperature changes, which may lead to cracks or separation between the copper layer and the aluminum core.
Concentration of stress: Stresses generated during heat treatment or use of the copper and aluminum materials may lead to separation or detachment of the two.
- Incorrect Temperature Control During the Cladding Process
Problem Description: During the cladding process, the melting temperatures of copper and aluminium vary greatly and improper temperature control can lead to poor copper cladding results.
Cause Analysis:
Excessive temperature: Too high a temperature can lead to poor metallurgical bonding between the copper and aluminium layers, or even to burn-out or excessive expansion of the material.
Too low temperature: Too low a temperature can result in insufficient bonding between the copper and aluminium, creating a weak interface.
How can these problems be avoided?
Tight control of process parameters: Ensure that process parameters (e.g. temperature, pressure, drawing speed, etc.) such as rolling, cladding, drawing and welding are within reasonable limits.
Improve raw material quality: Use high quality copper and aluminium raw materials to avoid the influence of raw material impurities on performance.
Optimise surface treatment: Before cladding, completely clean the surface of the aluminium core, remove the oxide layer and impurities to ensure a strong metallurgical bond between the copper layer and the aluminium.
Strengthen quality control: real-time monitoring during the production process to ensure that dimensions, copper layer thickness, surface finish and other quality indicators meet requirements.
Strengthen equipment maintenance and upgrade: Regularly check and maintain the production equipment to ensure the stability and precision of the equipment.
Packaging and storage: Adopt effective moisture-proof and antioxidant measures to ensure that the quality of CCA BUSBAR is not affected during storage and transportation.
Through reasonable process optimisation, quality control and strict testing, we can effectively reduce various problems encountered during the production of CCA BUSBAR and ensure the stability and reliability of the product.
