AAAC | All Aluminium Alloy Conductors

AAAC (All-Aluminum Alloy Conductor) is a concentrically stranded conductor typically made from 6000 series high-strength aluminum alloy with magnesium and silicon. Compared to traditional ACSR (Aluminum Conductor Steel Reinforced), AAAC is a pure aluminum construction, offering greater strength, better transmission efficiency, and superior corrosion resistance.

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Chalco’s AAAC complies with standards such as BS 3242, BS EN 50182, IEC 61089, ASTM B 399M, DIN 48201-6, ASTM B231, TS IEC 1089, and DIN 48201. It is widely used in bare overhead distribution and transmission lines (from 11 kV to 800 kV lines) and primary and secondary transmission in high-voltage substations.

Chalco can customize high-strength aluminum alloy wires of various sizes and supply them to one of the world-renowned power company suppliers such as SIEMENS, HITACHI (ABB), TOSHIBA, LEGRAND, and EATON.

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Conductor Construction of AAAC(All Aluminium Alloy Conductors)

Conductors: 6201-T81 aluminum alloy conductors. 6201-T81 aluminum alloy is a high strength aluminum alloy for added durability and reduced sag when stranded overhead. 6201-T81 aluminum alloy is also more resistant to abrasion than 1350-H19 aluminum.Stranding: Helically stranded.Ampacity: Medium to high voltages.

features of aluminum round wire for overhead stranded wire

AAAC(All Aluminium Alloy Conductors) vs ACSR(Aluminium Conductor Steel Reinforced)

Corrosion Resistance: AAAC has excellent corrosion resistance, but its tensile strength is lower than ACSR due to the absence of a steel core.
Current Carrying Capacity: AAAC has 15-20% higher current carrying capacity compared to ACSR of the same size.
Service Life: AAAC has a longer service life of approximately 60 years compared to 30 years for ACSR of the same size.
Surface Hardness: AAAC has a surface hardness of 80 BHN, which is significantly higher than the 35 BHN of ACSR. This makes it less susceptible to damage during handling, resulting in reduced corona loss and radio interference at EHV levels.
Operating Temperature: AAAC can operate at a stable temperature of 85°C, which is higher than the 75°C for ACSR.
Strength-to-Weight Ratio: AAAC has a higher strength-to-weight ratio, allowing for spans to be increased by 2-15%. This results in overall cost reduction for towers and other accessories in the transmission line system.

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Chalco high-strength aluminum alloy wire common specifications

Alloy	6061 6101 6021 8006 8030 8176
Single aluminum wire diameter (mm)	0.2-6.0
Conductor construction	7 to 91 Aluminum Alloy
Conductor cross-section	34.4 mm², 54.6 mm², 114 mm², 117 mm², 148 mm², 150 mm², 182 mm², 185 mm², 228 mm², 240 mm², 288 mm², 300 mm², 366 mm², 400 mm², 570 mm², 851 mm², 1144 mm²
Conductivity of Aluminium	52.5% to 53% ICAS
Standard	BS 3242, BS EN 50182, IEC 61089, ASTM B 399M, DIN 48201-6, ASTM B231, TS IEC 1089, and DIN 48201

Physical properties of AAAC (All-Aluminum Alloy Conductor)

At a temperature of 20°C (68°F), the density of hard-drawn aluminium has been taken as 2.703 g/cm3 (168.74 lb/cf).

SR. NO.	CONDUCTOR CONSTRUCTION	MODULUS OF MPA	*ELASTISITY KSI**	LINEAR COEFFCIENT*
				/℃	/℉
1	7 Strands	62000	8992	23.0 X 10^-6	12.8 X 10^-6
2	19 Strands	60000	8702	23.0 X 10^-6	12.8 X 10^-6
3	37 Strands	57000	8267	23.0 X 10^-6	12.8 X 10^-6
4	61 Strands	55000	7977	23.0 X 10^-6	12.8 X 10^-6

Construction Parameters of AAAC (All-Aluminum Alloy Conductor)

BS 3242

Code	AL Nominal Area	Cu Nominal Area Equivalent	Total Area	Stranding	Overall Diameter	Weight
	mm^2	mm^2	mm^2	No.×mm	mm	kg/km
-	-	6.45	11.7	7/1.47	4.41	32.2
Box	-	9.68	18.8	7/1.85	5.55	51.7
Acacia	-	12.9	21.9	7/2.08	6.24	66.1
Almond	25	16.1	30.1	7/2.34	7.02	82.9
Ceda	30	19.4	35.5	7/2.54	7.62	97.8
-	40	22.6	42.2	7/2.77	8.31	116.4
Fir	50	25.8	47.8	7/2.95	8.85	131.8
Hazel	100	32.3	59.9	7/3.30	9.9	165
Pine	-	38.7	71.7	7/3.61	10.83	197.7
-	-	45.2	84.1	7/3.91	11.73	231.6
Willow	150	48.4	89.8	7/4.04	12.12	247.5
-	175	51.6	96.5	7/4.19	12.57	266.2
-	300	58.1	108.8	7/4.45	13.35	299.8
Oak	-	64.5	118.9	7/4.65	13.95	327.8
-	-	80.6	118.8	19/2.82	14.1	327.6
Mulberry	-	96.8	151.1	19/3.18	15.9	416.7
Ash	-	113	180.7	19/3.48	17.4	498.1
Elm	-	129	211	19/3.76	18.8	582.1
Poplar	-	145	239	37/2.87	20.09	658.8
-	-	161	270.8	37/3.05	21.35	746.7
Sycamore	-	194	303	37/3.23	22.61	834.9
Upas	-	226	362.1	37/3.53	24.71	998.6
-	-	258	421.8	37/3.81	26.47	1163
Yew	-	-	479.9	37/4.06	28.42	1323

(*) Note: The values of current rating mentioned in above Table are based on wind velocity of 0.6 metre/second, solar heat radiation of 1200 watt/metre2, ambient temperature of 50° C & conductor temperature of 80°C.

BS EN 50182

Code	Stranding	Nominal Area	Overall Diameter	Weight	Rated Strength	Electrical Resistance	Current Rating*
	No.脳mm	mm^2	mm	kg/km	KN	惟/Km	A
Box	7/1.85	18.8	5.55	51.4	5.55	1.748	87
Acacia	7/2.08	23.8	6.24	64.9	7.02	1.3828	101
Almond	7/2.34	30.1	7.02	82.2	8.88	1.0926	116
Cedar	7/2.54	35.5	7.62	96.8	10.46	0.9273	129
Deodar	7/2.77	42.2	8.31	115.2	12.44	0.7797	143
Fir	7/2.95	47.8	8.85	130.6	14.11	0.6875	155
Hazel	7/3.30	59.9	9.9	163.4	17.66	0.5494	178
Pine	7/3.61	71.6	10.83	195.6	21.14	0.4591	199
Holly	7/3.91	84.1	11.73	229.5	24.79	0.3913	219
Willow	7/4.04	89.7	12.12	245	26.47	0.3665	228
Oak	7/4.65	118.9	13.95	324.5	35.07	0.2767	272
Mulberry	19/3.18	150.9	15.9	414.3	44.52	0.2192	314
Ash	19/3.48	180.7	17.4	496.1	53.31	0.183	351
Elm	19/3.76	211	18.8	579.2	62.24	0.1568	386
Poplar	37/2.87	239.4	20.09	659.4	70.61	0.1387	416
Sycamore	37/3.23	303.2	22.61	835.2	89.4	0.1095	480
Upas	37/3.53	362.1	24.71	997.5	106.82	0.0917	535
Yew	37/4.06	479	28.42	1319.6	141.31	0.0693	633
Totara	37/4.14	498.1	28.98	1372.1	146.93	0.0666	648
Rubus	61/3.50	586.9	31.5	1622	173.13	0.0567	714
Sorbus	61/3.71	659.4	33.39	1822.5	194.53	0.0505	764
Araucaria	61/4.14	821.1	37.26	2269.4	242.24	0.0406	868
Redwood	61/4.56	996.2	41.04	2753.2	293.88	0.0334	970

Note: *The values of current rating mentioned in above Table are based on wind velocity of 0.6 metre/second, solar heat radiation of 1200 watt/metre2, ambient temperature of 50° C & conductor temperature of 80°C.

IEC 61089

Code	Nominal Area	Stranding	Overall Diameter	Weight	Rated Strength	Electrical Resistance	Current Rating*
	mm^2	No.脳mm	mm	kg/km	KN	Ω/Km	A
16	18.4	18.4	5.49	50.4	5.43	1.7896	86
25	28.8	28.8	6.87	78.7	8.49	1.1453	113
40	46	46	8.67	125.9	13.58	0.7158	151
63	72.5	72.5	10.89	198.3	21.39	0.4545	200
100	115	115	13.9	316.3	33.95	0.2877	266
125	144	144	15.5	395.4	42.44	0.2302	305
160	184	184	17.55	506.1	54.32	0.1798	355
200	230	230	19.65	632.7	67.91	0.1439	407
250	288	288	21.95	790.8	84.88	0.1151	466
315	363	363	24.71	998.9	106.95	0.0916	535
400	460	460	27.86	1268.4	135.81	0.0721	618
450	518	518	29.54	1426.9	152.79	0.0641	663
500	575	575	31.15	1585.5	169.76	0.0577	706
560	645	645	33.03	1778.4	190.14	0.0516	755
630	725	725	35.01	2000.7	213.9	0.0458	809
710	817	817	37.17	2254.8	241.07	0.0407	866
800	921	921	39.42	2540.6	271.62	0.0361	928
900*	1036	1036	41.91	2861.1	305.58	0.0321	992
1000*	1151	1151	44.11	3179	339.53	0.0289	1051
1120*	1289	1289	46.75	3560.5	380.27	0.0258	1118
1250*	1439	1439	49.39	3973.7	424.41	0.0231	1185

Chemical composition of Chalco high strength aluminum alloy wire

Chemical composition
Alloy	6061	6101	6021	8006	8030	8176
Si	0.4-0.8%	0.30-0.6%	0.9-1.2%	0.4-0.8%	0.7-1.3%	0.6-1.0%
Mg	0.8-1.2%	-	0.8-1.3%	0.8-1.3%	0.8-1.5%	0.8-1.4%
Fe	0.7% max	0.10% max	0.7% max	0.50% max	0.7% max	0.70% max
Cu	0.15-0.4%	0.03-0.05%	0.10-0.30%	0.10-0.30%	0.10-0.30%	0.10-0.25%
Mn	0.15% max	0.03% max	0.50-1.1%	0.20-0.60%	0.10% max	0.15% max
Zn	0.25% max	0.10% max	0.25% max	0.10% max	0.10% max	0.10% max
Cr	0.04-0.35%	0.03% max	0.10% max	0.10% max	0.10% max	0.10% max
Ti	0.15% max	-	-	-	-	-
Other elements	0.05% each 0.15% total	0.05% each 0.15% total	0.05% each 0.15% total	0.05% each 0.15% total	0.05% each 0.15% total	0.05% each 0.15% total

Note that these chemical composition values are general ranges and specific alloy compositions may vary by manufacturer, product and specification requirements.

Mechanical properties of Chalco high strength aluminum alloy wire

Alloy	Temper	Tensile strength (MPa)	Yield strength (MPa)	Elongation (%)	Conductivity (% IACS)
6061	T6	240	210	12	40-45
6101	T61	180-250	130-190	8-20	52-55
6101	T81	180-250	130-190	8-20	52-55
6021	T4	180-220	120-180	8-12	50-52
6021	T6	180-220	120-180	8-12	50-52
8006	O	160-220	150-200	4-8	53-55
8006	H18	160-220	150-200	4-8	53-55
8030	O	160-220	150-200	4-8	53-55
8030	H18	160-220	150-200	4-8	53-55
8176	O	160-220	150-200	4-8	53-55
8176	H18	160-220	150-200	4-8	53-55

Please note that these values are general ranges and may vary depending on factors such as manufacturer, product specification and manufacturing process. In actual application, please refer to specific product specifications and data provided by suppliers.

Physical properties of aluminum-magnesium-silicon alloy round wire for overhead stranded wire

Model	LHA1	LHA2
Conductivity	52.5% IACS	53% IACS
Density at 20℃/ (g/cm3 )	2.703	2.703
Coefficient of linear expansion/ (10-6/℃)	23	23
Temperature Coefficient of Resistance at 20°C / (1/°C)	0.0036	0.0036

Mechanical properties of aluminum-magnesium-silicon alloy round wire for overhead stranded wire

Diameter d/mm	LHA1		LHA2
	Tensile strength/Mpa	Elongation after break (%)	Tensile strength/Mpa	Elongation after break (%)
≤3.50	325	3.0	295	3.5
＞3.50	315

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Application of high-strength aluminum alloy wire for overhead line conductors

6061 aluminum alloy wire has good mechanical properties and weldability, and is widely used in high-strength overhead aluminum stranded wire. It has excellent corrosion resistance and electrical conductivity.

6201 aluminum alloy wire is a special aluminum alloy in which copper is added as an alloying element. This alloy has higher strength and electrical conductivity and is suitable for overhead lines under high load conditions.

6101 aluminum alloy wire is a high-strength aluminum alloy wire with good electrical conductivity and oxidation resistance. It is commonly used in power transmission lines and electrical applications.

8006 aluminum alloy wire belongs to the 8000 series aluminum alloy wire, which contains alloy elements such as lithium and copper. It has good electrical conductivity and high mechanical strength, and is suitable for overhead lines under high load conditions.

8030 aluminum alloy wire also belongs to the 8000 series aluminum alloy, which contains lithium, copper and other alloying elements. It has high strength and good corrosion resistance and is often used in transmission lines and power applications.

8176 aluminum alloy wire is also a high-strength aluminum alloy in the 8000 series, which contains alloying elements such as lithium and copper. It has high electrical conductivity and mechanical strength, and is suitable for long-distance transmission lines and high-load conditions.

Application of high-strength aluminum alloy wire for overhead line conductors

High strength aluminum alloy wire price

Price of high-strength aluminum alloy wire:

(LME ingot price + processing fee) x weight + packaging fee + transportation fee

High strength aluminum alloy wire price

The price of high-strength aluminum alloy wire will be affected by many factors, such as market supply and demand, raw material prices, processing costs, specifications, and other factors. Different manufacturers and suppliers may have different pricing strategies and price levels. In addition, it is also affected by factors such as currency exchange rate and international economic situation.

Therefore, pleasecontact Chalco aluminum for inquiry, we will provide you with the best quotation and service.

AAAC (All-Aluminum Alloy Conductor) Key Considerations

1.Conductor Material and Performance Indicators

Alloy composition not only affects strength, conductivity, and corrosion resistance but also influences the compatibility of surface treatments, such as coating adhesion and wear resistance. Conductivity should remain stable over time, while tensile strength and elongation are critical to the mechanical properties of the conductor. Fatigue performance determines the conductor's lifespan.

2.Geometric Dimensions

Diameter tolerance affects the conductor's cross-sectional area and current-carrying capacity. Roundness affects contact area and resistance; the better the roundness, the lower the resistance.

3.Surface Treatment of Aluminum Alloy Wire

If the coating is too thin, the protective effect is poor; if it is too thick, it affects conductivity. Coating uniformity and adhesion must ensure that the coating does not peel off, and different coating types can be selected based on the environment.

4.Finished Coil Dimensions

The coil size should match the conductor diameter and weight, and the loading capacity of the transportation vehicle should be considered to avoid affecting winding quality or causing deformation.

5.Price and Delivery

Price composition includes material, processing, packaging, and transportation costs. Payment terms should be flexible, and delivery time should be negotiated reasonably with the supplier to avoid affecting the project schedule.

Chalco can provide you the most comprehensive inventory of aluminum products and can also supply you customized products. Precise quotation will be provided within 24 hours.

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