At present, China's aluminum transformer production technology has reached the world's advanced level. Since 2006, more than 10 million aluminum ring transformers have been produced and exported in batches to Japan, Germany, Italy, Spain and other countries. The market response is very good, and there has not been a single batch quality complaint due to the use of aluminum, which has received unanimous praise.
Compared with copper and aluminum, the disadvantage of aluminum is that its resistivity is greater than that of copper (20℃, ρaluminum = 2.83×10-8, ρcopper = 1.75×10-8). This point can be corrected by adjusting the wire diameter during transformer design (dcopper×1.28=daluminum) to make the resistance of each winding of the aluminum transformer equal to or less than the resistance of each winding of the copper transformer.
After adjustment, the copper loss of the copper transformer is almost the same as the aluminum loss of the aluminum transformer, thus achieving similar electrical parameters of the two transformers. Regarding the welding problem, this point has been completely solved with the advancement of material technology and the successful development of advanced welding equipment. The company adopts the domestically pioneered and internationally leading welding process to make tin penetrate the aluminum to form a tin-aluminum alloy layer on the aluminum surface, realizing contact between the two metal atoms (as shown in the figure: the thickened part of the tin-aluminum contact surface is tin-aluminum alloy, mutual penetration), welding is in an oxygen-free state, a purely physical method, does not use any paint remover and flux, and is environmentally friendly, pollution-free, and corrosion-free. This welding technology and process is significantly better than tinning copper wire with an ordinary soldering iron. It not only successfully solves the difficulty of aluminum welding, but also does not leave any hidden dangers of cold soldering.
The two major problems that have long plagued the production of aluminum transformers are solved.
