The hardness (HV approximately 70-90) and yield strength (200-300 mpa) of copper busbars are superior to those of pure aluminum busbars (HV approximately 20-30, yield strength 50-70 mpa). In environments with significant vibration or mechanical stress (such as rail transit), copper busbars have better resistance to deformation. However, the strength of aluminum bars can be significantly enhanced through alloying (such as adding magnesium or silicon). The yield strength of 6063 aluminum alloy can reach 240MPa, approaching the level of copper bars, while maintaining a relatively light weight.
In terms of processability, the ductility of copper bars (elongation rate 45%-50%) makes them easy to bend and punch, but when processing aluminum bars into complex shapes, the issue of springback needs to be taken into consideration. As flexible conductors, cables are irreplaceable in scenarios where space is limited or dynamic connections are required, such as robot joints. However, their contact resistance and heat dissipation capacity are weaker than those of rigid conductors.