Transformer Winding Aluminium Foil

Transformer aluminum foil generally uses 1050 aluminum foil, 1060 aluminum foil, 1070 aluminum foil, and 1350 aluminum foil. They have soft texture, high conductivity, flat surface, smooth edges, and no burrs.

  1. Properties of Aluminum Foil for Transformers
  2. Specifications of Aluminum Foil for Transformer
  3. Benefits of Aluminum Foil in Transformers
  4. Aluminium Foil For Transformer Winding Alloy Selection
  5. How Aluminum Foils used in Transformer?
  6. Manufacturing Process
  7. Transformer Winding
  8. Why do we use an Aluminum Foil Strip for HV Transformer Winding?
  9. Frequently Asked Questions (FAQ) about Aluminum Foil for Transformer Winding
  10. Conclusion

Aluminum foil plays a crucial role in the manufacturing of transformers, contributing significantly to their efficiency and performance.

Transformers are essential components in the electrical power distribution system, responsible for transforming voltage levels for transmission and distribution.

Aluminium Foil For Transformer Winding

Properties of Aluminum Foil for Transformers

1. High Purity and Quality

Aluminum foil used in transformers is typically of high purity, often exceeding 99.5%. This ensures minimal impurities that could compromise the electrical properties of the foil.

2. Excellent Electrical Conductivity

Aluminum possesses excellent electrical conductivity, making it an ideal choice for transformer applications. High conductivity ensures efficient energy transfer within the transformer, minimizing energy losses.

3. Thermal Conductivity

Aluminum foil exhibits good thermal conductivity, aiding in the dissipation of heat generated during transformer operation. Efficient heat dissipation is crucial for maintaining the transformer's temperature within acceptable limits.

4. Formability and Flexibility

Aluminum foil is malleable and can be easily formed into the required shapes during the transformer winding process. Its flexibility allows for the creation of intricate winding patterns, optimizing the space within the transformer and enhancing its overall efficiency.

Aluminum Foil for Transformers

Specifications of Aluminum Foil for Transformer

Alloy 1050 1060 1070 1350
Temper O
Thickness 0.2-3.5mm
Width 20-1350mm
Quantity tolerance ±10%
ID 152.4, 200, 300, 400 and 500mm
Surface treatment Mill finish
Application Transformer winding
Packaging Wooden Pallet

Tolerance

ALLOY-TEMPER 1050-O, 1060-O, 1070-O
Thickness 0.2-0.4 0.4-0.8 0.9-1.1 1.2-1.6 1.8-2.5
Tolerance ±0.01 ±0.015 ±0.02 ±0.025 ±0.03
Width less than 100 100-200 201-500 501-1250 >1250
Tolerance ±0.1 ±0.2 ±0.2 ±1 ±2

Tolerance Burr and Collapse

THICKNESS OF ALUMINIUM STRIP BURR’S HEIGHT COLLAPSED SIDE’S HEIGHT
less than 0.2 0.01 >0.05-0.1
0.2-1.0 0.015
1.1-1.5 0.02
>1.6 0.03

Benefits of Aluminum Foil in Transformers

Lightweight

Aluminum is significantly lighter than copper, offering a weight advantage in transformer design and installation.

Cost-Effective

Aluminum foil is more cost-effective than copper, providing a balance between performance and economic considerations.

Corrosion Resistance

Aluminum exhibits natural corrosion resistance, ensuring the longevity and reliability of transformers in diverse environmental conditions.

Aluminium Foil For Transformer Winding Alloy Selection

Commonly used alloys include 1050, 1060, and 1070, known for their high electrical conductivity and formability.

1050 Aluminium Foil For Transformer Winding

Examples:

Medium-sized distribution transformers used in local power distribution networks.

1050 Aluminium Foil For Transformer Winding

1060 Aluminium Foil For Transformer Winding

Examples:

Large power transformers used in high-voltage transmission networks.

Instrument transformers for measuring current and voltage in substations.

1070 Aluminium Foil For Transformer Winding

Examples:

Large power transformers used in grid substations.

Distribution transformers for supplying electricity to residential and industrial areas.

1350 Aluminium Foil For Transformer Winding

Examples:

Extra-high-voltage transformers used in electricity transmission over long distances.

Dry-type transformers commonly found in indoor or sensitive environments.

1350 Aluminium Foil For Transformer Winding

Differences and Considerations

Purity: Alloy 1350 is known for its higher purity compared to the 1000 series alloys. This high purity is advantageous in applications where low levels of impurities are critical, such as in high-voltage and dry-type transformers.

Strength: Alloys 1050, 1060, and 1070 generally have higher strength compared to 1350. The choice of alloy may depend on the mechanical strength requirements of the specific transformer application.

Applications: Alloys 1050, 1060, and 1070 are commonly used in a wide range of transformers, including distribution and power transformers. Alloy 1350 is often chosen for applications where high purity is essential, such as in high-voltage and dry-type transformers.

Formability: Alloys 1050, 1060, and 1070 are known for their good formability, making them suitable for intricate winding patterns in transformer coils.

Corrosion Resistance: Alloy 1060 is known for its good corrosion resistance, which can be advantageous in environments where exposure to moisture is a concern.

The selection of a specific alloy depends on the transformer's design requirements, voltage class, and the desired balance of electrical, mechanical, and environmental properties.

How Aluminum Foils used in Transformer?

Aluminum foil is an integral component in the construction of transformers, and it serves specific purposes within different sections of a transformer. Here's how aluminum foil is used and where it is specifically employed in transformers:

Aluminum Foil for Winding Conductors

Aluminum Foil for Layered Winding

Aluminum Foil for Insulation

Aluminum Foil for Cooling and Heat Dissipation

Aluminum Foil for Oil Immersed Transformers

Aluminum Foil for Oil Immersed Transformers

Aluminum Foil for Tank Construction

Aluminum Foil for Conservator

Aluminum Foil for High Voltage Insulation

In summary, aluminum foil is strategically utilized throughout the various components of a transformer, from the windings and insulation to the tank and cooling systems. Its combination of electrical conductivity, thermal properties, and formability make it a versatile material for optimizing the performance and efficiency of transformers in diverse applications.

Manufacturing Process

1. Casting and Rolling

The selected aluminum alloy undergoes a casting process to create large ingots. These ingots are then hot-rolled into thin sheets, which serve as the basis for the transformer foil.

2. Annealing

The rolled aluminum sheets undergo an annealing process to enhance their softness and conductivity. Annealing involves heating the material to a specific temperature and then slowly cooling it to achieve the desired properties.

3. Surface Treatment

The surface of the aluminum foil may undergo treatment processes such as chemical cleaning or anodizing to improve its insulation properties and resistance to environmental factors.

Transformer Winding

Layered Winding

Aluminum foil is used in the winding process of transformers, forming layers between the transformer's primary and secondary windings. The layered configuration helps optimize the magnetic flux and reduces losses.

Insulation

Insulating materials are often interleaved with the aluminum foil to prevent short circuits and ensure the reliable performance of the transformer.

Why do we use an Aluminum Foil Strip for HV Transformer Winding?

The aluminum foils strips are used for high-voltage transformer with thickness and width ranges from 0.1mm to 3.0mm, and 10mm to 1370mm, respectively.

Generally, tempered aluminum alloy is used for HV transformers like 1060 O and 1070 O.

High-grade insulating foils are placed between aluminum foil strips. Mostly 1060 and 1070 alloys of aluminum are used to wind the high-voltage transformer windings.

The relatively high windings exhibit good ageing qualities under all operating conditions and corrosion-proof. For HV transformer windings, an aluminum foil strip provides a basic winding method with high electrical safety.

Frequently Asked Questions (FAQ) about Aluminum Foil for Transformer Winding

1. Why is aluminum foil used in transformer winding?

Aluminum foil is used in transformer winding due to its high electrical conductivity, formability, and thermal conductivity. It serves as a conductor in the transformer windings, facilitating efficient energy transfer.

2. What thickness of aluminum foil is suitable for transformer winding?

The thickness of aluminum foil for transformer winding varies based on the specific requirements of the transformer. It is typically in the range of 10 to 20 microns, but thicker foils may be used for certain applications.

3. How is aluminum foil protected during transportation and storage?

Aluminum foil for transformer winding is often protected with appropriate packaging materials such as moisture-resistant films and cartons. These materials shield the foil from moisture, dust, and other environmental factors.

4. What are the insulation properties of aluminum foil for transformer winding?

Aluminum foil may undergo treatments or have coatings to enhance its insulation properties. This is crucial to prevent electrical breakdowns within the transformer and ensure safe and reliable operation.

5. Can aluminum foil be used in all types of transformers?

Aluminum foil is commonly used in various types of transformers, including distribution transformers, power transformers, and instrument transformers. The specific alloy and thickness may vary based on the transformer's design and application.

6. How is the formability of aluminum foil maintained during packaging?

Proper handling and packaging techniques are employed to maintain the formability of aluminum foil. Packaging materials are chosen to avoid any damage or deformities to the foil during transportation and storage.

7. Are there specific standards for aluminum foil used in transformer winding?

Yes, there are industry standards and specifications that define the requirements for aluminum foil used in transformer winding. Manufacturers adhere to these standards to ensure the quality and performance of the foil in transformers.

Conclusion

In conclusion, aluminum foil is a fundamental component in the construction of transformers, contributing to their electrical and thermal performance. The careful selection of high-purity alloys, coupled with precise manufacturing processes, results in aluminum foil that meets the demanding requirements of the transformer industry.

As electrical systems evolve, the role of aluminum foil in transformers remains pivotal, enabling the efficient and reliable transmission of electrical power across the grid.

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