As technical staff at Haomei Aluminum responsible for the production of transformer winding aluminum foil, we recommend 1060 O aluminium foil—a core conductive material specifically designed for transformer windings. With its high purity, excellent formability, and strong adaptability, 1060 O aluminium foil for transformer winding has served over 40 transformer manufacturers worldwide, covering distribution transformers, power transformers, and special transformers. Having passed stringent international standard certifications, it has become a cost-effective alternative to copper foil.
1060 O transformer winding aluminum foil is categorized by transformer type and winding structure, rejecting generic templates and tailored to specific application scenarios.
The aluminum foil for distribution transformers emphasizes lightweight and low cost, with thicknesses ranging from 0.15-0.30mm, suitable for low-voltage windings of 10-35kV distribution transformers. Our exported products to Southeast Asia have achieved a 99.8% winding pass rate according to customer tests.
The aluminum foil for power transformers focuses on high conductivity and creep resistance, with a thickness of 0.30-0.50mm. Through optimized annealing processes, it enhances material stability and is suitable for 110kV and above high-voltage transformer windings. It has already been applied in European power grid upgrade projects.
Special transformer-specific aluminum foil is customized for high-frequency and high-temperature operating conditions, with a thickness of 0.10-0.15mm. Its surface undergoes special passivation treatment, making it suitable for special transformers in the new energy and rail transit sectors, solving the problem of conductivity loss under high-frequency conditions.
The dimensional precision of 1060 O aluminum foil directly determines the conductivity efficiency and operational stability of transformer windings. We have established comprehensive specification standards based on a mature production system.
Regarding alloy purity, we strictly control the 1060 alloy aluminum content to ≥99.6% and impurity content to ≤0.4%, with harmful impurities such as iron and silicon ≤0.2%, ensuring stable conductivity and avoiding increased resistance loss caused by impurities.
Thickness specifications cover 0.10-0.50mm, with tolerances precisely controlled within ±0.005mm. Produced using a four-roll precision rolling mill, it solves industry pain points such as wrinkling of thin foil and uneven thickness.
Width covers 100-1200mm and can be customized according to customer winding dimensions, adapting to the winding requirements of different transformer models.
The core adopts the 76mm/152mm international standard, compatible with mainstream global winding equipment.
Regarding the state, strict control is maintained over the O-state (fully soft state) performance, with annealing temperature precisely controlled at 380-410℃ and holding time of 2-3 hours, ensuring an aluminum foil elongation ≥30% and hardness ≤25HB, meeting the bending and stretching requirements during winding, without cracks or springback.
The core competitiveness of 1060 O aluminum foil for transformer winding stems from its material properties and our optimized processes, perfectly adapting to the core requirements of transformer windings.
In terms of electrical conductivity, the 1060 alloy boasts a thermal conductivity of 238 W/(m·K) and a conductivity ≥60% IACS, 2%-3% higher than ordinary aluminum foil. Actual measurements show that, under the same specifications, winding conductivity losses are 4% lower than the industry average, contributing to improved transformer efficiency.
Regarding formability, its fully soft O-state characteristic provides excellent plasticity, allowing for tight bonding to the core during winding without gaps or looseness, preventing partial discharge caused by winding looseness. Our optimized online annealing process controls the aluminum foil surface roughness to Ra≤0.2μm, reducing frictional losses during winding and improving production efficiency.
In terms of corrosion resistance, chromium-free passivation treatment and a neutral salt spray test duration exceeding 480 hours effectively resist transformer oil corrosion, prevent winding oxidation, and extend transformer lifespan. Long-term feedback from customers in the Middle East and Southeast Asia indicates that the winding failure rate has decreased to below 0.1%.
Combining practical production experience with export expertise, the practical advantages of 1060 O aluminium foil permeate the entire chain of production, application, and cost, providing customers with cost-effective solutions.
On the production side, we achieve large-scale continuous production, with roll lengths ranging from 5000-10000m, reducing the number of roll changes for customers and shortening roll changedown time by 35%. Simultaneously, we employ closed-loop quality control, testing the conductivity, thickness, and elongation of each batch of products, keeping the defective rate below 0.05%.
On the application side, compared to copper foil, 1060 O aluminum foil has a density of only 35% of copper, reducing the overall weight of transformers by 40%, lowering transportation and installation costs. It is also compatible with both oil-immersed and dry-type winding processes in transformers, requiring no adjustments to production equipment and exhibiting strong compatibility. Our customized aluminum foil for dry-type transformers for European customers has successfully replaced copper foil, reducing overall costs by 25%.
Regarding export adaptability, our products have passed international standard certifications such as EU CE, US ASTM B209, and IEC 60287. For different regional needs, we can customize chromium-free passivation processes to meet local environmental standards. For example, our products optimized for North American customers fully comply with California Proposition 65 requirements, with annual exports exceeding 2,000 tons.
As an export-oriented enterprise, we leverage our years of experience exporting transformer aluminum foil to provide customized technical services to global customers. For the differences in transformer specifications across regions, we can customize thickness, width, and surface treatment solutions. For example, we optimize the winding aluminum foil width for African customers to meet their needs for small distribution transformers; and we provide aluminum foil joint optimization technology for high-voltage transformer customers to reduce joint resistance loss. Simultaneously, we have established a professional technical after-sales team to provide winding parameter guidance, product quality traceability, and other services to ensure smooth customer production. Currently, our 1060 O transformer winding aluminum foil has been exported to more than 20 countries and regions in Southeast Asia, Europe, and Africa, gaining unanimous customer recognition.
Haomei Aluminum’s 1060 O transformer winding aluminum foil, with its core features of high purity, precise specifications, and superior performance, combined with its advantages in large-scale production and global service, provides transformer manufacturers with low-cost, high-efficiency, and highly stable conductive material solutions. Whether you need cost-effective solutions for distribution transformers or customized materials for special transformers, we can provide full-process technical support from material selection and specification customization to mass production, helping your products enhance their core competitiveness and expand into global markets.
