I. Overview of collector material characteristics

(I) AL1060

AL1060 is industrial pure aluminum made by adding a small amount of copper to pure aluminum, with an aluminum content of up to 99.6%. It has extremely high plasticity and is easy to process and shape. It can be made into collector parts of various complex shapes through processes such as rolling and stretching. It has excellent conductivity and can effectively reduce resistance loss and heat generation during current transmission in collector applications. In addition, AL1060 is relatively cheap and has significant advantages in cost-sensitive mass production scenarios. However, the material has low strength and hardness, and may be deformed or even damaged in an environment with large external forces or complex mechanical stresses. ​
(II) AL3003

AL3003 is an aluminum-manganese alloy. The addition of manganese significantly improves its strength compared to AL1060, which is about 10%-20% higher than AL1060. It still maintains good processing performance and can be processed by stamping, bending and other processes. In terms of corrosion resistance, AL3003 performs well and can work stably in humid environments with slightly corrosive gases or liquids. It is suitable for collector application scenarios that require environmental adaptability. However, its conductivity is slightly lower than AL1060, and relatively high resistance loss will be generated during current transmission. ​
(III) AL5052​
AL5052 is an aluminum-magnesium alloy. The addition of magnesium gives it higher strength and good fatigue resistance. Its tensile strength can reach 170-350MPa. This material has excellent corrosion resistance, especially in marine environments or media containing chloride ions, and can effectively resist corrosion erosion. At the same time, AL5052 has good low-temperature performance and can still maintain good mechanical properties and conductivity in low-temperature environments. It is suitable for collectors under some special low-temperature conditions. However, compared with the first two materials, the cost of AL5052 is relatively high, which limits its application in some cost-sensitive fields.​
(IV) AL6061​
AL6061 is a heat-treated aluminum alloy with magnesium and silicon as the main alloying elements. After heat treatment, its strength is greatly improved, with a tensile strength of up to 310MPa, and it has good toughness and fatigue resistance. AL6061 also has excellent processing performance and can be precision machined, making it suitable for manufacturing collector parts with high requirements for dimensional accuracy and shape. In addition, it also has good welding performance, which is convenient for assembly with other parts. However, in terms of conductivity, AL6061 is not as good as AL1060 made of pure aluminum, and the heat treatment process increases production costs and processing cycles. ​
II. Performance of collectors of various materials under different currents​
(I) Performance analysis under Φ43 current​
AL1060: Under Φ43 current, due to the high conductivity of AL1060, the resistance during current transmission is small, the heating phenomenon is relatively unobvious, and the stable current transmission performance can be maintained. Its good plasticity allows the collector to be designed into complex shapes according to circuit requirements to optimize current distribution. However, due to its low strength, care should be taken to avoid deformation caused by external forces during installation and use to avoid affecting the current transmission effect. ​
AL3003: Although the conductivity of the AL3003 collector is slightly inferior to that of AL1060 at Φ43 current, it can still meet general current transmission needs. Its higher strength makes it more advantageous during installation and use, and it is not easy to deform. At the same time, good corrosion resistance ensures the long-term stable operation of the collector in a variety of environments, reducing the performance degradation and failure risks caused by corrosion. ​
AL5052: For the collector made of AL5052, its excellent conductivity and good mechanical properties make it perform well at Φ43 current. High strength and fatigue resistance ensure that the collector will not be damaged by mechanical stress during long-term operation, and good corrosion resistance makes it suitable for harsh environments. However, the relatively high cost may become a limiting factor in some projects with strict cost control.​
AL6061: The AL6061 collector can stably transmit current and resist certain mechanical stresses at Φ43 current with its good conductivity and high strength. Its performance advantage after heat treatment is more obvious under complex working conditions, which can ensure the normal operation of the collector in environments such as vibration and impact. However, due to its relatively weak conductivity, it may generate more heat during long-distance current transmission, and heat dissipation measures need to be considered. ​
(II) Performance analysis under Φ60 current ​
AL1060: When the current increases to Φ60, the resistance loss of the AL1060 collector will increase accordingly, and the heating phenomenon will intensify. Although its high conductivity can still maintain a certain current transmission capacity, continuous high temperature may affect the performance and service life of the collector. In addition, the lower strength makes it subject to the risk of deformation under the electromagnetic force generated by large current, which in turn affects the stability of current transmission. ​
AL3003: Under Φ60 current, due to its limited conductivity, the resistance loss of the AL3003 collector further increases, and the heating problem is more prominent. However, higher strength helps to resist the electromagnetic force generated by high current and reduce the possibility of deformation. In this case, it is necessary to strengthen the heat dissipation design, such as adding heat sinks or using packaging materials with better heat dissipation performance, to ensure the normal operation of the collector. ​
AL5052: The collector made of AL5052 material can cope with the challenges brought by high current to a certain extent under Φ60 current with its good conductivity and high strength. Its excellent fatigue resistance enables it to maintain a stable mechanical structure under long-term high current working conditions. At the same time, good corrosion resistance ensures that the collector will not be affected by corrosion in harsh environments, but it is also necessary to pay attention to heat dissipation to prevent performance degradation due to overheating. ​
AL6061: For the AL6061 collector, under Φ60 current, its strength advantage helps to resist the electromagnetic force and mechanical stress generated by high current, but the problem of insufficient conductivity is more prominent. The large amount of heat generated under high current needs to be dissipated in time, otherwise it will seriously affect the performance and reliability of the collector. More efficient heat dissipation technology, such as liquid cooling or heat pipe cooling, may be required to ensure the normal operation of the collector under high current conditions.​
III. Application scenarios of collectors of different materials under corresponding currents​
(I) AL1060​
Under Φ43 current, the AL1060 collector is suitable for scenarios that are cost-sensitive, have high requirements for current transmission accuracy, have a relatively stable working environment, and have low mechanical stress, such as circuit board collectors in some small electronic devices and consumer electronic products. Under Φ60 current, due to its heat dissipation and strength issues, it is only suitable for temporary or simple circuit systems that are extremely cost-sensitive, have short working hours, and have low performance requirements. ​
(II) AL3003​
Under Φ43 current, the AL3003 collector can be used in scenarios that require environmental adaptability and require a certain strength guarantee, such as collectors in outdoor electronic equipment and industrial automation equipment. Under Φ60 current, after proper heat dissipation design, it can be used in some industrial control circuits and power transmission equipment that have high strength requirements and a certain balance between cost and performance.​
(III) AL5052​
Under Φ43 current, the AL5052 collector is suitable for marine environment, low temperature environment or special working conditions with high requirements for corrosion resistance and mechanical properties, such as collectors in ship electronic equipment and aerospace equipment. Under Φ60 current, it is also suitable for these special environments, but it needs to strengthen heat dissipation and optimize design to meet the needs of high current operation. It can be applied to deep-sea exploration equipment, polar scientific research equipment, etc. ​
(IV) AL6061​
Under Φ43 current, the AL6061 collector is suitable for scenes with high requirements for dimensional accuracy and shape and need to withstand certain mechanical stress, such as collectors in precision instruments and CNC machine tools. Under Φ60 current, after strengthening the heat dissipation design, it can be used in industrial automation production lines and power electronic equipment with extremely high requirements for strength and stability, such as collectors in high-voltage inverters and high-power power supplies.