1060 Transformer Aluminum Foils is a kind of pure aluminum foil strip, the content of aluminum can reach more than 99.5%, because it does not contain other technical elements, so production process is relatively simple, the price is relatively cheap,1060 aluminum foil strip most commonly uses alloy in conventional industry.
Aluminum strip is widely used in transformer winding because of its high conductivity. The main alloying elements of 1060 aluminum foils strips for transformers winding are copper (0.1%), zinc (0.05%) and magnesium (0.05%).
Engineered for Zero-Breakdown Reliability & Maximum Space Factor
Replacing conventional copper/aluminium conductors by using 1060 High Purity Aluminium Foil as a replacement can greatly improve the performance of LV Transformer winding:
Burr-Free Edge Protection (Guaranteed ≤ 0.005mm Burr Height): Inter-layer insulation (DMD/PET/Nomex®) puncture is predominantly due to sharp slitting burrs. Our active edge-chamfering technology bends foil edges into a smooth, straight, arc profile in order to eliminate this mechanical failure mode.
Ultra-Clean Surface (Dyne Level >= 38dynes/cm): All roll-oil and organics removed 100% by vacuum degreasing and ultrasonic washing. This results in wetting and bonding in film as well as under encapsulation in epoxy resin or impregnation under vacuum pressure (VPI).
Best for O-Temper Soft Annealing. ( 25 – 35% Elongation ) Fully annealed condition presents the best ductility, suitable for high tension automatic coil winding without edge tear and the axial spring back deformation.
High Space Utilization & Thermal Dissipation: The space fill factor of foil-wound coils is greater than 90%. The heat transfer from surface-to-surface ensures heat is dissipated away from the coil to avoid local hot spot formation and also enhances the life of the transformer.
1060 aluminum foils for transformer winding
| Thickness | Nominal Width | |||||
| ≤100 | >100–300 | >300–500 | >500–1250 | >1250–1650 | >1650–2000 | |
| Width Tolerance (+) | ||||||
| >0.20–0.60 | 0.5 | 0.6 | 1 | 3 | 4 | 4 |
| >0.60–1.00 | 0.5 | 0.8 | 1.5 | 3 | 4 | 4 |
| >1.00–3.00 | 0.6 | 1 | 2 | 3 | 4 | 5 |
Chemical Component :
| Elements | Si | Fe | Cu | Mn | Mg | Cr | Zn | Ti | Zr | Al |
| % | 0.25 | 0.35 | 0.05 | 0.03 | 0.03 | – | 0.05 | 0.03 | – | 99.6 |
Mechanical properties :
| Temper | Tensile Strength (Rm/MPa) | Yield Strength (MPa) |
| 1060-O | 60-100 | 15-25 |
| 1060-H12 1060-H24 | 95-135 | 70 |
| 1060-H16 1060-H26 | 110-155 | 75 |
| 1060-H18 | 160 | 85 |
Precision Processing Technology
Burr-Free Rotary Carbide Slitting & Micro-Arc Edge Chamfering
Standard shear slitting will produce sharp micro-burrs. These microburrs will erode insulation when
Automatic shear slitting milling is an alternative method that does not produce a sharp edge, as shown:
Tungsten carbide slitting: The detail of and the process of Precision Rotary Cutter under the fixed closed loop tension control is Active Micro-Arc Edge Rounding: Secondary online mechanically polish edges into an arc radius (R >= t/2), one or more sharp corners possible.
Inline laser inspection An intrachip optical profile (also known as a inline laser inspection) guarantees the burr height stays at 0.005 mm.
Inert Gas Vacuum Annealing & Degreasing
To prevent coil delamination and partial discharge in resin-cast transformers:
Alloyed at 380 deg C – 420 deg C in a vacuum furnace with an inert atmosphere, so that the organic lubricant residue were evaporated.
100 Dyne Pen Tested: Ensures that there is enough surface energy in order 38 dynes/cm to allow a type of insulating varnish or epoxy resin to stick without dielectric bubbles.
Quality Control & Mill Test Certification (MTC)
All 1060 Transformer Aluminum Foils are supplied with full EN 10204 3.1 Mill Test Certificate:
Eddy current conductivity test: Confirmed to ASTM E1004 ( must be or better). Edge microstructure inspection: Using an optical microscope, burrs, tears, or micro-cracks are checked.
Tensile & Ductility Testing: Using a universal testing machine to confirme the tensile strength and elongation of the head/tail sample.
Export sea-worthy packing. Coils shall be wrapped with moisture-proof VCI film, silicates with silica gel desiccants and shall be fixed in wooden case with eye to sky or eye to wall arrangement.
Primary Industry Applications
Cast Resin Dry-Type Power Transformers (LV Windings for F-Class & H-Class Insulation)
Oil-Immersed Distribution & Power Transformers
Amorphous Alloy Core Transformers requiring high space fill factor
High-Capacity Low-Voltage Industrial Reactors & Solar/Wind Inverter Inductors
Why Do Transformers Use 1060 Aluminum Foil?
1060 aluminum foil is a commercially pure aluminum alloy (with aluminum content >= 99.60%) featuring exceptional electrical and thermal conductivity, high corrosion resistance, and excellent formability. When fully annealed to the soft O-temper (1060-O), it exhibits superior plasticity, allowing it to be seamlessly processed and tightly wound into various precise transformer coil geometries without cracking.
Additionally, 1060 aluminum foil offers a straightforward manufacturing process with stable quality control and significant cost advantages. Beyond its widespread use in appliance linings, its optimal balance of high conductivity, formability, and cost-efficiency makes 1060-O aluminum foil a premier material choice for dry-type and power transformer windings.
