Product Introduction

Enameled flat aluminum wire is a magnet wire with a flat aluminum conductor uniformly coated with multiple layers of insulating varnish and cured at high temperatures. It is suitable for transformers, compressor motors, traction motors, and high-voltage coil windings.

Products parameters

Product Name		Temperature Index	Production Range	Properties and Application	Standard
Enameled Aluminum Flat Wire	PVF Flat Aluminum Wire-Class 120	E	Al: Thickness: 1.80~5.60mm, Width: 4.00~18.00mm Cross section: 3~80mm²	Good resistance to transformer oil, excellent scratch resistance, good flexibility and adhesion, and good hydrolysis resistance.	IEC60317 NEMA-MW1000 JIS C3202 JIS C3003 GB/T7095.1~7 GB/T23312.1~2 GB6109.1~7, 9~23 Technical Agreement
	EIW Flat Aluminum Wire-Class 180	H		Excellent heat resistance, high solvent resistance and good thermal shock resistance.
	EI/AIW Flat Aluminum Wire-Class 200	C		It has excellent comprehensive performance, especially excellent refrigerant resistance, solvent resistance and radiation resistance.

Material

Highly conductive electrical aluminum, such as JIS C3003, 1350, or E-Al99.7, is used.

Bonding Method

The insulating varnish is applied through multiple dip coatings and high-temperature baking (approximately 350–420°C) to form a dense, adherent layer, firmly bonding to the aluminum substrate.

Shape

The conductor cross-section is a flat rectangular.

insulation material

Polyvinylidene fluoride (PVF, Class 120), polyesterimide (EIW, Class 180), or polyimide/AIW (Class 200) varnish is used.

Customization

Wire Size
Wire width, thickness, and cross-sectional area can be customized according to customer requirements.

Surface Treatment
Glossy or frosted finish available upon request.

Color
Insulating varnish can be customized in a variety of colors.

Quality Inspection

Eddy Current Detection System--Real-time Monitoring to Prevent Defects

During the drawing process, the eddy current probe continuously excites and monitors signal changes.

If defects such as cracks, scratches, dirt, or burrs appear on the aluminum wire surface or interior, the signal immediately becomes unbalanced, the system issues an alarm, and the machine automatically shuts down, preventing continued production of defective products.

Process Coordination--Optimizing Lubrication and Dies to Improve Detection Stability

The use of water-soluble lubricants and diamond high-precision molds can reduce friction and surface defects, make the aluminum wire smooth, reduce eddy current false alarms, and ensure stable detection.

Closed-loop control--integrated defect detection and recovery

The system provides full process control including detection, alarm, shutdown, repair, and recovery. After repairs, the production line automatically resumes operation, ensuring continuous and stable production.

Aluminum Bare Wire Process

Wire Drawing Process

Aluminum rods are drawn through progressively smaller tungsten carbide dies, reducing their diameter and increasing their length, thereby increasing the material's tensile strength.

Extrusion Process

Aluminum billets are heated to 400–500°C and extruded through a die under high pressure into wire. Precise temperature control and water or air cooling ensure uniform surface quality and stable performance.

Annealing Furnace

Heating the wire to 360–400°C releases its internal stress and allows the grains to recrystallize, improving the material's flexibility and workability.

Enamelling

We utilize advanced equipment imported from Austrian company MAG. MAG's production line incorporates innovations in pay-off, furnace temperature control, and painting, enabling the production of high-quality enameled wire. MAG also effectively controls waste gas, wastewater, and wastewater emissions, contributing to environmental protection.