UHV Shield AL1050

Application – Electric Field Grading & Insulation Protection (UHV ≥1000kV)

This CNC metal spun AL1050 aluminum shield is engineered for ultra-high voltage (UHV) transmission systems, providing electric field grading, corona suppression, and anti-flashover protection.
Widely used in substations, insulator strings, bushings, and busbar terminations operating in 1000kV+ environments.

Material – AL1050 High-Conductivity Spinning Alloy

Manufactured from commercially pure aluminum AL1050 (≥99.5% Al), optimized for metal spinning formability and electrical performance.

• Electrical conductivity: ≥62% IACS
• Yield strength: ≥30 MPa
• Tensile strength: ≥90 MPa
• Elongation: ≥25% (excellent for deep spinning)
• Density: 2.70 g/cm³

Material Advantage:
High ductility enables crack-free spinning of thin-wall axisymmetric shells, while high conductivity improves electric field distribution uniformity.

Geometry & Dimensional Accuracy

• Diameter: Ø510 mm
• Height: 105 mm
• Wall thickness: 2.0 mm (±0.12 mm)
• Roundness: ≤0.3 mm
• Flatness: ≤0.2 mm/m
• Surface roughness: Ra ≤0.4 μm
• Standard: GB/T 1804-m

Ensures stable integration in high-voltage insulation assemblies.

Core Manufacturing Process – CNC Metal Spinning + Progressive Polishing

1. CNC Metal Spinning (Primary Forming)

Formed using CNC1250 spinning lathe with controlled incremental deformation:

• Spindle speed: 500–900 rpm
• Roller feed: 4–8 mm/s
• Reduction per pass: 0.4–0.6 mm
• Total deformation: 1.9–2.1 mm

Process Characteristics:

• Axisymmetric seamless forming (no weld seams)
• Controlled material flow with minimal thinning
• Improved grain flow alignment along contour
• High repeatability for batch production

2. Surface Engineering – Multi-Stage Precision Polishing

• 3-stage mechanical polishing (800# → 1500# → 2000#)
• Final surface roughness: Ra ≤0.4 μm
• Gloss: ≥90 GU

Functional Benefit:
Ultra-smooth surface reduces electric field concentration points, minimizing partial discharge and corona effects.

3. Auxiliary Process Flow

Degreasing → acid brightening → leveling → CNC spinning → deburring → multi-stage polishing → ultrasonic cleaning → drying → inspection

Process Control – Spinning Stability & Dimensional Consistency

• Real-time monitoring of wall thickness (±0.01 mm)
• CMM geometric verification
• Spinning profile conformity ≥98%
• Edge radiusing (R ≥1.5 mm, stress reduction)

Ensures consistent dielectric performance across batches.

Quality Assurance – Electrical & Structural Reliability

• ISO 9001:2015 certified manufacturing
• Spectrochemical verification (Al ≥99.5%)
• Ultrasonic NDT (no inclusions or defects)
• Surface inspection (defect-free, no oxidation or residue)
• Salt spray resistance ≥96h

All components include full traceability (material + process + inspection data).

Electrical Performance (UHV Systems)

• Rated voltage: ≥1000 kV
• Dielectric strength: ≥36 kV/mm
• Operating temperature: -40°C to 120°C

Engineering Functions:

• Electric field equalization (grading control)
• Corona suppression
• Anti-pollution flashover protection
• Insulation system reliability enhancement

Production Capacity & Lead Time

• Capacity: 60 pcs/day, 1800 pcs/month
• Lead time:
  • Standard: 5–8 days
  • Bulk: 8–12 days
  • Urgent: 3–5 days

Custom Metal Spinning Capability

• Diameter range: Ø300–800 mm
• Height range: 50–200 mm
• Material options: AL1050 / AL1060 / AL5052
• Custom design based on voltage level, field distribution, and installation interface

Application Scenarios

Primary Applications

• UHV substations (1000kV+)
• Transmission tower insulator strings
• Bushing and termination shielding
• Busbar electric field grading components

Extended Applications

• 220kV / 500kV substations
• Transformer outlet shielding
• Rail transit high-voltage systems
• Wind / solar high-voltage collection systems

Engineering Value – Why Spun Aluminum Shields

Compared with fabricated or welded shielding components:

• Seamless structure → eliminates weld-induced discharge risk
• Superior surface finish → reduces electric field concentration
• Better material utilization → lower cost vs machining
• High dimensional consistency → stable electrical performance

After-Sales & Technical Support

• 24-month warranty
• Free replacement for dimensional or surface defects
• Technical documentation (drawings, test reports)
• 24h response, 1–3 day engineering solution
• Long-term maintenance and refurbishment support

Get a Quote

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