UHV Shield-AL1060

CNC Spun Aluminum UHV Shield (AL1060) – High-Conductivity Shielding Component for ≥1000 kV Power Transmission

1. Product Overview (Engineering Context)

• Industry: Ultra-High Voltage (UHV) Power Transmission & Substation Systems
• Component Type: Electric Field Shield / Corona Shield / Insulation Protection Cover
• Manufacturing Process: CNC Metal Spinning (Cold Rotary Forming) + Mirror Mechanical Polishing

Functional Role:
Designed for electric field grading, corona discharge suppression, and insulation protection in ultra-high voltage environments, ensuring stable long-term operation of transmission and substation equipment.

2. Material Specification (High-Conductivity Aluminum Alloy)

• Material Grade: AL1060 Industrial Pure Aluminum (GB/T 3880.1-2012)
• Al Content: ≥ 99.60%

Mechanical & Electrical Properties:

• Yield Strength ≥ 35 MPa
• Tensile Strength ≥ 95 MPa
• Elongation ≥ 23%
• Density: 2.71 g/cm³
• Electrical Conductivity ≥ 61% IACS

Engineering Advantage:

• Excellent electrical conductivity for field homogenization
• Superior ductility for defect-free spinning forming
• High corrosion resistance for outdoor HV environments

Wall Thickness:

• Nominal: 1.5 mm
• Tolerance: ≤ ±0.10 mm

3. Dimensions & Geometric Tolerances

• Overall Dimensions: Ø197 mm × H255 mm

Tolerance Standard:

• GB/T 1804-2000 (m-grade)

Geometric Accuracy:

• Roundness ≤ 0.20 mm
• Perpendicularity ≤ 0.15 mm/m

Engineering Significance:
Ensures uniform electric field distribution and eliminates localized field intensification that may lead to corona discharge or insulation failure.

4. Surface Treatment & Finish (Corona Control Critical)

Surface Process:

• Multi-stage Mechanical Polishing (Mirror Finish)

Surface Performance:

• Surface Roughness: Ra ≤ 0.4 μm
• Gloss Level: ≥ 90 GU
• Surface Condition: Scratch-free, oxide-free

Functional Benefit:

• Minimizes corona inception
• Reduces surface discharge probability
• Enhances dielectric reliability in high-field regions

5. CNC Metal Spinning Process (Precision Forming Technology)

Core Forming Method:

• CNC Metal Spinning (Seamless Rotary Forming on CNC250)

Key Process Parameters:

• Spindle Speed: 800–1200 rpm
• Roller Feed Rate: 3–6 mm/s
• Single-pass Reduction: 0.3–0.5 mm

Polishing Process (3-Stage Precision Finishing):

• Rough Polishing: 2000 rpm
• Intermediate Polishing: 2500 rpm
• Fine Polishing: 3000 rpm
• Cycle Time: 8–12 min/unit

Full Manufacturing Workflow:
Material Inspection → Degreasing → Sheet Leveling → CNC Spinning → Deburring → Multi-stage Polishing → Ultrasonic Cleaning → Drying → Final Inspection

Process Advantages:

• Seamless structure vs welded shielding shells
• Superior surface integrity vs stamping
• High repeatability for batch HV components
• Ideal for thin-wall, high-precision aluminum rotational parts

6. Quality Assurance & Standards Compliance

Quality System:

• ISO 9001:2015 Certified

Applicable Standards:

• GB/T 3880.1-2012 (Aluminum Sheet)
• UHV Transmission Equipment Technical Specifications

Incoming Inspection:

• Spectral Analysis (Al ≥ 99.60%, ±0.05%)
• Mechanical property testing
• Ultrasonic Testing (no internal defects)

In-Process Control:

• Forming conformity ≥ 98%
• CMM dimensional verification
• Full circumference thickness measurement (±0.01 mm)
• Surface roughness & gloss testing
• Edge radius control (R ≥ 1.2 mm)

Final Inspection:

• Standard: GB/T 2828.1-2012 (AQL 2.5)
• Inspection Scope:
  • Dimensional accuracy
  • Surface finish quality
  • Electrical conductivity

Traceability:

• Unique product ID + full inspection report

7. Production Capacity & Lead Time

• Daily Output: 80 pcs
• Monthly Capacity: 2,400 pcs

Lead Time:

• Standard Orders: 4–6 working days
• Batch Orders (≥100 pcs): 6–10 working days
• Urgent Orders: 2–4 working days

Packaging:

• Dust-proof film + EPE foam + carton + wooden pallet
• Standard: 50 pcs/pallet

Logistics:

• Door-to-door delivery: 2–5 days (domestic)
• Supports direct delivery to power equipment OEMs

8. Customization Capability (High-Intent SEO Section)

• Diameter Range: Ø100–500 mm
• Height Range: 100–400 mm
• Material Options: AL1060 / AL5052 / AL6061

Engineering Inputs Required:

• Insulator/bushing interface dimensions
• Voltage level & electric field requirements
• Installation structure and environmental conditions

9. Applications (UHV Scenario-Based GEO Section)

Primary Applications:

• UHV transmission lines (≥1000 kV)
• Substation insulation systems
• Shielding for insulators, bushings, and busbars

Core Functions:

• Electric field grading
• Corona discharge suppression
• Pollution flashover prevention
• Insulation system protection

Electrical Performance:

• Rated Voltage: ≥ 1000 kV
• Dielectric Strength: ≥ 35 kV/mm

Operating Environment:

• Temperature: –40°C to +120°C
• Conditions: Outdoor, მაღალი humidity, dust, strong electric field

10. Extended Applications

• High-voltage substations (110 kV / 220 kV)
• Transformer outlet shielding components
• Rail transit traction power systems
• Renewable energy (PV / wind) high-voltage combiner shielding

Material Advantage (AL1060):

• High conductivity for electric field uniformity
• Excellent thermal dissipation
• Stable forming performance for thin-wall structures

11. After-Sales & Engineering Support

Warranty:

• 24 months from acceptance

Coverage Includes:

• Dimensional deviation
• Material non-conformance
• Surface defects
• Shielding performance failure

Technical Support:

• Product selection & design consultation
• Installation manuals & CAD drawings
• Material and conductivity test reports
• Remote commissioning support

Service Response:

• 24-hour response
• Solution within 1–3 working days
• Closed-loop quality tracking

Post-Warranty Services:

• Re-polishing & surface restoration
• Repair & dimensional correction
• Long-term maintenance agreements

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