Flat Enameled Aluminium Wire

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Manufacturing Process Overview

The production of enameled flat aluminum wire starts with high-purity aluminum coil rod as the raw material, and the core process follows these key steps:

1. Continuous Extrusion Forming: The aluminum rod is processed through a continuous extrusion unit, which pushes the material through the die hole by the friction heat generated in the wheel groove. This process completely eliminates surface defects such as burrs, oil stains, and pitting, and the finished flat blank has a smooth surface that meets the subsequent painting requirements. You can learn more about this high-efficiency forming technology through this continuous extrusion process introduction.
2. Low-Oxygen Softening & Rapid Cooling: The formed flat aluminum wire is sent into a softening furnace under an oxygen-free or low-oxygen environment, kept at a constant temperature of 480°C to 520°C for recrystallization softening, then quickly immersed in 20-30°C circulating water for quenching. This step avoids surface oxidation of the aluminum material and ensures the conductor has uniform and stable mechanical properties.
3. Multi-Layer Enamel Coating & Curing: The pretreated flat aluminum wire passes through the enamel painting system multiple times, applying 10 to 30 layers of different types of insulating paint in sequence. Each layer is fully cured in a high-temperature curing furnace to ensure no bubbles or cracks in the insulation layer. For detailed technical parameters of enameled film curing, you can refer to this magnet wire insulation coating guide.
4. Final Performance Testing: The finished product will go through strict dimensional inspection, high-voltage withstand test, insulation continuity test, and surface quality inspection before leaving the factory, to ensure that all indicators meet IEC and national industry standards.

This optimized process not only reduces production energy consumption by more than 40% compared with the traditional multi-pass cold drawing process, but also significantly improves the yield and consistency of the finished product, making enameled flat aluminum wire a more cost-effective and lightweight alternative in the field of high-power electrical equipment manufacturing.