UHV Shield-AL5052

1. Product Overview

Industry: Ultra-High Voltage (UHV) Power Transmission
Product Name: UHV Aluminum Shield
Material: AL5052 Aluminum Alloy
Standard Compliance: GB/T 3880.1-2012

The UHV Shield manufactured from AL5052 aluminum alloy is a precision-formed protective component designed for electric field shielding and insulation protection in ultra-high voltage transmission systems. Compared with pure aluminum grades such as AL1060, AL5052 offers higher mechanical strength and superior corrosion resistance, making it suitable for harsh outdoor power grid environments.

2. Material Properties

• Yield Strength: ≥ 190 MPa
  
• Tensile Strength: ≥ 260 MPa
  
• Elongation: ≥ 12%
  
• Density: 2.68 g/cm³
  
• Corrosion Resistance: Excellent (enhanced Mg alloy performance)
  

Thickness: 2.0 mm
Thickness Tolerance: ≤ ±0.12 mm

3. Surface Finish and Dimensional Accuracy

Surface Treatment: Mechanical Polishing

• Surface Roughness: Ra ≤ 0.4 μm
  
• Gloss Level: ≥ 90 GU
  
• Surface Condition: Free from scratches, oxidation spots, and oil residues
  

Overall Dimensions: Ø320 mm × H49 mm

Geometric Tolerances:

• General tolerance according to GB/T 1804-2000, Grade m
  
• Roundness: ≤ 0.3 mm
  
• Flatness: ≤ 0.2 mm/m
  

4. Manufacturing Process

4.1 Core Manufacturing Technology

• Primary Process: CNC Metal Spinning + Progressive Mechanical Polishing
  
• Equipment: CNC Spinning Machine (Model: CNC800)
  
• Polishing System: Fully automated multi-stage polishing line
  

4.2 Key Process Parameters

• Spindle Speed: 600–1000 rpm
  
• Roller Feed Rate: 4–8 mm/s
  
• Single-pass Deformation: 0.4–0.6 mm
  
• Total Controlled Deformation: 1.9–2.1 mm
  

Polishing Stages:

• Rough Polishing: 1800 rpm (800# abrasive)
  
• Intermediate Polishing: 2400 rpm (1500# abrasive)
  
• Fine Polishing: 3000 rpm (2000# abrasive)
  
• Total Polishing Time: 6–10 minutes per unit
  

4.3 Auxiliary Processes

Alkaline Degreasing → Acid Brightening → Rinsing & Neutralization → Drying & Flattening (≤ 0.2 mm/m) → CNC Metal Spinning → Mechanical Deburring (3000 rpm) → Three-stage Polishing → Ultrasonic Cleaning → Drying → Final Dimensional Inspection

5. Quality Control and Standards

5.1 Quality System

• ISO 9001:2015 Quality Management System
  
• GB/T 3880.1-2012 Aluminum Alloy Standard
  
• UHV Power Transmission Equipment Protection Specifications
  

5.2 Raw Material Inspection

• Spectral Composition Analysis
  
  • Mg: 2.2%–2.8%
    
  • Cr: 0.15%–0.35%
    
  • Element deviation ≤ ±0.05%
    
• Mechanical Property Testing
  
• Ultrasonic Testing: No porosity or inclusions
  

5.3 In-Process Inspection

• Spinning profile conformity ≥ 98%
  
• CMM dimensional verification
  
• Full-circumference wall thickness inspection (±0.01 mm)
  
• Surface roughness and gloss inspection
  
• Edge chamfering: R ≥ 1.5 mm, burr-free
  

5.4 Final Inspection

Sampling inspection per GB/T 2828.1-2012 (AQL 2.5), including:

• Dimensional accuracy
  
• Surface quality
  
• Corrosion resistance (Neutral Salt Spray Test ≥ 96 hours)
  

Each qualified product is supplied with traceability code and complete inspection reports.

6. Production Capacity and Delivery

Production Capacity:

• Daily Output: ~70 units
  
• Monthly Capacity: ~2,100 units
  
• Multi-machine parallel production supported
  

Lead Time:

• Standard Orders: 5–7 working days
  
• Batch Orders (≥100 pcs): 7–11 working days
  
• Urgent Orders: 3–5 working days (capacity confirmation required)
  

Packaging & Logistics:
Dust-proof film + EPE foam + customized cartons + wooden pallets

• 40 units per pallet
  
• Door-to-door domestic logistics (2–6 working days)
  
• On-site delivery to power equipment manufacturers supported
  

7. Customization Capabilities

• Diameter Range: Ø200–600 mm
  
• Height Range: 30–150 mm
  
• Optional Materials: AL1060 / AL6061
  
• Customization requires equipment interface parameters and operating conditions
  

8. Application Scenarios

8.1 Primary Applications

Designed for ≥1000 kV UHV transmission systems, including:

• UHV substations
  
• Transmission towers
  
• Insulator strings
  
• Bushing terminals
  
• Busbar connections
  

Functions include electric field equalization, anti-pollution flashover protection, and insulation enhancement, ensuring safe and stable power transmission.

8.2 Operating Conditions

• Temperature Range: –40°C to +120°C
  
• Environment: Outdoor, high humidity, dust, strong UV exposure
  
• Rated Voltage Level: ≥1000 kV
  
• Dielectric Breakdown Strength: ≥38 kV/mm
  

9. Extended Applications

Applicable to:

• 220 kV / 500 kV substations
  
• Transformer outlet shielding components
  
• Rail transit power supply systems
  
• Offshore wind power high-voltage collector systems
  

AL5052 alloy ensures high structural strength and corrosion resistance for medium- and high-voltage power equipment.

10. After-Sales Service

• Warranty: 24 months
  
• Free repair or replacement for quality issues, including dimensional deviation, material mismatch, polishing defects, corrosion failure, or shielding performance non-compliance
  
• Logistics and on-site service costs covered
  

Technical Support:

• Pre-sales technical consultation
  
• Installation manuals and drawings
  
• Material and performance test reports
  
• Remote installation and commissioning support
  

Response Time:

• 24-hour response
  
• Solution provided within 1–3 working days
  

Post-Warranty Services:

• Paid repair and re-polishing
  
• Long-term maintenance agreements
  
• Periodic inspection and technical recommendations for equipment manufacturers

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