Aluminum wire is commonly used in place of copper wire for a variety of commercial and residential applications, due in part to several of the advantages that will be covered here.
With that said, as with anything in life, it’s not all positive or negative. Let’s cover the advantages and disadvantages of aluminum wire.
Weight
One of the main advantages of aluminum is that it is significantly lighter than copper – like by a factor of several times.
This means aerial installations are easier as it is easier to handle aluminum, but it also means that transporting aluminum is economical because it doesn’t weigh as much.
Conductivity to Weight Ratio
While copper is technically a better conductor than aluminum, part of the picture is the effectiveness of the conductor with respect to weight.
Less mass in aluminum is needed to convey the same conductive capacity as copper, which is called conductivity-to-weight ratio, another considerable selling point of aluminum.
Corrosion Resistance
Copper is highly reactive and extremely subject to chemical attack. As a result, copper must be protected when used in corrosive environments. This is one of the reasons that copper marine battery cables are individually tinned.
With aluminum, corrosion is less of a concern, and it tends to stand up to chemical attack better than copper conductors.
Cost
Here is, far and away, the most attractive attribute of aluminum conductors. Since aluminum is considerably more affordable than copper, it is widely used in applications such as triplex wire. Using aluminum for such applications generates substantial cost efficiencies, where the price of copper would be an inhibitor.
Now for the Shortcomings
While aluminum is highly attractive for applications such as triplex and quadruplex wire, it’s not ideal across the board. Here are some of the disadvantages of aluminum wire.
Strength
While aluminum is lightweight and highly flexible, it lacks the tensile strength of copper. As a result, it fatigues more easily, and when stressed it tends to snap. Also, aluminum cables and wire subjected to constant vibration form cracks and fail more easily than copper.
Difficult to Solder
For what it’s worth, establishing connections with aluminum wire with solder is very difficult, primarily as a result of the thin layer of oxide that forms on the surface of exposed aluminum, which, while it insulates (and protects) the aluminum, inhibits effective soldering.
Dangerous When Used Incorrectly
Aluminum is safe when used appropriately and installed correctly. However, it is very dangerous when not properly installed, primarily as a result of the differentials in resistivity that can occur at connections. Also, expansion-contraction cycles that occur as a result of temperature fluctuations can loosen connections, elevating the risk of overheating, arcing, sparking and fire hazards.
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