Copper vs. Aluminium Wires: Understanding the Pros and Cons

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Is it about wiring your new construction project? Or are there electrical problems with the property’s current wiring configuration? Are you uncertain about the type of wiring that will make the residence safer? The manufacturing industries and researchers strive hard to improve the quality of electric wires to offer the highest safety and best quality.

There is a wide variety of electric wires currently available in the market, synthesized from natural and synthetic materials. Copper and aluminium are the most often used metals in electrical wire manufacture. These metals have special qualities that make them ideal for a variety of uses. The following article will explain the most prevalent differences between wires made of copper and aluminium.

Copper Wires: The Pros and Cons

Understanding the applications of copper wire is important. So, before we get into the pros and cons of it, let’s have a look at the applications of copper wires:

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1. The electrical conductivity of bare copper wire allows it to be employed in circuits and overhead power transmission lines. They have been used in heavy machinery, commercial transformers, cars, and submarines.
2. Compared to other naturally present metals, copper wires have comparatively stronger magnetic characteristics. It is useful in the making of solenoids and magnetic bars.
3. Copper wires are commonly used in high-speed machinery and appliances that are subjected to continuous high-temperature conditions and vibrations because of their exceptional resistance to tear and damage and long lifespan.

Here are certain pros and cons of copper wires that would help you make an informed decision:

Pros of Copper Wires

• Better conductor than aluminium
• Higher durability
• Less corrosive nature
• Malleable in nature and offers flexibility for desired size and shape
• Lesser expansion and contraction owing to low thermal expansion
• Enhanced connection security
• 40% better tensile strength
• Requires 56% lesser cross-sectional area compared to copper for the same current carrying capacity

Cons of Copper Wires

• Expensive on purchase
• Heavier in weight
• Not suitable for the long run
• Unable to tolerate electrical surges
• Offer electromagnetic interference, thus disrupting safety

Aluminum Wires: The Pros and Cons

Before getting into the pros and cons of aluminium wires. Let’s take a look at their use and why are they used:

1. Aluminium has applications in electrical wiring. It is so because it is a highly effective electrical conductor and is frequently employed in electrical applications where space and/or weight pose significant considerations.
2. Because aluminium resists corrosion, it is also put to use in certain high-voltage applications.
3. Aluminium is commonly used to make telephone cables because of its electrical conductivity and resistance to corrosion.
4. Due to its lower weight and greater corrosion resistance, aluminium wire is also frequently used in place of steel wire in several automobile applications.

Here are certain pros and cons of aluminium wiring that would help you make an informed decision:

Pros of Aluminium Wires

• Extensive home and commercial applications
• Uses lesser quantity compared to copper
• Half the cost of copper
• Lighter in nature
• Offers lesser resistance to current flow
• Malleable in nature, thus making it easy to be drawn into wire
• Environmental friendly and comprises recyclable properties without loss of quality
• Easier to use
• Provides safety on proper installation
• Resistant to corrosion
• Come with a long lifespan

Cons of Aluminium Wires

• Expands while power is drawn from the wire but contracts when it isn’t
• Loosens over time, thus leading to fires
• Melts the fixtures on experiencing high temperatures
• Requires dedicated parts like screws and lugs
• Terminal parts require a compatibility test
• Less resistant to corrosion and become brittle, decreasing long-term suitability
• Quick corrosion on contact with other metals
• Softer and hence prone to breakage
• Not insurance friendly
• More wear and tear poses a higher replacement frequency of aluminium wires compared to copper wires.

Difference between Copper-Coated Aluminum Wire and Copper Wire

The basic difference between copper-coated aluminium wire and copper wire is given below:

1. Copper-coated aluminium wires have a higher DC resistance than pure copper wires because copper has better conductivity than aluminium.
2. Pure copper wires and copper-coated aluminium wires are both sold by weight, but copper-coated aluminium wires are slightly more costly than pure copper wires of the same weight.
3. Copper-coated aluminium is softer than pure copper. Thus, wires produced from copper-coated aluminium conductors are softer than pure copper cables.
4. The electrical conductivity of copper-coated aluminium wire is lower than that of solid copper wire. Copper-coated aluminium wire continues to be more conductive than aluminium, but it doesn’t have the same electrical conductivity as solid copper wire.

Copper Wire vs. Aluminum Wire Resistance

Aluminium cable is more resistant and can carry less current (by roughly 40%) than a comparable copper conductor.

Aluminium has a higher electrical resistance than copper. This low resistance causes copper wires to heat up less, lose a lower amount of energy, and undergo a lower voltage fall.

Copper Wire vs. Aluminum Wire in AC

Since copper is a more effective conductor and has lower resistance, it is usually applied in AC systems. Copper can readily handle AC currents due to its low resistance and low heat generation.

The use of aluminium in AC systems is possible. Still, because of its greater resistance and the skin effect, it may result in higher energy decline, heating up, and potential performance issues. Aluminium wires in AC systems often have to be wider in diameter to make up for these shortcomings, which can address the higher resistance.

Aluminium vs. Copper Wire Ampacity

In comparison to aluminium wires of the same size, copper wires often have a greater ampacity. Heavy-duty appliances and circuits require greater ampacity applications where copper is commonly used.

To attain an equivalent current-carrying capacity as copper, aluminium wires used in high-amperage applications need to be greater in diameter or size. This may increase the need for more space and raise implementation costs.

Understanding the Different Types of Copper & Aluminum Electric Wires

Let us explore the multiple options that you can choose from:

Winding wires: Offered in two conductor materials, aluminium and copper, the winding wires are available with a breakdown voltage of 5 kV. These winding wires are suitable for applications concerning general and submersible motors. There are four types of insulation material available: polyester, PVC, polyester and polyesterimide. Top companies like Polywrap, RR Shramik and many others provide the services.

Electric wire: The most preferred conductor materials, aluminium, copper and HRFR, are easily available with base materials in different forms. For instance, wires are also available as annealed copper, ETP copper, solid and stranded copper. Other types of electric wires, such as eco-friendly, FR active, advanced, PVC, lead-free, FRLSH, HRLF, ZHFR, twin insulate, and many more, are also available. The offered voltage rating is also wide from 220 to 1100 V, and the current rating is from 10 to 93 Amperes.

Alloy Wire: Aluminum Magnesium Alloy wire is gaining popularity too. The wires are single-filar type and find a wide range of applications in complex and significant tasks. It is of use in electrical transmission, the automotive industry, bicycle and sporting goods, marine construction materials, and aerospace construction.

When Should You Use Copper and Aluminium Wire?

Electrical systems in homes and businesses have consistently used copper wiring. It is often chosen over aluminium wiring due to its great tensile strength. Copper’s elemental composition also makes it a very good and affordable conductor. When it comes to exposed overhead cables outdoors, aluminium wires work better. It is so because when placed under the weather, the aluminium wire forms a thick oxide film. This prevents oxidation and corrosion caused by air and precipitation.

Procuring Online at L&T-SuFin: A Smart Choice

The comparison, of copper vs aluminium wire, indicates that both serve unique advantages and disadvantages. Replacing either of them, depending on the use, is a wise decision. A thorough understanding of the requirements aids in choosing the right material for electric wire. Be it commercial electricity services, facility maintenance services, or the incorporation of electric wires in regular electrical applications, L&T-SuFin provides wires that offer the product’s best quality and brand. Trusted by numerous and have delivered excellent service for a long time, we welcome you to surf our site to learn more about the diverse range of our offerings.

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