From Copper to Aluminum: Selection and Cost Optimization of Conductor Materials for Cables

From Copper to Aluminum: Selection and Cost Optimization of Conductor Materials for Cables

In cable manufacturing, the choice of conductor material has a direct impact on the performance and economics of cables. Copper conductors have long dominated the market with their excellent electrical conductivity and mechanical strength, but their high price has prompted a search for more economical alternatives. 

Aluminum conductors, with their light weight and low cost advantages, are gradually gaining wide application in areas such as power transmission. From the point of view of electrical conductivity, the conductivity of copper is about 58MS/m, which is significantly better than the 35MS/m of aluminum, which means that copper has a smaller resistance and lower power loss under the same cross-sectional area. 

However, a similar current-carrying capacity can be achieved by appropriately increasing the cross-sectional area of the aluminum conductor. In terms of mechanical properties, copper tensile strength of 200-300MPa, excellent flexibility, especially suitable for the need for frequent movement or complex wiring occasions; while the tensile strength of aluminum is only about 100MPa, long-term use of the phenomenon may be “cold creep”, the need to take a special connection process.

 Cost advantage is the most prominent feature of aluminum, its price is only one-third of the copper, in the same flow-carrying can save 20% -40% of the cost, and the density of only 30% of copper, can significantly reduce the weight of the cable. In practice, high-voltage transmission mostly uses aluminum conductors, building power distribution can choose copper or aluminum alloy according to demand, data centers and other precision equipment must use copper conductors to ensure stability. 

In order to optimize the cost, copper-clad aluminum structure or aluminum alloy conductor can be used, and at the same time, through the rational design of cross-sectional area to balance the performance and price. As technology advances, the development of recycled materials and new composite conductors will bring more possibilities to the cable industry. When choosing conductor materials, companies need to consider factors such as conductive demand, mechanical strength, usage environment and budget to find the best balance between the reliability of copper and the economy of aluminum.