In the ever-evolving world of transformer manufacturing, choosing the right conductor material for windings is critical. Both aluminium foil and copper foil have been widely used in transformer winding applications for decades. However, with rising costs and shifting industry preferences, many manufacturers are now re-evaluating their options. So, in 2025, which is better for transformer winding: aluminium or copper? Let’s dive into the comparison.

Cost Advantage

One of the biggest drivers in the shift toward aluminium is cost efficiency. Aluminium foil is significantly cheaper than copper foil—often by 30% to 50% depending on market fluctuations. For large-volume applications like power or distribution transformers, this price difference can result in substantial savings.

• Aluminium foil for transformer: lower raw material cost
• Copper foil for transformer: stable but increasingly expensive

 Electrical Conductivity

Copper has higher conductivity compared to aluminium. However, aluminium's conductivity-to-weight ratio makes it very attractive for applications where lightweight designs are preferred. With proper design adjustments (such as wider foil width), aluminium can match copper's electrical performance at a lower cost.

 Weight & Handling

Aluminium is approximately 60% lighter than copper, which offers benefits in shipping, handling, and installation. This makes it especially useful in large distribution and power transformers where ease of winding and transport is important.

 Availability and Lead Time

In 2025, global copper supply has faced disruptions, leading to longer lead times and fluctuating prices. In contrast, aluminium strip and foil—especially from Chinese manufacturers like Chalco—remain readily available and competitively priced.

Performance in Oil-Immersed Transformers

Modern aluminium foil is engineered to meet the same mechanical and electrical requirements as copper foil in oil-immersed transformers. Aluminium strip for transformer winding now features excellent elongation, clean edges, and insulation compatibility.

 Environmental Impact

Aluminium production has improved dramatically in terms of sustainability. Aluminium is also fully recyclable, with a lower carbon footprint in many regions compared to copper mining and processing.

Conclusion: Aluminium Foil Is the Smart Choice in 2025

While copper remains a high-performance option, the balance of cost, weight, availability, and recyclability makes aluminium foil the better choice for transformer winding in 2025—especially for manufacturers looking to scale efficiently without compromising quality.

At Transformer-Aluminium-Strip.com, we supply high-quality aluminium strip and foil specifically designed for transformer winding. Whether you're building dry-type or oil-immersed transformers, we offer custom slitting, fast delivery, and technical support.