Enameled Aluminum Wire
CCA vs Pure Aluminum Strip in Transformer Windings
CCA vs Pure Aluminum Strip in Transformer Windings
As global demand for cost-efficient transformers rises, manufacturers often consider using Copper Clad Aluminum (CCA) wire and pure aluminum strip as conductor options. This article compares the two materials and evaluates their suitability for transformer windings.
Material Overview
- CCA Wire: Aluminum core with a copper outer layer. Used mainly in cables, not originally designed for transformer coils.
- Pure Aluminum Strip: Flat-rolled aluminum (such as 1060 or 1070) with high purity and conductivity. Standard material for transformers globally.
Comparison Table
| Property | Copper Clad Aluminum (CCA) | Pure Aluminum Strip |
|---|---|---|
| Conductivity | 60–63% IACS | 61–62% IACS |
| Form Factor | Round wire | Flat strip or foil |
| Winding Efficiency | Low, not optimized for strip machines | High, compatible with automatic winding |
| Cost | Lower than copper, higher than aluminum | Most cost-effective large-scale material |
| Suitability for Transformers | Limited | Preferred and widely accepted |
While CCA wire is common in data and communication cables, pure aluminum strip is far more practical and widely used in transformer windings—especially in oil-immersed, dry-type, solar inverter, and distribution transformers. Its superior workability, form factor, and compatibility with industry standards make it the material of choice for manufacturers worldwide.
FAQs: CCA vs Aluminum Strip in Transformers
A: Not effectively. CCA is typically produced in round wire form, making it incompatible with the flat winding structure required in transformer coils. Pure aluminum strip remains the industry standard for efficiency and ease of use.
A: Aluminum strip is far better suited. It offers high conductivity, easy shaping, and lighter weight—critical for dry-type units used in commercial and industrial buildings.
A: In cost-sensitive markets like Egypt, Nigeria, and the UAE, aluminum strip (1060/1070/1350) is preferred due to affordability, availability, and support for large production volumes with reliable performance.
A: Rarely. CCA’s copper layer is thin and can’t effectively handle high-frequency losses. Pure aluminum strip performs better thermally and electromagnetically in such cases.
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