Enameled Aluminum Wire
Aluminum vs Copper: Which Conducts Better?
Aluminum vs Copper Conductivity: Which Is Better for Electrical Applications?
When choosing materials for electrical applications such as transformer windings, busbars, or power transmission lines, two metals dominate the market: aluminum and copper. While copper is often praised for its high conductivity, aluminum offers a compelling mix of electrical performance, weight, and cost advantages.
Conductivity Comparison
| Material | Conductivity (% IACS at 20°C) | Resistivity (Ω·mm²/m) |
|---|---|---|
| Copper (C11000) | 100% | 0.01724 |
| Aluminum (1350-O) | 61% – 63% | 0.0282 – 0.0286 |
While aluminum has lower electrical conductivity than copper, it is still efficient enough for most applications — especially when size and weight considerations are factored in.
Weight & Density Advantage
- Aluminum Density: ~2.7 g/cm³
- Copper Density: ~8.9 g/cm³
Aluminum is approximately three times lighter than copper. This makes it ideal for large-scale installations and overhead power lines where weight reduction is critical.
Cost Considerations
On average, aluminum costs 30%–60% less than copper per unit weight. In high-volume applications such as power transformers or industrial wiring, this can result in major cost savings without sacrificing performance.
Other Key Comparisons
- Oxidation Resistance: Aluminum forms a protective oxide layer; copper oxidizes more but still conducts well.
- Machinability: Aluminum is easier to cut, weld, and form.
- Unit Conductivity by Weight: Aluminum outperforms copper — more conductivity per kilogram.
Where Aluminum Excels
Because of its combination of good conductivity, light weight, and lower price, aluminum is commonly used in:
- Transformer winding coils
- Overhead transmission cables
- Busbars and switchgear panels
- Consumer electronics and HVAC systems
Choose Smartly, Not Traditionally
While copper remains the benchmark for maximum conductivity, aluminum is the practical and economic choice in many modern electrical systems. As aluminum strip and coil suppliers, we help clients optimize their material decisions based on application, budget, and engineering needs.
