Aluminum is widely used as an electrical conductor, although its electrical conductivity is lower than that of silver, gold, and copper. Silver has the highest conductivity, followed by gold and then copper. However, due to their high cost, silver and gold are not commonly used in general industrial applications. Copper and aluminum, on the other hand, are the most frequently used conductive materials. The resistivity of soft copper is approximately 17.24 nΩ·m, while that of soft aluminum is around 27.8 nΩ·m. This means that aluminum's resistivity is about 61.3% higher than that of copper. If copper is considered as 100% IACS (International Annealed Copper Standard), aluminum would be roughly 61.5% IACS.
Despite its lower conductivity, aluminum has a much lower density compared to copper—only 2700 kg/m³ versus 8890 kg/m³ for copper. This makes aluminum significantly lighter, which is a major advantage when it comes to long-distance power transmission. For instance, aluminum conductors can weigh about half as much as copper ones with the same level of conductivity. This reduces the load on towers and allows for greater spacing between power lines, making installation more efficient and cost-effective.
In terms of cost, aluminum is far more affordable than copper. In May 2012, the price of aluminum on the Shanghai Futures Exchange was around 15,900 yuan per ton, while copper was priced at about 54,500 yuan per ton—nearly 3.4 times more expensive. Additionally, global copper reserves are limited, totaling only 365 million tons, whereas aluminum is one of the most abundant metals on Earth, making up over 8% of the Earth’s crust.
Another key advantage of aluminum is its excellent resistance to sulfide corrosion, which is important because many insulation materials contain sulfur compounds. Unlike copper, which requires tinning before insulation, aluminum can be directly coated without this step. Moreover, aluminum wires do not react with insulating oils, ensuring better compatibility and longer-lasting performance.
Aluminum also excels in heat dissipation. Even though its thermal conductivity is lower than copper’s, the larger surface area of aluminum conductors allows for more effective cooling. This is especially beneficial in high-current applications where heat management is critical.
While aluminum has many advantages, it also has some drawbacks. It is more prone to creep, which can cause sudden breakage if not properly accounted for in design. The creep strength of hard aluminum is around 12 N/mm², but alloys like aluminum-magnesium-silicon offer improved performance. Additionally, aluminum is more susceptible to fatigue under continuous stress from wind and vibration, and it has a higher coefficient of linear expansion than copper.
Despite these challenges, aluminum remains a vital material in electrical systems worldwide. It is extensively used in power transmission, telecommunications, and transportation. The global aluminum wire aluminization rate reached 36.6% in the U.S. in 2011, reflecting its widespread adoption. Since the early 20th century, aluminum has gradually replaced copper in overhead power lines, thanks to its lightweight and cost-effectiveness. Today, it is the dominant conductor material in most high-voltage transmission systems, even though indoor wiring still largely relies on copper.
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