Aluminum is widely used as a conductor material in electrical applications, although its 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. Instead, copper and aluminum are the primary conductive materials. The resistivity of soft copper is approximately 17.24 nΩ·m, while that of soft aluminum is about 27.8 nΩ·m. This means that aluminum's resistivity is roughly 61.3% higher than copper’s. If copper is considered 100% IACS (International Annealed Copper Standard), aluminum would be around 61.5% IACS.
Despite this 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, with a weight about one-third of copper. As a result, for the same level of conductivity, an aluminum wire weighs only half that of a copper wire, making it easier to handle and install, especially in large-scale projects like high-voltage transmission lines. For example, using aluminum instead of copper could reduce the number of towers needed across major rivers, saving both time and resources.
Additionally, aluminum is 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, making copper over three times more expensive. Furthermore, global copper reserves are limited, totaling around 365 million tons, whereas aluminum is the third most abundant element in the Earth's crust, accounting for over 8% of the solid surface. Its availability makes it a sustainable choice for long-term infrastructure development.
Aluminum also exhibits superior resistance to sulfide corrosion, which is beneficial when used with insulating materials that often contain sulfur compounds. Unlike copper, aluminum does not require tinning before insulation, simplifying the manufacturing process. It also shows better compatibility with insulating coatings, reducing the risk of chemical reactions during application.
Another advantage of aluminum is its excellent heat dissipation properties. Although its thermal conductivity is lower than copper’s, the larger surface area of aluminum conductors allows for more efficient cooling, especially in high-current applications. This helps prevent overheating and improves the overall reliability of electrical systems.
However, aluminum is not without its challenges. It has a relatively low creep resistance, which can lead to unexpected breakage in wires under prolonged stress. Creep strength must be considered alongside tensile strength when designing overhead lines. Additionally, aluminum is prone to fatigue failure due to continuous vibration from wind, and its coefficient of linear expansion is 35.5% higher than that of copper, which can cause issues in temperature-sensitive environments.
Despite these drawbacks, aluminum remains a cost-effective and widely used conductor material. In 2011, about 16.60 kt of aluminum was used globally for electric wires and cables, with a significant portion coming from recycled sources. Developing countries tend to use more aluminum in their expanding power infrastructures, while developed nations have higher copper usage in indoor wiring.
Aluminum has been used in electrical applications since the late 19th century, with early installations such as the first aluminum overhead conductor in Bolton in 1876. The development of ACSR (Aluminum Conductor Steel Reinforced) in 1910 marked a major advancement in high-voltage transmission. Today, most power conductors worldwide are made of aluminum, though copper is still preferred for indoor applications.
The global aluminum aluminization rate, which measures the proportion of aluminum used in place of copper, reached 36.6% in the U.S. in 2011, highlighting its growing importance in modern electrical systems. Overall, aluminum continues to play a crucial role in power distribution, telecommunications, and transportation, offering a balance between performance, cost, and sustainability.
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