Aluminum vs Copper Conductors | International Wire

Aluminum vs. Copper Conductors

Posted by International Wire on February 19, 2025 12:00 am

Conductors transmit electrical current from one point to another, often either from a power source to a device or from one component or circuit to another. Choosing the right conductor requires careful consideration of application-specific requirements. Some of the factors to weigh include:

Cost considerations
Electrical conductivity of the material
Wire flexibility, weight, and diameter
Safety considerations

The two most popular conductors are copper and aluminum. In this guide, we explore the key characteristics, pros and cons, and applications of these two materials so you can select the electrical wire conductor for your project.

Aluminum Conductors

Aluminum is a cost-effective material for conductors with a long history of use in electrical installations. It offers the following advantages for manufacturers and installers:

Lightweight. Aluminum is significantly lighter than copper, weighing less than a third of copper’s weight. However, it is also less conductive than copper when comparing conductors of the same size.
Cost-effectiveness. Aluminum is less expensive than copper, making it a suitable choice for applications requiring extensive wiring, provided there is sufficient space to accommodate thicker conductors.

Aluminum is generally flexible, which makes it easier to work with as a material. However, this flexibility also makes it more prone to damage, especially when exposed to vibration.

Types of Aluminum Conductors

Manufacturers commonly use two types of aluminum alloys for electrical conductors: AA-1350 series aluminum and AA-8000 series aluminum.

AA-1350 Series Aluminum: This alloy contains at least 99.5% aluminum. It was widely used in residential wiring systems across the United States during the 1960s and 1970s due to its significantly lower cost compared to copper. However, poor installation practices at the time often led to high-resistance connections, which posed serious fire hazards.
AA-8000 Series Aluminum: Modern builders and manufacturers now prefer AA-8000 series aluminum alloys. These alloys exhibit characteristics similar to copper, such as improved creep resistance and elongation properties. Unlike AA-1350 series wires, which are prohibited under Article 310 of the National Electric Code, AA-8000 series wires meet current safety and regulatory standards, including those outlined in ASTM B800.

Applications

Aluminum conductors are widely used in various applications, including:

Wiring in aircraft and aerospace vehicles: Aluminum’s lightweight nature makes it ideal for reducing overall weight in these applications.
Prototypes for fuel-efficient automobiles: Aluminum conductors play a critical role in the development of lighter and more energy-efficient vehicle designs.
Overhead transmission lines: Aluminum is commonly used in power transmission due to its high conductivity-to-weight ratio and cost-effectiveness.

Additionally, combining aluminum with other metals, including copper, enables users to leverage the strengths of multiple materials, optimizing performance for specific applications.

Copper Conductors

Copper conductors are far more conductive than aluminum, ensuring minimal energy loss during electrical transmission. As one of the oldest known materials, copper has been integral to early electrical applications, used by scientists and industry pioneers.

In 1913, copper became the international standard for electrical conductors, leading to the establishment of the International Annealed Copper Standard (IACS). This organization defines conductivity standards for annealed copper and evaluates all other metals relative to this benchmark. Commercially pure copper is rated at 100% IACS conductivity, serving as the reference point for electrical efficiency across materials.

Types of Copper Conductors

Over the years, advancements in manufacturing have led to the production of increasingly pure copper, resulting in conductors with exceptional conductivity. Modern copper conductors not only surpass the original standards but also exhibit superior strength and improved thermal expansion characteristics.

Annealed copper conductors, widely used for electrical purposes, meet stringent safety and product standards as defined by ASTM B3, Specification for Soft or Annealed Copper Wire.

Applications

Copper’s exceptional electrical conductivity and durability make it the preferred material for a variety of applications, including:

Commercial and residential buildings: Copper conductors are extensively used for wiring in homes, offices, and industrial facilities.
Power systems: Copper is a key component in power distribution and generation systems due to its reliability and efficiency.
Automobiles: Copper is essential for automotive electrical systems, including wiring, motors, and battery connections.

Conductors at International Wire Group, Inc.

At International Wire, we’ve been developing and manufacturing electrical conductors for over 100 years. We use cutting-edge manufacturing technology and tight adherence to quality management standards to give our clients reliable access to standard and specialty conductors. We manufacture specialty conductors, composite electrical components, flat wire, and high-tensile-strength alloy conductors. Our products include silver-plate, nickel-plated, and tin-plated wiring solutions.