Dry-Type Transformer Windings Wire: Copper VS Aluminium

Copper winding wire and Aluminum winding wire in transformer refer to the wire materials used to wind transformer coils. Transformers transmit electrical energy through these winding wire wires and increase or decrease voltage. Below we mainly discuss the difference between Copper winding wire and Aluminum winding wire, and how to choose the material.

1. Difference in conductive performance
Copper winding wire transformer
Excellent conductivity: Copper has high electrical conductivity and can transmit current more efficiently.
Low resistance and low loss: Due to the low resistance, the heat loss generated during the transmission of current is small. And the efficiency of the transformer is improved.

Aluminum winding wire transformer
Low conductivity: Aluminum has relatively low electrical conductivity. Although it can still transmit current, it is not as efficient as Copper winding wire.
High resistance and large loss: Due to the high resistance of aluminum, the heat loss generated during the transmission process is large. This directly leads to the relatively low efficiency of the transformer.

2. Different mechanical strengths
Copper winding wire transformer
High mechanical strength: Copper has high strength and hardness and can withstand greater mechanical stress.
Good durability and fatigue resistance: Copper has excellent fatigue performance and can maintain good performance after long-term use and is not easy to break.

Aluminum winding wire transformer
Low mechanical strength: Aluminum has low strength and hardness and is easy to deform or break under mechanical stress.
Poor durability: Aluminum’s fatigue performance is not as good as copper, and it may break or degrade after long-term use.

3. Different Weight and heat dissipation
Copper winding wire transformers are heavier than Aluminum winding wire transformers. Copper has a high density and is heavier than aluminum at the same volume. Therefore, Copper winding wire transformers are heavier overall, and the difficulty and cost of installation and transportation are relatively high.
Copper winding wire has excellent heat dissipation performance: Copper has good thermal conductivity, which is conducive to effectively dissipating heat. The temperature rise of the transformer is low during operation. Aluminum winding wire has relatively poor heat dissipation.

4. Different application scenarios
Copper winding wire transformers are suitable for high-demand occasions: Copper winding wire transformers perform well in occasions that require high reliability and long-term stable operation. Because of its excellent conductivity, corrosion resistance and mechanical strength.
Commonly used in critical power systems, industrial equipment, etc. These occasions have extremely high requirements for the stability and reliability of equipment, such as power transmission and distribution systems, large industrial machinery and equipment, data centers, medical equipment, etc.

Aluminum winding wire transformers are suitable for cost-sensitive and low-weight occasions: Aluminum winding wire transformers are suitable for applications with limited budgets and requirements for transformer weight. Because of its lower cost and weight.
Commonly used in residential and commercial buildings: These occasions have relatively low performance requirements for transformers. More attention needs to be paid to cost-effectiveness and ease of installation.

5. Connection and installation
Copper winding wire transformers have good connectivity: copper has good conductivity and mechanical strength, and can provide reliable connection performance. In electrical connectors, Copper winding wire can ensure good electrical contact, reduce contact resistance and heating. Thereby improving the safety and stability of the connection.
Relatively complex installation: Copper winding wire transformers are usually designed to be more complex. The bending and connection of Copper winding wires during installation require higher precision and technology. The Copper winding wire itself is heavy, and additional support and fixing measures are required during installation. This makes the installation process relatively complicated and time-consuming.

Aluminum winding wire transformers have poor connectivity and are easy to oxidize: Although aluminum has good conductivity, its mechanical strength is poor. Aluminum winding wire is prone to deformation and breakage. Secondly, aluminum is easily oxidized in the air to form a layer of aluminum oxide film. This film is resistive and affects the reliability of electrical connection. Therefore, the connectivity of Aluminum winding wire is relatively poor, and poor contact and heating problems are prone to occur.
Simple installation: The installation process of Aluminum winding wire transformers is relatively simple because Aluminum winding wire is lighter and easier to operate and fix. Since the connection quality of Aluminum winding wire directly affects its performance, special attention must be paid to the treatment of the connection parts during installation. The contact surfaces must be kept clean and tight to avoid poor contact due to oxidation and looseness.

6. Environmental adaptability
Copper winding wire transformers are more corrosion-resistant: copper has good corrosion resistance. Enameled Copper winding wire performs well in harsh environments such as humidity, acidity, alkalinity, etc., and is not prone to corrosion and oxidation.
Adapt to harsh environments: Due to the corrosion resistance and mechanical strength of copper, Copper winding wire transformers can operate stably for a long time in harsh environments such as high temperature, high humidity, and high salt spray. This enables Copper winding wire transformers to cope with various extreme environmental conditions.

Aluminum winding wire transformers are more susceptible to corrosion: aluminum has poor corrosion resistance, especially in humid or acidic and alkaline environments. Aluminum is prone to oxidation corrosion, forming a layer of aluminum oxide film, which affects its conductivity and mechanical strength. The service life and reliability of Aluminum winding wire transformers in harsh environments are relatively low.
Adapt to general environments: Aluminum winding wire transformers are more suitable for use in relatively mild environmental conditions, such as indoors or general outdoor environments. Aluminum winding wire transformers need to take protective measures, such as coating with anti-oxidation coating or using special wiring terminals, to extend their service life and stability.

In general, enameled copper winding wire is more suitable for dry-type transformers. We have enameled copper winding wire and enameled Aluminum winding wire, providing reliable solutions for customers with different budgets. Welcome to consult at any time!