This article intends to explain the

advantages of Aluminium over Copper for

its application as electrical current carrying
conductor

Aluminium
v/s Copper
conductors
Advantages of Aluminium
over copper for electrical
application

Udit Sharma
Introduction

Copper (Cu) and Aluminium (Al) are two of the most widely used metals for conduction
of electric current, to be used as bus bars in any electrical equipment. Both the metals have their merits
and demerits that impact on their usage in various electrical applications. Both materials have been in
considered for their use in the electrical industry for many decades. On one hand Al is abundantly
available; on the other hand the demand and scarcity of Cu have caused the cost of same to increase
sharply. Both materials differ in their properties which are the criterion of selection for their application.
Below tables display some of the key properties of both materials:

Fact table-1: Aluminium

Aluminium Property Unit Value

Atomic number - 13
Atomic weight - 26.98
0
Melting Point C 1090
0
Boiling Point C 2519
3
Density gm/cm 2.70
Tensile strength N/mm2 200
0
Resistivity @ 20 C Ω-mm 3.05 x 10-5
Thermal conductivity W/m/K 205
Coefficient of thermal expansion mm/mm 23.4 x 10-6
Specific heat J/gm/K 0.900

Fact table-2: Copper

Copper Property Unit Value

Atomic number - 29
Atomic weight - 63.54
0
Melting Point C 1083
0
Boiling Point C 2562
3
Density gm/cm 8.94
2
Tensile strength N/mm 220
Resistivity @ 200C Ω-mm 1.72 x 10-5
Thermal conductivity W/m/K 401
Coefficient of thermal expansion mm/mm 16.6 x 10-6
Specific heat J/gm/K 0.386
This article intends to explain the advantages of Al over Cu for its application as an electrical conductor.
There are various properties which need to be considered while selecting a material as current carrying
conductor, few of such properties are mentioned below:

1. Current Carrying Capacity

2. Weight
3. Tensile strength
4. Corrosion resistance
5. Cost

1. Current Carrying Capacity: The electrical and mechanical properties of a material depend upon
its chemical composition and alloy. The Cu used for electrical application generally comes with
98% - 99% conductivity on IACS (International Annealed Copper Standard) scale. Pure Al is
generally not used as an electrical conductor because it is quite soft for its application as
conductor (mechanical assemblies) therefore Al is suitably alloyed with other materials such as
Magnesium, Copper, Manganese, Silicon etc. to make it suitable for such purpose. Al alloy 6101
is the most commonly used alloy as bus bar which is stronger than pure Al and is hardened by
heat treatment. It has 56.5% IACS conductivity. The lower conductivity of Al 6101 does not
indicate that the Al conductor will see higher temperature rise for same application as
compared to Cu, but it indicates that Al conductor for the same ampere rating should have a
higher cross sectional area. For same current density Al requires 56% more cross section area
compared to Cu. While considering a material only cross section area is not the only deciding
factor, but other parameters such as conductor weight, heat dissipation coefficient and cost are
also taken in to account which all put together makes Al as an economical choice.

2. Weight: The density of Al is 2.7 gm/cm3 compared to Cu with 8.94 gm/cm3 as density. This
indicates that the Cu is 3.3 times heavier than Al. For same conductivity the area of Al required
is 1.56 times as compared to Cu, while the overall weight of Cu for same conductivity will be
2.12 times more than Al. This explains that even if the cross section of Al is higher compared to
Cu for same conductivity, the overall weight of Al conductor will be much lower and will result in
to significantly lower cost as compared to Cu. Lower weight of Al impacts the overall system as
the support structure, hardware size, manpower efforts etc. are required of optimum level. This
property of Al results in to following advantages:
a. Lower weight of overall system
b. Lower mechanical stresses on the supports and structures
c. Lower creep of enclosures and support system
d. Lower cost of overall system
e. Lower human efforts required for installation
f. Increased personnel safety
3. Tensile Strength: Al alloy 6101 which is most widely used as electrical conductor and Cu are
comparable for their mechanical strength. Al alloy 6101 gives equivalent strength and is very
well compatible with various structural materials such as steel etc. Moreover being lower in
weight for same conductivity Al has a very good “weight – strength” ratio, compared to copper
which results in to a significant weight of Cu conductor for similar strength and therefore higher
cost of conductor and supports.

4. Corrosion Resistance: Aluminium naturally generates a protective oxide coating and is highly
corrosion resistant. Different types of surface treatment such as tin/silver electroplating,
anodizing or lacquering can further improve this property. It is particularly useful for
applications where protection and conservation are required. On the other hand the presence
of hydrogen sulfide (H2S) in the atmosphere is of main concern for base metal Cu and silver
plating. Both corrode heavily in a relatively low concentration of H2S and most intensely in
locations usually having an elevated temperature while the equipment is energized. This
concern makes Al as the preferred choice for conduction of electric current.

5. Cost: Today’s era of economic principal societies, cost is the major concern while making a
correct choice of material. Al being an abundantly available material and because of its vast
presence beneath earth’s crest across the globe, is available at a very economical price. On the
other hand Cu is facing scarcity in availability because of limited resources which have already
been exhausted rapidly. This fact creates a supply-demand issue and results in to a very high
fluctuation of Cu prices. Nowadays Al is available at 1/3 price that of Cu. Also as stated above
the Al weight for same conductivity comes out to be half of the Cu and adding the advantage of
price, the overall cost of Al conductor can be as low as 20% of the cost of Cu conductor which
makes Al a most economical and appropriate solution for an electrical conductor application.
Various regions across the globe prefer and have standardized Al as the only solution for current
carrying elements.
References:

 Copper Association
 Aluminium Association
 National Electrical Code
 Underwriters Laboratories Inc.
 National Electrical Manufacturers Association