Definition and Classification
Definition: Aluminum wire is a longitudinal pressure-processed product, usually delivered in coils. It has a variety of cross-sectional shapes, including round, oval, square, rectangular and so on.
Classification: It can be divided into pure aluminum wire and alloy aluminum wire according to material; and into industrial aluminum wire and craft aluminum wire according to application. In addition, there is a type called copper-clad aluminum wire, which is made by coating a thin copper layer on an aluminum core wire and combines some advantages of both copper and aluminum.
Performance Characteristics
Advantages
Lightweight: The density of aluminum is only about 30% that of copper. Under the same current-carrying capacity, aluminum wire is lighter in weight, making it particularly suitable for long-distance overhead transmission lines, which can significantly reduce the load on transmission towers and construction costs.
Low Cost: The price of aluminum is relatively lower than that of copper. Taking a cross-section of 50 square millimeters as an example, the unit price of aluminum wire is about 40% that of copper wire, which can save a lot of costs in large-scale power engineering projects.
Good Corrosion Resistance: When exposed to air, aluminum forms a dense and hard aluminum oxide film, which can effectively prevent the internal metal from further oxidation and corrosion, enhance durability, and make it suitable for outdoor or humid environments.
Easy Processing and Connection: Aluminum wire is relatively soft with a certain bending radius, facilitating bending and wiring. It can be easily installed at construction sites and is suitable for large-scale deployment.
Disadvantages
Low Mechanical Strength: Its tensile strength is usually only 40%–50% that of copper wire, making it prone to breakage in long-span or high-wind areas.
High Contact Resistance: An aluminum oxide film is likely to form on the surface of aluminum wire, which will increase contact resistance and may cause joint overheating and even fire hazards.
High Thermal Expansion Coefficient: In high-temperature areas or regions with frequent temperature changes, aluminum wire is prone to joint loosening and poor contact due to thermal expansion and contraction.
Application Scenarios
Power Transmission: Widely used in the laying of low-voltage and medium-voltage power lines, especially suitable for rural low-voltage power distribution, temporary power supply and other areas with relatively low safety requirements.
Telecommunications Industry: Due to its excellent electrical conductivity and lightweight properties, it is widely used in communication cables and signal transmission lines.
Construction Industry: Can be used for electrical connection and cable laying of building electrical equipment, elevators, air conditioning systems, etc.
Electronic Equipment: Commonly used as connecting wires for electrical components and electronic products, as well as in the assembly of electronic circuits.
Common Types
Bare Aluminum Wire: Without an insulating layer, it is used in direct exposure. It is often applied in low-voltage overhead transmission lines, but due to its obvious disadvantages, it has been gradually replaced in modern power grid construction.
Aluminum Conductor Steel-Reinforced (ACSR): Stranded from high-strength steel wires in the inner core and multiple strands of aluminum wires on the outer layer, it combines high electrical conductivity with high mechanical strength, making it suitable for high-voltage and ultra-high-voltage transmission lines.
Insulated Aluminum Wire: Coated with insulating materials on the outer layer, it can effectively avoid electric shock and short-circuit risks, and is suitable for densely populated areas or complex terrains and other scenarios with high safety requirements.
