With the improvement of aluminum alloy cable research and development technology, aluminum alloy cable is expected to replace copper core cable in the general power transmission field; copper core cable must be used in places with special requirements in the building electrical design specifications, because after all, the two are different in structure and manufacturing process. Below TST CABLES will introduce the difference between aluminum alloy cable and copper core cable.
1. Under the same power load, because the current carrying capacity of aluminum is much smaller than that of copper, the diameter of aluminum wire is larger than that of copper wire. For example, for a 6KW electric water heater, 6 square copper core wire is enough, and aluminum wire may need 10 square.
2. The price of aluminum is much lower than that of copper, so the cost of aluminum cable is lower than that of copper cable when the power supply requirements are met at the same distance. Aluminum wire can also reduce the risk of theft (because the recycling price is low); but the manufacturing process of aluminum alloy cable is different for each cable factory, and the price of aluminum alloy cable that meets national standards will definitely not be only 50% of copper core cable.
3. Comparison of technical parameters such as cross-section, current carrying capacity, voltage loss, and comprehensive performance of aluminum alloy cable and copper core cable
Copper cable and aluminum alloy cable selection comparison table
| Copper cable core section (mm2) | 90℃ copper core cable current carrying capacity (A) laid in air | 90℃ copper core cable current carrying capacity (A) underground laying | Aluminum alloy cable core section (mm2) | 90℃ Aluminum alloy cable current carrying capacity (A) laid in air | 90℃ Aluminum Alloy Cable Current Carrying Capacity(A) Underground Laying |
| 16 | 105 | 125 | 25 | 102 | 117 |
| 25 | 134 | 159 | 35 | 127 | 139 |
| 35 | 164 | 189 | 50 | 155 | 170 |
| 50 | 200 | 225 | 70 | 195 | 205 |
| 70 | 252 | 227 | 120 | 277 | 282 |
| 95 | 304 | 324 | 150 | 315 | 316 |
| 120 | 355 | 370 | 185 | 366 | 361 |
| 150 | 407 | 417 | 240 | 435 | 417 |
| 185 | 462 | 462 | 300 | 484 | 464 |
| 240 | 551 | 542 | 400 | 593 | 542 |
| 300 | 630 | 611 | 500 | 680 | 612 |
| 400 | 747 | 699 | 630 | 803 | 699 |
Comparison table of voltage loss between copper cable and aluminum alloy cable
| Copper cable coreCross section (mm2) | Resistance (Ω/km)θ=80℃ | Voltage loss[%/(A·km)]cosφ=0.8 | Aluminum alloy cableCore cross section (mm2) | Resistance (Ω/km)θ=80℃ | Voltage loss[%/(A·km)]cosφ=0.8 |
| 16 | 1.359 | 0.518 | 25 | 1.348 | 0.512 |
| 25 | 0.870 | 0.340 | 35 | 0.869 | 0.339 |
| 35 | 0.622 | 0.249 | 50 | 0.617 | 0.248 |
| 50 | 0.435 | 0.180 | 70 | 0.430 | 0.178 |
| 70 | 0.310 | 0.134 | 120 | 0.308 | 0.120 |
| 95 | 0.229 | 0.105 | 150 | 0.224 | 0.101 |
| 120 | 0.181 | 0.087 | 185 | 0.179 | 0.080 |
| 150 | 0.145 | 0.074 | 240 | 0.140 | 0.071 |
| 185 | 0.118 | 0.064 | 300 | 0.112 | 0.059 |
Comprehensive performance analysis of aluminum alloy power cables and copper cables
| Model | YJV 4×150 | YJHLV 4×240 | Notes |
| Material | Copper | Aluminum, iron, zinc, silicon, manganese, rare earth, etc. | |
| Cable diameter | 52mm | 59mm | |
| Designed service life | =30-year polyethylene | ≥40 years cross-linked polyethylene | |
| Safety | Safety | Safety | |
| Provide customers | Cable products | System solutions, installation guidance | |
| Armor | Non-self-locking armored | Self-locking armor | Construction difficulty is reduced |
| Bending radius | =15d | =7d | Save labor costs |
| Fatigue resistance | Excellent | Excellent | 25% higher than copper cable |
| Flexibility | Excellent | Excellent | 25% higher than copper cable |
| Comparison of same current carrying capacity | 408Amps 52mm | 418Amps 59.5mm | Same current carrying capacity |
| Grade | Normal | Low smoke and halogen-free, flame retardant and fire-resistant | Better than traditional copper cable |
| Total cable weight | 8060KG/km | 3746KG/km | 54% lighter than copper cable |
| Voltage drop | 0.29 | 0.29 | Same |
| Tensile strength | Excellent | Excellent | |
| Corrosion resistance | Excellent | Excellent | |
| Rebound performance | High | Low | 40% lower than copper cable |
Copper cable and aluminum alloy cable are both commonly used conductor materials in electrical engineering, but they each have different characteristics and applicable scenarios. The following is a comparison of the main parameters between the two:
1. Conductivity
Copper cable: The conductivity of copper is very high, about 100% IACS (International Annealed Copper Standard), which means that it has less energy loss when transmitting current.
Aluminum alloy cable: The conductivity of aluminum alloy is about 61% IACS, which means that in order to achieve the same current carrying capacity as copper cable, aluminum alloy cable needs a larger cross-sectional area.
2. Weight
Copper cable: Due to the high density of copper, copper cable is heavier than aluminum cable at the same length and current carrying capacity.
Aluminum alloy cable: In contrast, aluminum alloy cable is lighter and easier to transport and install.
3. Tensile strength and flexibility
Copper cable: Copper has high tensile strength and good flexibility, is easy to bend and form, and is suitable for wiring needs in small spaces.
Aluminum Alloy Cable: Although aluminum alloy cable does not have the same tensile strength as pure copper, its mechanical properties are significantly improved after alloying, and in some cases it may be more suitable for specific applications.
4. Corrosion resistance
Copper cable: Copper has natural corrosion resistance, especially in humid environments.
Aluminum Alloy Cable: Aluminum alloy easily forms an oxide film on the surface, which can prevent further corrosion, but additional protection measures are still required in certain chemical environments.
5. Cost-effectiveness
Copper cable: Given that copper is generally more expensive than aluminum, the cost of copper cable is relatively high.
Aluminum Alloy Cable: Aluminum alloy cable is an economical choice due to its low raw material cost and is particularly popular in some price-sensitive applications.
6. Environmental impact
Copper cable: Copper is a fully recyclable resource that helps reduce environmental burden.
Aluminum Alloy Cable: Aluminum is also a highly recyclable material, which is conducive to sustainable development.
Which type of cable to choose depends on factors such as specific application requirements, budget constraints, and long-term maintenance considerations. For example, copper cables may be preferred where high-efficiency power transmission is required; while aluminum alloy cables may be preferred in the case of pursuing cost-effectiveness or reducing structural loads. If you have customized requirements for copper cables and aluminum alloy cables, please email TST CABLES cable engineers to obtain solutions and free samples.
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