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Aluminum Wire
Aluminum wire is a versatile conductive material manufactured from high-purity aluminum (1xxx series) or alloyed aluminum (3xxx, 5xxx, 6xxx series). It exhibits:
- High electrical conductivity (up to 61% IACS for 1350 alloy)
- Excellent ductility and formability, enabling fine-diameter drawing without cracking
- Lightweight — density ~2.7 g/cm³, 30% lighter than copper
- Natural corrosion resistance due to protective oxide layer formation
- Thermal expansion coefficient higher than copper, requiring careful termination design
- Cost-effective alternative to copper in bulk power transmission and non-critical electrical applications
Chemical Composition (wt%)
Element | 1350 (Pure) | 6061 | 7075 | 3003 |
Al | ≥99.5% | Bal. | Bal. | Bal. |
Si | ≤0.25% | 0.4–0.8 | 0.40 | 0.60 |
Fe | ≤0.40% | ≤0.7 | ≤0.50 | ≤0.7 |
Cu | ≤0.05% | 0.15–0.4 | 1.2–2.0 | ≤0.20 |
Mn | ≤0.05% | ≤0.15 | ≤0.30 | 1.0–1.5 |
Mg | — | 0.8–1.2 | 2.1–2.9 | — |
Cr | — | 0.04–0.35 | 0.18–0.28 | — |
Zn | — | ≤0.25 | 5.1–6.1 | — |
Ti | ≤0.03% | ≤0.15 | ≤0.20 | — |
P, S | ≤0.03% each | ≤0.05 each | ≤0.05 each | ≤0.05 each |
Parameter | Range | Units |
Diameter | 0.5 – 6.5 | mm |
Tolerance | ±0.01 – ±0.05 | mm |
Density | 2.65 – 2.75 | g/cm³ |
Hardness (HV) | 20 – 80 | HV |
Yield Strength | 40 – 220 | MPa |
Tensile Strength | 50 – 300 | MPa |
Elongation | 5 – 35% | % |
Surface Treatment
- Bright Drawing — No coating; polished surface via lubricated drawing dies
- Anodizing — Electrochemical formation of porous Al₂O₃ layer (5–25 μm thick); enhances corrosion/wear resistance; can be dyed for coloration
- Coating — Polymer or enamel insulation (e.g., polyurethane, polyester) for magnet wire applications
- Lubrication — Temporary wax or oil coatings for wire drawing and spooling
- Passivation — Chemical treatment to stabilize native oxide layer
Why Choose Us ?
- High-Purity Alloys — 99.5%+ Al content for optimal conductivity (1350 grade)
- ISO 9001 & IATF 16949 Certified — Consistent quality across batches
- Customizable Tempering & Packaging — Tailored hardness, coil weight (50–500 kg), and labeling
- Competitive Lead Time — 7–10 days for standard orders; 15 days for custom alloys
- Global Compliance — RoHS, REACH, and UL-certified materials for electronics and automotive use
Technical Support — On-site installation guidance and termination best practices
Applications & Industries
Electrical Conductors:
Aluminum wire is widely used in power transmission and distribution, especially in overhead lines like steel-core aluminum cables (ACSR), thanks to its good conductivity, light weight, and cost-effectiveness .
Structural & Construction Applications:
Used in building materials such as aluminum window screens, curtain walls, and aerospace or automotive components due to its high strength-to-weight ratio, corrosion resistance, and durability .
Packaging and Industrial Uses:
Employed in food and pharmaceutical packaging (e.g., foil wraps), as well as in capacitors, coatings, and spray wires for industrial protection .
Frequently Asked Questions
Q1: Why does aluminum wire break during drawing?
A: Breakage occurs due to impurities, improper lubrication, excessive reduction per pass, or residual stress from prior annealing. Use controlled multi-stage drawing with intermediate annealing to maintain ductility.
Q2: Is aluminum wiring safe in homes?
A: Yes, if installed correctly. Use only CO/ALR-rated outlets and connectors. Never use standard copper terminals. Aluminum expands more than copper — loose connections cause overheating. Pig-tailing with copper via approved connectors (e.g., WAGO) is recommended for retrofits.
Q3: Can aluminum wire be soldered?
A: Not with standard tin-lead solder. Use specialized aluminum solder (e.g., zinc-based) or mechanical crimping. Surface oxidation prevents wetting — clean with abrasive pad and apply flux immediately before joining.
Q4: How does aluminum compare to copper in conductivity?
A: Aluminum has ~61% of copper’s conductivity. To carry the same current, use a wire with ~56% larger cross-section. However, aluminum’s lower density makes it lighter and more cost-effective for long-distance lines.
Q5: What causes oxidation on aluminum wire terminations?
A: Exposure to moisture and air forms non-conductive Al₂O₃. Use antioxidant paste (zinc dust in petroleum base) and sealed connectors to prevent this. Never use copper-only terminals.
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