Aluminum Chassis/Primary Wire
Aluminum Chassis/Primary Wire
(OP)
Has anyone here used aluminum for chassis wiring or battery primary cabling? I was looking into the price/weight difference and I have been unable to even find any SGX, GXL, etc wiring with a stranded aluminum conductor instead of copper. Does anyone do this?





RE: Aluminum Chassis/Primary Wire
> Flammability
> Electromigration
TTFN
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RE: Aluminum Chassis/Primary Wire
RE: Aluminum Chassis/Primary Wire
We never considered aluminium because of the oxidtaion and corrosion issues as we had sodium hydroxide solution all over the shop.
Cheers
Greg Locock
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RE: Aluminum Chassis/Primary Wire
As far as I know, they don't even use this on F! where they will spend thousands just to save a few grams.
Regards
Pat
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RE: Aluminum Chassis/Primary Wire
RE: Aluminum Chassis/Primary Wire
One place where aluminum still has some distinct advantage is in the wiring between the integrated circuit and its package leads. The annoying property of aluminum galling to other materials is actually an advantage when trying to ultrasonically weld aluminum to aluminum pads on the die and copper, gold, or kovar studs on the package.
TTFN
FAQ731-376: Eng-Tips.com Forum Policies
RE: Aluminum Chassis/Primary Wire
Regards
Pat
See FAQ731-376: Eng-Tips.com Forum Policies for tips on use of eng-tips by professional engineers &
http://eng-tips.com/market.cfm
for site rules
RE: Aluminum Chassis/Primary Wire
TTFN
FAQ731-376: Eng-Tips.com Forum Policies
RE: Aluminum Chassis/Primary Wire
Modern receptacles and fixtures often also have CuAl stamped or engraved on them, meaning they can also be used with aluminum wire. Their coefficient of thermal expansion matches that of the aluminum wires, which reduces the amount of air gap that forms upon heating. If properly installed (correct fixtures and antioxidant paste), aluminum wire can be safely used in residential settings. In fact, the main feed from the power pole into the house is often aluminum wire.
Contrast this to a typical automotive environment, where vibration, heat/cold cycles, corrosive environments (road salt), and (sometimes) exposed connections with no ability to retain antioxidant compounds make aluminum a non-starter.