Copper conductors are typically preferred for most cables and wires due to their high conductivity, flexibility, tensile strength, and cost-effectiveness. These qualities make copper the ideal choice for a variety of applications. In some cases, conductors made of aluminium are used, particularly in energy transmission.
However, aluminium has a conductivity of only about 63 per cent when compared to copper. This results in a higher voltage drop and reduced current-carrying capacity for the same cross section. To attain equal voltage drop and current capacity as copper cables, larger cross sections are required for aluminium cables. Furthermore, aluminium is more prone to breaking than copper when subjected to multiple bends, resulting in weaker bending resistance. Therefore, aluminium cables are primarily used for fixed installations or low mechanical stress.
When aluminium comes into contact with bare copper, an element formation occurs, leading to corrosion. Therefore, aluminium cables require a separate connection technology that must not use cable lugs intended for copper cables. Instead, only specially approved connection products should be used. Handling, tools, and specialist knowledge required are also unique.
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