Aluminum and Aluminum Alloys Electrical Power Wires
Last Updated: April 1, 2025
Description
Aluminum and aluminum alloys electrical power wires are conductors used to transmit electrical power. These wires are composed of aluminum or its alloys, which are known for their excellent corrosion resistance and good electrical and thermal conductivity. They are often used in power conductors and wire shielding due to their lightweight nature, being one-third the density of steel.
Working Principle
Aluminum and aluminum alloy wires work by conducting electricity through the metal's lattice structure, which allows electrons to flow with minimal resistance. The high conductivity-to-weight ratio of aluminum makes it particularly useful in applications where weight savings are crucial, such as in aerospace and automotive industries. The spiral stranding of aluminum conductors provides flexibility, which is essential for overhead transmission lines.
Applications
Aluminum and aluminum alloy electrical power wires are used in various applications, including overhead transmission lines and underground cables. Specific examples include AAC (all-aluminum conductors), AAAC (all-aluminum alloy conductors), ACSR (aluminum conductors, steel reinforced), and ACAR (aluminum conductors, alloy reinforced) . They are also approved for use in airborne applications for power systems in gauges of 6 AWG or larger .
Advantages over other Electrical Power Wires
Aluminum wires offer several advantages over copper wires, including a higher strength-to-weight and conductivity-to-weight ratio . The low density of aluminum results in significant weight savings, which is a critical design consideration in aerospace and automotive applications. Additionally, the resistivity density product factor is lower for aluminum, making it a more efficient conductor in certain scenarios .
Limitations
One limitation of aluminum wires is their inability to be easily soldered or plated to improve solderability . This can pose challenges in certain electrical systems. Additionally, aluminum wires may require bimetallic adaptors to interface with copper conductors to prevent galvanic corrosion, which can compromise fire safety .
Considerations
When considering aluminum and aluminum alloy electrical power wires, it is important to evaluate initial costs, operating expenses, and durability. Aluminum wires are generally more cost-effective than copper wires due to the lower material cost. However, considerations for replacement and maintenance costs should include potential issues with corrosion and the need for special adaptors when interfacing with other metals. The durability of aluminum wires is enhanced by their excellent corrosion resistance, but their performance in high-temperature environments may not match that of copper wires .
from Carlisle Interconnect Technologies
An increased wall thickness version utilizing an aluminum conductor for power feeder applications. Improved mechanical performance including superior flexibility as compared to traditional polyimide insulated power feeder cables. TLA is rated at 175 °C. Excellent Temperature Performance. [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Insulation: PTFE
- Cable Jacket: PTFE
- North American: 8
from Hi-Tech Controls, Inc.
Suitable for indoor installation and in cable ducts, outdoors, underground and in water as well as for installation on cable trays for industries, switch-boards and power stations. The PE-outer jacket is resistant to high mechanical stress for laying the cables. This PE-jacket is not flame-resistant... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Rated Voltage: 45
- Number of Conductors: 1
- Rated Temperature: -20 to 90
from Belden Inc.
Bus Bar Wire, 8AWG (Solid) Soft Annealed Aluminium [See More]
- Cable Conductor: Aluminum and Aluminum Alloys; Aluminum - Solid
- Number of Conductors: 1
- Product Type: Single Conductor Wire
- Cable Jacket: None
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 7 CONDUCTOR(S). 2 AWG CONDUCTOR SIZE. REEL PACKAGING. AAC TYPE CODE. 75 DEG C TEMPERATURE. SOUTHWIRE[R] BRAND. TRADE NAME IRIS. STRANDING 7. WEIGHT 700 LB [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 7
- Product Type: Multiconductor Cable
- North American: 2
from General Cable
General Cable is recognized worldwide for its leadership and breadth in power, control and instrumentation cable products. Our solutions span a very broad range of manufacturing and industrial distribution applications, engineered to perform reliably in the most demanding environments. Our... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys; Copper
- Number of Conductors: 2 to 6
- Product Type: Multiconductor Cable; Single Conductor Wire; Transmission / Distribution Wire
- Rated Voltage: 0.6000 to 35
from Hi-Tech Controls, Inc.
Suitable for indoor installation and in cable ducts, outdoors, underground and in water as well as for installation on cable trays for industries, switch-boards and power stations. The PE-outer jacket is resistant to high mechanical stress for laying the cables. This PE-jacket is not flame-resistant... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Rated Voltage: 45
- Number of Conductors: 1
- Rated Temperature: -20 to 90
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 1 CONDUCTOR(S). 4 AWG CONDUCTOR SIZE. REEL PACKAGING. ACSR TYPE CODE. SOUTHWIRE[R] BRAND. TRADE NAME SWAN. STRANDING 6/1. WEIGHT 884 LB [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 1
- Product Type: Multiconductor Cable
- North American: 4
from General Cable
As your long-standing energy partner, we have the breadth of product and application engineering expertise to meet your specific transmission, distribution, generation and substation cabling needs. With over one hundred years of experience in developing advanced materials and compounds that deliver... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys; Aluminum Clad Steel; Copper
- Rated Voltage: 0.3000 to 500
- Product Type: Multiconductor Cable
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 1 CONDUCTOR(S). 2 AWG CONDUCTOR SIZE. COIL PACKAGING. ACSR TYPE CODE. SOUTHWIRE[R] BRAND. TRADE NAME SPARATE. STRANDING 7/1. WEIGHT 241 LB [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 1
- Product Type: Multiconductor Cable
- North American: 2
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 1 CONDUCTOR(S). 123.3 KCMIL CONDUCTOR SIZE. REEL PACKAGING. AAAC TYPE CODE. 75 DEG C TEMPERATURE. SOUTHWIRE[R] BRAND. TRADE NAME AZUSA. STRANDING 7. WEIGHT 695 LB [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 1
- Product Type: Multiconductor Cable
- International: 123
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 1 CONDUCTOR(S). POLYETHYLENE INSULATION MATERIAL. 2 AWG CONDUCTOR SIZE. 6700 FT REEL PACKAGING. ACSR TYPE CODE. 75 DEG C TEMPERATURE. SOUTHWIRE[R] BRAND. TRADE NAME PIGNUT. STRANDING 6/1. WEIGHT 118 LB PER 1000 FT [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 1
- Product Type: Multiconductor Cable
- Cable Insulation: Polyethylene
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 1 CONDUCTOR(S). POLYETHYLENE INSULATION MATERIAL. 6 AWG CONDUCTOR SIZE. 600 V VOLTAGE. 1000 FT COIL PACKAGING. 6 AWG NEUTRAL CONDUCTOR SIZE. DUPLEX TYPE CODE. 75 DEG C TEMPERATURE. 1 NEUTRAL CONDUCTOR(S). SOUTHWIRE[R] BRAND. TRADE NAME COLLIE. STRANDING 7... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 1
- Product Type: Multiconductor Cable
- Cable Insulation: Polyethylene
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 2 CONDUCTOR(S). POLYETHYLENE INSULATION MATERIAL. 4 AWG CONDUCTOR SIZE. 600 V VOLTAGE. 1500 FT REEL PACKAGING. 4 AWG NEUTRAL CONDUCTOR SIZE. TRIPLEX TYPE CODE. 75 DEG C TEMPERATURE. 1 NEUTRAL CONDUCTOR(S). SOUTHWIRE[R] BRAND. TRADE NAME OYSTER. STRANDING 7... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 2
- Product Type: Multiconductor Cable
- Cable Insulation: Polyethylene
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 3 CONDUCTOR(S). POLYETHYLENE INSULATION MATERIAL. 6 AWG CONDUCTOR SIZE. 600 V VOLTAGE. 500 FT COIL PACKAGING. 6 AWG NEUTRAL CONDUCTOR SIZE. QUADRUPLEX TYPE CODE. 75 DEG C TEMPERATURE. 1 NEUTRAL CONDUCTOR(S). SOUTHWIRE[R] BRAND. TRADE NAME CHOLA. STRANDING 7 (PHASE), 6/1... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 3
- Product Type: Multiconductor Cable
- Cable Insulation: Polyethylene
from Southwire Company, LLC
ALUMINUM CONDUCTOR MATERIAL. 2 CONDUCTOR(S). XLPE INSULATION MATERIAL. 4/0 AWG CONDUCTOR SIZE. 600 V VOLTAGE. 1000 FT REEL PACKAGING. 4/0 AWG NEUTRAL CONDUCTOR SIZE. 90 DEG C TEMPERATURE. 1 NEUTRAL CONDUCTOR(S). SOUTHWIRE[R] BRAND. TRADE NAME DURANT. STRANDING 7 (PHASE/NEUTRAL). WEIGHT 756 LB PER... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Number of Conductors: 2
- Product Type: Multiconductor Cable
- > AWG 0: 4/0 AWG
from Southwire Company, LLC
SEU TYPE. 1000 FT. 1000 LENGTH IN FT. ALUMINUM CONDUCTOR MATERIAL. UL 44, UL 83, UL 854 APPROVAL. 600 V VOLTAGE RATING. 90 DEG C TEMPERATURE RATING. WITH GROUND WIRE. (2) 8 AWG CONDUCTOR SIZE. GRAY PVC JACKET MATERIAL. REEL PACKAGE TYPE. 8 AWG GROUND CONDUCTOR SIZE. SOUTHWIRE[R] BRAND [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1000
- Product Type: Multiconductor Cable
- Rated Voltage: 0.6000
from Southwire Company, LLC
DIRECT BURIAL TYPE. 1000 FT. 1000 LENGTH IN FT. 403 MIL OUTER DIAMETER. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 155 AMPERE DIRECT BURIAL, 115 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 92 LB/1000 FT WEIGHT. 1 CONDUCTOR(S). XLPE INSULATION MATERIAL. 2 AWG... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1000
- Product Type: Multiconductor Cable
- Number of Conductors: 1
from Southwire Company, LLC
DIRECT BURIAL TYPE. 1500 FT. 1500 LENGTH IN FT. 745 MIL OUTER DIAMETER. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 125 AMPERE DIRECT BURIAL, 90 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 191 LB/1000 FT WEIGHT. 3 CONDUCTOR(S). XLPE INSULATION MATERIAL. 4 AWG... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1500
- Product Type: Multiconductor Cable
- Number of Conductors: 3
from Southwire Company, LLC
DIRECT BURIAL TYPE. 1000 FT. 1000 LENGTH IN FT. 524 MIL OUTER DIAMETER. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 70 AMPERE DIRECT BURIAL, 55 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 64 LB/1000 FT WEIGHT. 2 CONDUCTOR(S). XLPE INSULATION MATERIAL. 8 AWG... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1000
- Product Type: Multiconductor Cable
- Number of Conductors: 2
from Southwire Company, LLC
DIRECT BURIAL TYPE. 1500 FT. 1500 LENGTH IN FT. 833 MIL OUTER DIAMETER. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 120 AMPERE DIRECT BURIAL, 85 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 255 LB/1000 FT WEIGHT. 4 CONDUCTOR(S). XLPE INSULATION MATERIAL. 4 AWG... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1500
- Product Type: Multiconductor Cable
- Number of Conductors: 4
from Southwire Company, LLC
DIRECT BURIAL TYPE. 1000 FT. 1000 LENGTH IN FT. 973 MIL OUTER DIAMETER. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 155 AMPERE DIRECT BURIAL, 115 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 343 LB/1000 FT WEIGHT. 4 CONDUCTOR(S). XLPE INSULATION MATERIAL. 2 AWG... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1000
- Product Type: Multiconductor Cable
- Number of Conductors: 4
from Southwire Company, LLC
DIRECT BURIAL TYPE. 1000 FT. 1000 LENGTH IN FT. 596 MIL OUTER DIAMETER. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 90 AMPERE DIRECT BURIAL, 65 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 90 LB/1000 FT WEIGHT. 2 CONDUCTOR(S). XLPE INSULATION MATERIAL. 6 AWG... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 1000
- Product Type: Multiconductor Cable
- Number of Conductors: 2
from Southwire Company, LLC
DIRECT BURIAL TYPE. 2500 FT. 2500 LENGTH IN FT. ALUMINUM CONDUCTOR MATERIAL. UL 854 APPROVAL. 600 V VOLTAGE RATING. 320 AMPERE DIRECT BURIAL, 250 AMPERE IN DUCT CURRENT RATING. 90 DEG C TEMPERATURE RATING. 4 CONDUCTOR(S). XLPE INSULATION MATERIAL. 250 KCMIL CONDUCTOR SIZE. BLACK, BLACK WITH YELLOW... [See More]
- Cable Conductor: Aluminum and Aluminum Alloys
- Cable Length: 2500
- Product Type: Multiconductor Cable
- Number of Conductors: 4