The Advantages of Using Aluminum vs. Copper Wire

The choice between aluminum and copper electrical wiring is based on a number of factors, including the current capacity needed, physical space limitations, and budget. Both are commonly used for a variety of applications; however, there are notable differences between them that must be considered.

American Wire Group carries America’s largest inventory of wire and cable products, including many aluminum and copper wire configurations. Here, we’ll break down the key differences to help you weigh the pros and cons of aluminum wire vs. copper wire for your next project.

Aluminum vs. Copper Wire

Aluminum and copper wiring are both widely used for electrical wiring in power utility, building, communications, electronic, and other applications. They have different physical properties that have an effect on when, where, and how they are best used.

Aluminum Wire

Advantages

• Lighter Weight. Aluminum is lightweight and requires less support, especially in extended runs. This can make installation faster in large-scale projects.
• Cost-Effective. Aluminum is less expensive per pound compared to copper, which may result in significant cost savings.
• Corrosion Resistance. Aluminum naturally forms a thin protective layer when exposed to oxygen, which helps prevent corrosion for durability in some environments.
• Electrical Conductivity. Aluminum is a good conductor of electricity, making it suitable for power transmission lines, computer motherboards, and LED lighting.
• Impermeable and Odorless. Even in thin layers, aluminum is impermeable and will not absorb or emit odors.
• Recyclability. Aluminum is 100% recyclable and retains physical properties. This makes it an eco-friendly and sustainable material choice.

Disadvantages

• Conductor Size. Aluminum is less conductive and has higher resistance than copper; therefore, it takes more aluminum material (i.e., larger-diameter conductors) to carry the same amperage as copper. This results in larger raceways and enclosures, and higher installation costs.
• Difficult to Solder. It is more difficult to solder aluminum than copper due to aluminum’s natural tendency to oxidize.
• Terminal Requirements. Aluminum requires the application of an anti-oxidation compound at terminal points to protect against oxidation and excessive resistance, which increases the risk of heat buildup. Applying compound adds time and expense during installation.

Copper Wire

Advantages

• High Conductivity. Copper wire is highly conductive with low resistance, making it a top choice for many applications.
• Tensile Strength. Copper has high tensile strength and high ductility. It can be pulled and bent to fit various wiring configurations without breaking.
• Higher Ampacity. Copper can carry a higher current without overheating, which is critical for safety in high-demand electrical systems.
• Versatility. Copper can be formed into fine wires and easily installed through tight spaces, making it versatile for a wide range of applications.
• Recyclable. Copper is easily recycled, which benefits the environment and helps maintain supply.

Disadvantages

• Higher Cost. Copper is more expensive than aluminum pound for pound. This often increases total project cost, particularly for large installations.
• Weight and Support. Copper is heavier than aluminum. It may require extra support structures over long expanses. Components made with copper wiring may also have higher overall weight than those made with aluminum wiring.
• Theft Risk. Copper’s higher value may make it a target for theft.

Aluminum and Copper Wire at American Wire Group

Weighing the benefits of copper vs. aluminum wire depends on many factors like budget, project scale, target current, installation timeframe, and other specific application needs. At American Wire Group, we provide a comprehensive selection of wire and cable products and services including cable management solutions, cable engineering and design, cut to length on stock lengths, and paralleling. On top of wire & cable solutions, we also offer a range of hardware, accessories, and equipment suitable for the renewable energy and utility markets. Our goal is to be a single source of these essential products for the power utility, renewable energy, construction, EV infrastructure, and other markets.

Contact us today to learn more about our products and services or to discuss your application.