What are the key differences between copper and aluminum conductors, and when is each material used?

2025-08-08

The choice between copper and aluminum depends on the specific application.

  • Aluminum is lighter and less expensive than copper. This makes it the preferred material for overhead transmission lines that span long distances. Its lightweight nature reduces the strain on support towers and infrastructure, and its lower cost makes large-scale projects more economical. To compensate for its lower conductivity, a larger diameter aluminum conductor is used to achieve the same current-carrying capacity as a copper wire.

  • Copper has superior electrical conductivity and is much stronger and more durable. It is more resistant to corrosion and thermal expansion, leading to more stable and long-lasting connections. For these reasons, copper is the standard for most underground cables, building wiring, and high-performance applications where its higher cost and weight are justified by its reliability and efficiency.

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