Aluminum vs Copper Strip in Distribution Transformers

In the manufacturing of distribution transformers, both aluminum and copper strips are widely used as winding materials. Each has distinct advantages in conductivity, cost, weight, and processability. This article provides a detailed comparison to help manufacturers and buyers choose the right material for their transformer applications.

 Electrical Conductivity

• Copper: Higher conductivity (about 100% IACS), allowing more current to pass through a smaller cross-section.
• Aluminum: Lower conductivity (~61% IACS), but larger cross-sections can compensate in transformer winding design.

 Material Cost

• Aluminum: Significantly lower raw material cost and more stable global pricing.
• Copper: Higher price, prone to greater market fluctuations, increasing total transformer cost.

 Weight and Handling

• Aluminum: Approximately one-third the density of copper, reducing transformer weight and making installation easier.
• Copper: Heavier, may improve compactness but increases transportation and structural support requirements.

 Processability and Bonding

• Aluminum: Requires specialized welding and connection techniques (e.g. ultrasonic welding).
• Copper: Easier to solder and bond with conventional methods.

Heat Dissipation

• Both materials conduct heat well, but aluminum's lower density may lead to slightly faster heat release in large coils.

 Performance Comparison Table

Which Is Better?

Both copper and aluminum strips have valid use cases in distribution transformers. For cost-sensitive projects or lighter weight needs, aluminum strip is a popular and effective choice. For applications requiring compactness and maximum conductivity, copper strip remains preferred.

We supply high-quality transformer aluminum strips in compliance with IEC and ASTM standards, offering tailored solutions based on your design requirements.

Contact us today to get a quote or request samples for your project.