Dec. 23, 2024
Metal conductors are an important part of wire and cable products. Copper and aluminum, as the basic materials of wire and cable conductors, have been widely used in the power industry all over the world. Conductor materials should not only meet the application requirements in terms of performance, but also reduce product costs, so as to conform to the background of the era of comprehensive utilization of resources, energy conservation and environmental protection.
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As early as the s, civil construction in the United States and Canada began to use pure aluminum conductors in power cables. Due to the lack of physical, mechanical and electrical properties of pure aluminum, and the installation and laying process at that time was not yet Imperfect, accidents often occurred in application. After World War II, U.S. cable companies, U.S. Underwriters Laboratories and related research institutions began to devote themselves to the development of all-aluminum alloy conductors.
In , the first cable with -series aluminum alloy as the conductor was successfully developed, and then began to be promoted in the United States, Canada and other countries. It is mainly used in military bases, residences, public buildings and wind farms, and its production has been standardized.
The all-aluminum alloy conductor is a new type of energy-saving product. It is a high elongation aluminum alloy material, which is made by adding copper, iron, magnesium and other elemental materials into pure aluminum, and through compression stranding technology and metal annealing treatment to tighten the existing voids in alloyed aluminum. The all-aluminum alloy conductor makes up for the shortcomings of the previous pure aluminum cables. Its insulation material uses flame-retardant silane cross-linked polyethylene, and the outer layer adopts metal chain armor structure, so the gap between the conductive performance of the all-aluminum alloy conductor and the copper core cable is greatly reduced, but the creep resistance, bending performance and corrosion resistance are greatly improved, which ensures that when the cable encounters overload and overheat during use, stability can be maintained for continuous performance.
In the production process of the all-aluminum alloy conductor, advanced compaction technology can make the filling coefficient of the conductor reach 93%; and the all-aluminum alloy conductor is made of silane cross-linked polyethylene, this insulation only needs PVC 2/3 of the thickness can far exceed the conventional insulation performance. However, the filling coefficient of copper can only reach 80% in general, and the commonly used insulation is polyvinyl chloride, so the outer diameter of the all-aluminum alloy conductor can be the same as that of the copper core cable by only increasing by 11% on the basis of the copper core cable. It can be seen that all-aluminum alloy conductors can be used normally without changing the original pipeline design of copper core cables.
All aluminum alloy conductors can completely replace copper core cables in terms of performance, and all aluminum alloy conductors can basically be used where copper core cables can be used. Compared with copper core cables, under the premise of consistent electrical performance, the conductors of all aluminum alloy conductors can resist creep, with the characteristics of high flexibility, strong ductility, low rebound, and stable connection. Its insulation has the characteristics of high temperature resistance, anti-combustion, anti-aging, strong durability, low-carbon and environmental protection. Its armor layer is made of aluminum alloy with interlocking armor, which has a self-locking form. Strong and tough armor layer ensures that the cable can withstand strong destructive forces from the outside world. Its outer sheath is made of lead-free and cadmium-free PVC material, which can be installed under humid environmental conditions or directly buried in cement. In general, the all-aluminum alloy conductor has better bending performance, ductility and creep resistance performance basically the same as that of copper core cable, light weight, energy saving and environmental protection, etc., which reduces the wear and tear between equipment and cables, making Installation work is easier. Under the premise of providing the same electrical performance, the weight of the all-aluminum alloy conductor is half of the copper core cable. Its cross-section is 1.3 times bigger than the traditional copper core cable, and the price is 40% lower than the traditional copper core cable. The comprehensive cost performance advantage is huge.
When the surface of aluminum is in contact with air, a thin and strong oxide layer is formed. The surface of this oxide layer is very resistant to various forms of corrosion, forming the anti-corrosion properties of aluminum itself. Rare earth elements further improve their corrosion resistance, especially in electrochemical corrosion performance. In some sulfur-containing environments, such as in some places such as railway tunnels, the corrosion resistance of aluminum alloys has more obvious advantages than copper.
When the all-aluminum alloy conductor is annealed, some elements added to it produce high-strength creep resistance, which greatly improves its connection performance. Especially the key is that even when the current is overheated and overloaded, the possibility of creep of the all-aluminum alloy conductor is very small, which ensures the stability of their connection. So the electrical connection of all aluminum alloy conductors and copper core cables is equally reliable in stability.
Under the premise of the same electrical performance between the all-aluminum alloy conductor and the copper core cable, the cost price of the all-aluminum alloy conductor is about 13% to 20% lower than the copper core cable, and there is also a saving in installation costs. Due to the high bending performance and lighter weight of the all-aluminum alloy conductor, especially the installation of aluminum alloy belt interlocking armored cable does not require bridges and pipes, saving a lot of steel, and the installation cost can be reduced by about 20%.
1. Since the resistivity of the all-aluminum alloy conductor is lower than the copper conductor, the same electrical function can only be achieved if the cross-section is larger than the copper cable. So the outer diameter of the finished product is 10% to 20% larger than the copper cable. This is the main disadvantage of all aluminum alloy conductors. But whether the link of the equipment or the layout of the cable, this size difference is within the allowable range of the design of the pipe.
2. The scope of application has certain limitations. In the special application environment with high temperature resistance above 700 &#;, the all-aluminum alloy conductor should not replace the copper core cable.
3.The production process of all-aluminum alloy conductors is different from traditional copper core cables. The production process and auxiliary materials cost are relatively high, and the core of its quality assurance is still in the conductors. Therefore, the process of manufacturing all-aluminum alloy conductors still needs to be improved.
The good mechanical properties and conductive properties of aluminum alloy power cables make it widely used in various fields of the national economy, such as high-rise buildings, subways, airports, tunnels, underground buildings, etc., and can also be used in metallurgy, coal mines, Shipbuilding, nuclear power plants, aerospace, military and other industries, as well as automobiles, public transportation facilities, etc., have very promising market prospects and attractive prospects, and will surely become the mainstream of power cable development in the future.
Aluminum alloy wire is a new type of material, which contains some other alloy elements, such as copper, iron, magnesium, silicon, zinc, boron, etc. So this new type of material, aluminum alloy electrical wire, has good mechanical property and electrical property that leads to being widely used in various fields of the national economy.
Here are 5 advantages of aluminum alloy wire that make it widely used in various fields as follows:
1. Strong creep resistanceThe alloy material and annealing process reduces the &#;creep&#; tendency of aluminum alloy conductor electrical wire under heat and pressure and improves the creep resistance by 300% compared with pure aluminum, avoiding the relaxation problem caused by cold flow and creep as well. In addition, aluminum conductor wire is 33% higher flexibility than copper, 40% lower elasticity, more safe and reliable, due to the addition of special ingredients and special processing technology. It also guarantees a stable connection even if overloaded and overheated for a long time.
2. Strong self-weight-bearing capacityAluminum alloys improve the tensile strength of pure aluminum. The weight-bearing capacity of aluminum alloy wire is usually specified in terms of the maximum load that it can support before breaking or deforming.
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In general, aluminum alloy wire has a lower tensile strength than copper wire, which means that it can support less weight for a given diameter. However, aluminum alloy wire can still support significant weight and is often used in applications such as power transmission and distribution, where it must support the weight of transmission lines. This advantage is particularly evident in the wiring of long-span buildings. Aluminum alloy cables can support a length of 4,000 meters of deadweight, while copper cables can only support 2,750 meters.
3. Strong corrosion resistanceThe corrosion resistance of aluminum is from its surface oxide layer that oxidized by contact with air. This oxide layer is particularly resistant to various forms of corrosion. And the additional rare earth elements in the aluminum alloy can further improve the corrosion resistance of aluminum alloys, especially electrochemical corrosion. Aluminum&#;s ability to withstand harsh environments makes it widely used as a conductor for cables in pallets, as well as many industrial components and holders.
4. With armoring characteristicsAluminum alloy cables use armored structures so could withstand the powerful destructive power of the outside. Even if it suffers from greater pressure and impact force, it is difficult to be broken down. At the same time, an armored structure makes the cable isolated from the outside world so it can help prevent damage from moisture, chemicals, and physical impact. Even in the case of fire, an armored layer improves the fire retardant level of the cable, reduces the risk factor of fire, and improves safety performance. Compared with steel tape armored structure, aluminum alloy tape armored structure is light in weight, convenient in laying, free from bridge installation, and can reduce the installation cost by 20%~40%.
5. With compaction characteristicsIncreased conductivity: When an aluminum alloy wire is compacted, its strands are forced closer together, which can increase the wire&#;s conductivity by reducing the resistance between strands.
Improved strength: Compacted aluminum alloy wire is stronger than uncompressed wire because the strands are tightly packed and less likely to move independently of one another.
Reduced weight: Compacted aluminum alloy wire is denser than uncompressed wire, which means that less material is required to achieve the same electrical conductivity. This can result in a lighter-weight wire, which can be beneficial in applications where weight is a concern.
Reduced diameter: Compacting aluminum alloy wire can reduce its overall diameter, which can be useful in applications where space is limited.
Improved flexibility: Compacting aluminum alloy wire can improve its flexibility, making it easier to bend and shape for use in a variety of applications.
In fact, aluminum alloy wire does not only have the advantages mentioned above, but it also has more advantages when used in various industries. If you want to buy aluminum alloy wire now, CHAL is your best choice. CHAL Aluminium Corporation is a professional supplier of Aluminium Alloy Wire with high quality, and the aluminum wire price is reasonable. Our products have excellent economic performance as well as excellent mechanical performance and safety. Please free feel to contact us and we will provide you with quality products and services.
Related Products Related ArticlesIf you want to learn more, please visit our website Metal Clad MC Cable.
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