Aluminum alloy power cables are a new type of power cable made with aluminum alloy as the conductor, using advanced technologies such as a special roll-formed stranding process and annealing treatment. Due to their excellent mechanical and electrical properties, aluminum alloy cables are widely used in various applications, including high-rise residential buildings, elevators, and supermarkets.
Advantages and Disadvantages of Aluminum Alloy Cables
Advantages:
1. Creep Resistance
The alloy material and annealing process of aluminum alloy conductors reduce the conductor's tendency to "creep" under heat and pressure. Compared to pure aluminum, creep resistance is improved by 300%, eliminating the problem of relaxation caused by cold flow or creep.
2. Tensile Strength and Elongation
Compared to pure aluminum conductors, aluminum alloy conductors have significantly improved tensile strength and elongation by 30% due to the addition of special ingredients and processing techniques. They are also 33% more flexible than copper and 40% less elastic, making them safer and more reliable.
3. Thermal Expansion Coefficient
The thermal expansion coefficient is used to calculate the dimensional change of a material with temperature changes. Aluminum alloy has a coefficient of thermal expansion comparable to that of copper. For many years, aluminum connectors have reliably worked with both copper and aluminum conductors. The majority of electrical connectors in use today are made of aluminum, making it particularly well-suited to aluminum alloys. Therefore, the expansion and contraction of aluminum alloy conductors and connectors are perfectly aligned.
4. Connection Performance
Electrical connections made with aluminum alloys are just as secure and stable as those made with copper conductors. The composition of aluminum alloys significantly improves their connection performance. When the conductor is annealed, the addition of iron imparts high creep resistance, ensuring a stable connection even under prolonged overload and overheating.
5. Strong Weight-Bearing Capacity
Aluminum alloys improve the tensile strength of pure aluminum. Aluminum alloy cables can support a length of 4,000 meters, while copper cables can only support 2,750 meters. This advantage is particularly evident when wiring long-span structures, such as stadiums.
6. Corrosion Resistance
Aluminum's inherent corrosion resistance stems from the thin, durable oxide layer that forms on the aluminum surface when it comes into contact with air. This oxide layer is exceptionally resistant to all forms of corrosion. The addition of rare earth elements further improves aluminum alloy's corrosion resistance, particularly electrochemical corrosion. Aluminum's ability to withstand harsh environments makes it widely used as conductors in cable trays, as well as in many industrial components and containers. Corrosion often occurs when dissimilar metals are connected in humid environments. Appropriate protective measures, such as lubricants, antioxidants, and protective coatings, can be used to prevent this. Alkaline soils and certain types of acidic soils are particularly corrosive to aluminum, so direct-buried aluminum conductors should be insulated or sheathed to prevent corrosion. In sulfur-containing environments, such as railway tunnels and other similar locations, aluminum alloy exhibits significantly better corrosion resistance than copper.
7. Flexibility
Aluminum alloy offers excellent bendability. Its unique alloy formulation and processing significantly enhance its flexibility. Aluminum alloy is 30% more flexible and 40% less resilient than copper. While the bending radius of typical copper cables is 10 to 20 times the outer diameter, aluminum alloy cables have a bending radius of only 7 times the outer diameter, making terminal connections easier.
8. Armor Characteristics
Most commonly used armored cables in China use steel tape armor, which offers a low safety rating. This poor resistance to external forces can easily lead to punctures. Furthermore, they are heavy, expensive to install, and suffer from poor corrosion resistance, resulting in a short service life. Our metal interlocked armored cable, developed in accordance with US standards, utilizes aluminum alloy tape armor. The interlocking structure between the layers ensures the cable can withstand strong external forces. Even under high pressure and impact, the cable is less susceptible to punctures, improving safety. Furthermore, the armor structure isolates the cable from the outside world. Even in the event of a fire, the armor layer enhances the cable's flame retardancy and fire resistance, reducing the risk of fire. Compared to steel tape armor, aluminum alloy tape armor is lighter and easier to install, eliminating the need for bridge installation and reducing installation costs by 20% to 40%. Different outer sheath layers can be selected based on the specific application, making armored cables more versatile.
9. Compression Properties
Based solely on volume conductivity, aluminum alloy is inferior to copper. However, the conductors we develop not only offer improvements in material properties but also significant breakthroughs in processing. We utilize exceptional compression technology to achieve a compression coefficient of 0.93, while the compression coefficient for special-shaped wires reaches 0.95, a domestic first. This extreme compression compensates for the aluminum alloy's lack of volume conductivity, making the stranded conductor core behave like a solid conductor. This significantly reduces the outer diameter of the core and improves conductivity. At the same current carrying capacity, the outer diameter of the conductor is only 10% larger than that of copper cable.
Disadvantages:
1. Application Limitations of Aluminum Alloy Cables
Aluminum alloy cables are best avoided in densely populated high-rise buildings. For safety reasons, engineers generally use copper cables for vertical shaft power supply trunks in densely populated high-rise buildings.
2. Not suitable for 16mm cables
Aluminum alloy cables offer significant advantages for cables with larger cross-sections. Technical personnel from the Building Electrical Engineering Branch of the Architectural Society of China and the international IEEE held a forum in Shanghai on the application of aluminum-conductor cables. The forum concluded that copper conductors are recommended for cables under 16 mm² due to mechanical strength issues. Because aluminum conductors weigh less than copper conductors, aluminum conductors have a clear advantage for larger cross-sections.
3. Aluminum Alloy Cables Are Not Suitable for Critical Applications
Aluminum cables are primarily used in common structures, such as factories, schools, residences, and commercial buildings. In these common areas, aluminum-conductor cables can completely replace copper cables. However, in more critical and specialized locations, such as urban power trunk lines, large power plants, and heavily polluted environments, where maintenance is difficult, aluminum-conductor cables are not the best choice. Because these locations must ensure the safety and reliability of the power supply, and require extremely high power stability, copper cables, which offer greater safety, are the preferred choice.
Aluminum Alloy Cable Specifications
Common Aluminum Alloy Specifications in China
YJHLV (TC90) aluminum alloy cable, i.e., cross-linked polyethylene insulated, PVC sheathed aluminum alloy power cable, is an unarmored alloy cable.
YJHLV8 (AC90) aluminum alloy cable, i.e., cross-linked polyethylene insulated, aluminum alloy with interlocking armor, is a flexible, self-locking aluminum alloy cable.
YJHLV82 (ACWU90) aluminum alloy cable, i.e., cross-linked polyethylene insulated, aluminum alloy with interlocking armor, is a flexible, self-locking aluminum alloy cable.
YJHLV22 aluminum alloy cable, i.e., cross-linked polyethylene insulated, steel tape armored, PVC sheathed aluminum alloy power cable, uses high-strength double steel tape armor.
YJHLY83 aluminum alloy cable, i.e., cross-linked polyethylene insulated, aluminum alloy with interlocking armor, is a polyolefin sheathed aluminum alloy power cable, is a halogen-free, low-smoke, self-locking aluminum alloy cable.
Common aluminum alloy specifications and models from abroad
AC90, ACWU90, SER, SEU, RW90, RWU90, MC, UD-1350, UD-8000, MHF, XHHW-2, and more.
