Aluminium Insulated Wire - Material Information

Aluminium insulated wire is a lightweight, cost-effective alternative to copper wiring, with excellent corrosion resistance and electrical performance. Thanks to its natural oxide layer and innovative insulation technologies, it is increasingly used in high-demand electrical and thermal environments.

Material Overview

Aluminium (Al), the most abundant metallic element in Earth's crust, naturally forms a passivating Al₂O₃ oxide layer, providing intrinsic corrosion and dielectric resistance. In insulated wire applications, this oxide layer can be further enhanced via anodization or plasma electrolytic oxidation (PEO), creating a robust insulating barrier [(Otto & Sang, 1987); (Bae et al., 2018)]. Depending on the method, this can produce either a barrier-layer anodic film or a dual-layer structure with hydrated alumina for added thermal shock resistance.

Applications and Advantages

Aluminium insulated wires are widely used in electrical equipment, transformers, and high-vacuum systems. They offer superior performance in thermal cycling environments due to their high heat resistance and low density. Sol-gel derived oxide coatings, for instance, have demonstrated excellent flexibility and resistance to outgassing, making them suitable for aerospace and high-temperature electronics [(Inazawa et al., 1990)]. Additionally, aluminium wiring supports significant weight savings over copper without compromising conductivity in many applications.

Goodfellow Availability

Goodfellow supplies aluminium insulated wire with customizable dimensions and specifications to meet research and engineering requirements. Various grades and insulation types are available for optimal performance in challenging environments.

Explore Aluminium (Al) - Insulated Wire - Material Information and other advanced materials in Goodfellow’s online catalogue: Goodfellow product finder.

References

• Otto, A. J., & Sang, H. (1987). Insulated aluminium wire. *Patent Publication*, GB2194032A.
• Inazawa, S., Yamada, K., & Sawada, K. (1990). Insulated electric wire. *Patent Publication*, JP H02-28388 A.
• Tomaskova, T., & Trnka, P. (2014). The influence of thermal properties of aluminum oxide on electrical insulating materials. *Proc. Int. Sci. Conf. on Electric Power Engineering*, 1–4.
• Dolan, S. E., Lombardo, M., Kuhns, E. C., Ziehm, M. W., & Murphy, M. A. (2015). High temperature insulated aluminum conductor. *Patent Publication*, US20150221959A1.
• Bae, J. Y., Nam, H. C., Ram, L. K., et al. (2018). Method for producing aluminum electrical wire having oxide layer. *Patent Publication*, KR20180008988A.