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Aluminum wire used before the mid-1970s had a somewhat higher rate of creep, but a more significant issue was that the same high price of copper driving the use of aluminum wire led to the use of brass-coated steel rather than solid brass screws for terminations at devices such as outlets and switches.
A copper strip is formed into the shape of a cylinder, while it is being wrapped around an aluminum core and the edges of the copper strip are welded together. The assembly is then pulled through a die, where the cladded wire is squeezed and stretched while also improving the bonding between the copper and the aluminum core. [1]
Aluminium–copper alloys (AlCu) are aluminium alloys that consist largely of aluminium (Al) and traces of copper (Cu) as the main alloying elements. Important grades also contain additives of magnesium , iron , nickel and silicon ( AlCu(Mg, Fe, Ni, Si) ), often manganese is also included to increase strength (see aluminium-manganese alloys ).
English: Comparison of SWG (red), AWG (blue) and IEC 60228 (black) wire gauge sizes from 0.03 to 200 mm² to scale on a 1 mm grid, by CMG Lee. In the SVG file, hover over an item to highlight it. In the SVG file, hover over an item to highlight it.
Comparison of SWG (red), AWG (blue) and IEC 60228 (black) wire gauge sizes from 0.03 to 200 mm² to scale on a 1 mm grid – in the SVG file, hover over a size to highlight it. In engineering applications, it is often most convenient to describe a wire in terms of its cross-section area, rather than its diameter, because the cross section is directly proportional to its strength and weight ...
Also, comparatively, more copper wire can fit in a given conduit than conductors with lower conductivities. This greater wire fill is a special advantage when a system is rewired or expanded. [17] Copper building wire is compatible with brass and quality plated screws. The wire provides connections that will not corrode or creep.
On the other hand, copper is a material with small ρ and large σ — because even a small electric field pulls a lot of current through it. This expression simplifies to the formula given above under "ideal case" when the resistivity is constant in the material and the geometry has a uniform cross-section.
Sample cross-section of high tension power (pylon) line, showing 1 strand (7 wires) of steel surrounded by 4 concentric layers of aluminium. Aluminum conductor steel-reinforced cable (ACSR) is a type of high-capacity, high-strength stranded conductor typically used in overhead power lines.