Mike Holt Enterprises Electrical News Source

Important Performance Differences Between Copper-Clad Aluminum and Aluminum

August 30, 2023
Share: Facebook Twitter

Here's a document I feel is worth sharing... Chuck Mello has authored a ground-breaking new Whitepaper that upends common misconceptions about CCA conductors. It's an excellent paper! I hope you find it has value. 

About the Whitepaper:

Some in the electrical industry hold two beliefs about copper-clad aluminum (CCA) conductors when used in power circuit applications. One of these beliefs is that conductors of CCA are just like single metal aluminum conductors and should therefore be treated in the same manner. The other belief is that at 60 Hz the current in CCA conductors runs mainly in the copper layer, like a “skin effect,” rather than being distributed throughout the entire cross-section of the conductor. This white paper provides evidence that these beliefs are unfounded.

This article was written by Chuck Mello for American Bimetallic Association (ABA)

To read whe Whitepaper, click here, or on the image to the right.

About Chuck Mello
Chuck Mello has held several certifications in electrical system testing and presently holds an active Master Electrician license from the State of Colorado. Chuck is a member of IAEI, IEEE and NFPA. He served as the IAEI International President for the IAEI in 2011. Chuck was a principal member of Code Making Panel 5 from 1996 to 2016. He is a nationally recognized speaker on the NEC, grounding and bonding, high voltage power systems, electrical safety, and field evaluations.

Comments
  • I am an early adoptor of technological advancements. There have been downsides to this propensity because of ill conceived "improvements" (think CFL lighting). As an electrician in the 70's, I installed many aluminum branch circuits with 10 and 12awg aluminum conductors. As an electrician in the 90's, 00's, 10's...and continuing to today, I deal with the flawed technology that was adopted when copper became too expensive and aluminum was foisted on the industry without adequate testing.

    That said, the white paper is compelling. It was proposed that the main objections to CCA were skin effect (please, I've spent too much time in high frequency to lend credibility to that theory(i.e. waveguide). Current acts more like DC at 60hz than it does at gigahertz). The other is a metallurgical question which I am profoundly inadequate to challenge.

    In my experience neither of the aforementioned issues are of primary consequence. My greatest objection to AL conductors, clad or unclad, as it were, is mechanical strength. The white paper addresses the oxidation issue which caused a resistive connection at the termination point, with its inherent heat, but didn't address the less malleable properties of AL vs CU. AL will suffer reconnection less reliability than copper and, over time, the relatively brittle nature of aluminum(when compared to copper) is the crux of the issue.

    In my experience failure of small wire gauge AL has been largely mechanical, not electrical.

    Broken wires at termination points have been the overwhelming cause of failure.

    Has this propensity been evaluated?

    Ken Johnson  August 30 2023, 8:25 pm EDT
    Reply to this comment


Get notified when new comments are posted here
* Your Email:
 
        
 
Add Your Comments to this Newsletter
* Your Name:
   Your name will appear under your comments.

* Your Email:
   Your email address is not displayed.
* Comments:

Email Notification Options:
Notify me when a reply is posted to this comment
Notify me whenever a comment is posted to this newsletter