Aluminum is often substituted for copper as a transformer’s conductor. This design decision is part of an engineering approach that can greatly increase the total cost of owning a transformer. The use of aluminum does not necessarily signify that a transformer will have a short life span. But aluminum is commonly a characteristic of transformers that fail in 10 to 15 years. Keep in mind that a properly designed transformer can perform for 50 years (or longer). If you’re not careful, your decision to save a few dollars today can be very expensive over time — you might have to replac that cheap transformer five (5) times during the comparable lifespan of a well built transformer.Aluminum Winding is Cheaper Than Copper WindingA high percentage of low voltage transformers rated 15 KVA or larger use aluminum windings. MJ Aluminium’s utility industry clients report that nearly all new service entrance connections at commercial industrial facilities use aluminum conductors. The technology has become commonplace over the past 30 years. Price is an important factor in the rise in popularity of aluminum.Aluminum magnet wire costs less than copper magnet wire. While this difference may not seem like much, you have to know that commodity transformers are engineered to exploit EVERY small source of savings. By skimping on your conductor material, the manufacturer can saves a little amount of money.Comparing Copper and AluminumCharacteristicAluminumCopperThermal Conductivity0.57 (Cal/s-cm-K)0.94 (Cal/s-cm-K)Electrical Resistivity2.69 (X 10^8, Ohm-m)1.673 (X 10^8, Ohm-m)Expansion Coefficient23.5 (X 10^6, 1/Deg.C)17.0 (X 10^6, 1/Deg.C)Tensile Strength12,000 (lb/in)^232,000 (lb/in)^2MJ Aluminium Transformers are Not Commodity TransformersCommodity TransformerMJ Aluminium Transformerapplication genericapplication specificcheap materialspremium materialshasty assemblymeticulous attention to detailliberal quality controlrigorous testing standardsautomated mass productionhand-crafted batch production10-15 year lifespan50+ year lifespan
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