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Why Use Copper Rather Than Aluminium in Power Transformers - Leonardo Energy - Knowledge Base
Why Use Copper Rather Than Aluminium in Power Transformers - Leonardo Energy - Knowledge Base
Copper displays low levels of creep. Under the extreme loading and temperature conditions of distribution
transformer windings, creep rates of aluminium can be up to 25 times higher than for copper. This results in
aluminium wound distribution transformers having a higher propensity to failure than copper wound ones.
Copper wire terminations are less prone to failure than aluminium wire terminations. A key reason for this is
the different behavior of their oxides. Copper oxide is soft, electrically conductive, and breaks down easily.
Aluminium oxide is strongly attached, hard to dislodge and electrically insulating. It also prevents non-
mechanical connections such as soldering, which is only possible after applying a layer of tin, copper, or nickel.
Copper wires have no galvanic action, as they are the same element as the connectors, which are usually
made of copper or brass (a copper alloy). Aluminium loses material through galvanic action, leading to a loss
of contact.
Copper is harder, stronger and more ductile than aluminium, expands less and does not flow at
terminations. Consequently it does not require periodic inspection and tightening of screws. Aluminium flows
The use of the right grade of copper is considered the best way to ensure high short-circuit withstand
capability in power transformers, due to copper’s outstanding mechanical properties, such as yield strength
and modulus of elasticity. Copper is available with a yield strength as high as 280 N/mm2 for heavy-duty
transformers with frequent short-circuits such as those used for arc furnaces. External short-circuits can cause
Copper wound distribution transformers are invariably smaller and lighter than aluminium wound ones of an
equivalent capacity and energy performance. Since the resistivity of copper is 0.6 times that of aluminium, the
cross-section of the aluminium conductor needs to be 1.66 times larger than that of the copper conductor for
the same resistance. This results in a larger transformer core and volume, which also leads to a larger
transformer tank than for the copper design. While aluminium is lighter than copper of an equal volume, in the
case of distribution transformers, this advantage is nullified by the increased volume (and thus weight) of the
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3/8/2018 Why use copper rather than aluminium in power transformers? – Leonardo Energy - Knowledge Base
Distribution transformers with HV windings made of copper conductors are less susceptible to metal
fatigue than aluminium ones. The fatigue life of aluminium HV winding conductors has been found to be much
less than those made of copper under similar operating stress conditions. This suggests that after loosening
the HV winding conductor, aluminium wound distribution transformers would fail earlier than copper wound
ones.
Higher copper content in transformers improves energy performance and consequently lowers lifecycle
costs in most cases. A study commissioned by the European Commission showed that the transformer design
option that gives the least lifecycle cost has lower energy losses and uses substantially more copper than the
Non-linear loads cause additional load losses in power transformers, which are influenced greatly by the
transformer geometry, winding configurations, and insulation and conductor materials. In particular,
the current distribution is more uniform with copper conductors due to the higher conductivity.
Finally, transformers with copper windings are often less expensive to manufacture than those with
aluminium windings. This is because it is not just the cost of conductor, but also the cost of magnetic steel,
tank and oil needed to achieve the specified energy performance level that determines the total transformer
manufacturing cost.
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