Looking for aluminum wire

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Posted by S. Krussell.

Coach on team #349, Robahamas, from International Academy and Ford Motor Co..

Posted on 9/13/2000 6:51 PM MST



Does anyone out there know of a place to purchase aluminum wiring around Oakland County? Looking to re-wire a couple motors before the upcoming post-season competitions. We've called quite a few places with no luck yet.

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Posted by Justin Stiltner.

Student on team #388, Epsilon, from Grundy High School and NASA, American Electric Power, Town of Grundy.

Posted on 9/13/2000 7:09 PM MST


In Reply to: Looking for aluminum wire posted by S. Krussell on 9/13/2000 6:51 PM MST:



: Does anyone out there know of a place to purchase aluminum wiring around Oakland County? Looking to re-wire a couple motors before the upcoming post-season competitions. We've called quite a few places with no luck yet.

Why do you need Al. wire?? If you are going to connect this to copper wire be very careful about crooding (thats the colsest spelling I can come up with right now) wires and terminals. Copper and Aluminum do not like each other.

Justin Stiltner
Team #388
Grundy Va,

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Posted by Michael Betts.

Engineer on team #177, Bobcat Robotics, from South Windsor High School and International Fuel Cells.

Posted on 9/14/2000 9:43 AM MST


In Reply to: Re: Looking for aluminum wire posted by Justin Stiltner on 9/13/2000 7:09 PM MST:



Mr. Krussell, et al,

This is a more serious issue than Justin indicates. The thermal expansion of aluminum wire is much higher than copper. Connections are expanded and weakened with every operation. Eventually, the connection resistance gets so high that the aluminum catches fire.

A great many homes burnt to the ground in the 60's before Al wiring was banned by the NEC (National Electrical Code) except for some very specific exceptions (main service feeds, etc.).

I have NEVER seen Al wire used for a motor winding. Windings normally use what is commonly called 'magnet wire'. It is a copper alloy coated with a varnish for insulation.

Rewinding motors is not a job for the weak of heart. Take care that the wire you use is of proper AWG, voltage rating and temperature rating. Failure to use the proper wire can result in spectacular results! Please wear safety glasses and take other appropriate precautions (fuses) when powering up a rebuilt motor.

Magnet wire can be purchased at an electrical supply house such as AllPhase. In addition, a local shop which rebuilds alternators may be a great resource of material and/or experience.

Mike

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Posted by Joe Johnson.   [PICTURE: SAME | NEW | HELP]


Engineer on team #47, Chief Delphi, from Pontiac Central High School and Delphi Automotive Systems.

Posted on 9/14/2000 10:35 AM MST


In Reply to: Re: Looking for aluminum wire posted by Michael Betts on 9/14/2000 9:43 AM MST:



You can get almost everything worthing getting from those guys with the yellow catalog (#106 is the latest revision).

Go to their online catalog. It is the best I know of on the web.

Their prices are good. Their shipping times are unbelievable (orders place via the web before about 5:30pm are almost always on our dock at 10am the next morning).

Finally, they sell magnet wire for your toaster... no I mean 'motor' experiments ;-)

Joe J.

P.S. Magnet wire is on page 641-FYI

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Posted by Janna.

Student on team #349, The RoBahamas, from International Academy and Ford Motor Company.

Posted on 9/14/2000 6:57 PM MST


In Reply to: McMaster to the Rescue... posted by Joe Johnson on 9/14/2000 10:35 AM MST:



Hey,

Just wanted to clarify to everyone...we aren't planning on rewiring the *insides* of the motors...I guess that was a little misleading. Just *replacing* the regular 10 gauge wire between the motors and speed controllers and other things... So yeah, we aren't planning on dissecting the motors and frying them...honestly, even if we wanted to we probably wouldn't know how. Thanks for all the warnings and the sources though!

Janna

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Posted by Justin Stiltner.

Student on team #388, Epsilon, from Grundy High School and NASA, American Electric Power, Town of Grundy.

Posted on 9/14/2000 7:50 PM MST


In Reply to: clarification... posted by Janna on 9/14/2000 6:57 PM MST:



: Hey,

: Just wanted to clarify to everyone...we aren't planning on rewiring the *insides* of the motors...I guess that was a little misleading. Just *replacing* the regular 10 gauge wire between the motors and speed controllers and other things... So yeah, we aren't planning on dissecting the motors and frying them...honestly, even if we wanted to we probably wouldn't know how. Thanks for all the warnings and the sources though!

: Janna


Joe,
You amaze me once again. I would have never thought of the thermal expansion. I knew that AL wire was not allowed in houses but I dident know why. I guess what they say is true you learn something every day.
Justin Stiltner
Team #388
Epsilon
Grundy Va,