Looking for aluminum wire

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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