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Aluminum and Copper-A Rusty Relationship

Aluminum and copper are the two most used metals for electrical conduction. This is partly due to their electrically conductive qualities concerning their overall prevalent quantity and ease with which they can be obtained from our environment.

The problem is that both aluminum and copper are individually susceptible to a process known as oxidation, which causes these metals to rust over time when exposed to the oxygen in our environment. When used together, that process is accelerated.

When improperly spliced together, copper and aluminum connections will eventually fail.

In a best-case scenario, the electrical circuit will cease to function altogether.

More commonly, however, what happens is that the increased oxidation increases the resistance in the electrical circuit. Higher resistance means that more heat is generated in the circuit. Every wire has an upper limit of the operational heat it can tolerate under regular use. Eventually, the wire gets too hot and combusts.

In the 60's and 70's, there were many house fires caused by aluminum wiring. While the technology for crafting aluminum wire has advanced significantly, aluminum is still less electrically conductive than copper. It can only tolerate a lesser electrical load than a like-sized copper wire could.

There are several different means for properly splicing aluminum and copper wires together. Furthermore, technological advances have created equipment terminations capable of safely accepting either metal without fear of corrosion.

Unfortunately, none of these solutions existed when the aluminum wire was originally installed in houses. When updating a home known to have aluminum wiring, the only two options are to either rewire it outright with copper or go through every single connection and remake them with the proper terminations- a potentially time-intensive process, depending on how accessible the wiring is.

Aluminum

  • Inferior electrical conductivity to copper.
  • Cheapest option.
  • More malleable than copper. Easier to work with.

Copper Clad Aluminum

  • Intermediary between aluminum and copper.
  • Cheaper than copper.

Copper

  • Best electrical conductivity.
  • The most prominently used electrical conduit.

Are There Any Better Options?

Why, yes! There are. If you feel excessively lavish in your electrical needs, have access to a manufacturer that will make it for you, and are willing to spend literal fortunes, you can use gold and silver electrical wiring- both of which share certain advantages and drawbacks over copper and aluminum.

Pure Gold

  • Less electrical conductivity than copper, more than aluminum.
  • The second least chemically reactive metal next to platinum. Does not oxidize.
  • Most malleable metal in existence. Easy to work with.

Pure Silver

  • Best electrical conductor of all known metals.
  • Noble metal-not is very chemically reactive. Does not oxidize.
  • It is the second most malleable metal in existence. Easy to work with.

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