Should a Transformer have copper or aluminium windings?
Many people have an interesting hobby – they make electrical circuits and transformers at home. Some do this to create interesting robotics, or because they're learning to become transformer prototyping engineers, or just because they enjoy having something to do with their hands. Inevitably, when creating electronics by yourself, you come up with questions. When you have a question, it's a good idea to ask a professional transformer prototyping engineer – that way, you get the best info and are less likely to hurt yourself.
One of the most common questions people building their own transformers ask is "should my transformer have copper or aluminium windings?" This is a very good question, and we've got a specialist transformer engineer here to answer it:
"Both copper and aluminium windings work in transformers. The question is – which is better? Aluminium windings have certainly become popular in recent years, especially for low voltage transformers rated above 15KVA. They're now standard in commercial industrial facilities. The reason for this is that they cost considerably less than copper, and that cost factor is always going to be important, especially to hobby electrical engineers in this economic climate.
Over 15KVA transformers usually require a lot of space anyway, but transformers below 15KVA have an issue with performance sensitivity. When designing a transformer below 15KVA, copper is definitely the superior metal for windings.
This is because copper is more conductive than aluminium, meaning a copper wire in a 15KVA or less transformer takes up less room than an aluminium one. An aluminium winding requires larger diameter coils and greater volume cores. This means you can create smaller – and therefore more stable – transformer units when using copper. At below 15KVA, copper is definitely the preferred metal for windings.
Other things to think about: copper has a lower coefficient of expansion, a lower electrical resistivity, and a greater tensile strength when compared with aluminium. Copper also has a greater thermal conductivity.
Don't allow cost to disadvantage your hobby transformer prototyping. When it's below 15KVA, copper is the winding to choose. If you can't afford copper winding – save up! Circuit performance and energy efficiency are more important than cost at 15KVA or less.
One of the most common questions people building their own transformers ask is "should my transformer have copper or aluminium windings?" This is a very good question, and we've got a specialist transformer engineer here to answer it:
"Both copper and aluminium windings work in transformers. The question is – which is better? Aluminium windings have certainly become popular in recent years, especially for low voltage transformers rated above 15KVA. They're now standard in commercial industrial facilities. The reason for this is that they cost considerably less than copper, and that cost factor is always going to be important, especially to hobby electrical engineers in this economic climate.
Over 15KVA transformers usually require a lot of space anyway, but transformers below 15KVA have an issue with performance sensitivity. When designing a transformer below 15KVA, copper is definitely the superior metal for windings.
This is because copper is more conductive than aluminium, meaning a copper wire in a 15KVA or less transformer takes up less room than an aluminium one. An aluminium winding requires larger diameter coils and greater volume cores. This means you can create smaller – and therefore more stable – transformer units when using copper. At below 15KVA, copper is definitely the preferred metal for windings.
Other things to think about: copper has a lower coefficient of expansion, a lower electrical resistivity, and a greater tensile strength when compared with aluminium. Copper also has a greater thermal conductivity.
Don't allow cost to disadvantage your hobby transformer prototyping. When it's below 15KVA, copper is the winding to choose. If you can't afford copper winding – save up! Circuit performance and energy efficiency are more important than cost at 15KVA or less.
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