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Using aluminium busbar/cables in an aircraft instead of copper
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I have just found out Airbus uses aluminium wiring in the A380 to save weight. However, I didn't see anything about whether all the wiring is aluminium, or if copper wiring is also used. What is the logic behind this, and do other aircraft manufacturers do the same? Does Airbus use aluminium wiring in aircraft produced since the A380 was introduced? Are there any risks associated with using aluminium wiring on aircraft?
airbus aircraft-physics
edited 10 hours ago
Juan Jimenez
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asked 10 hours ago
huyterganhuytergan
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
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$endgroup$
add a comment |
$begingroup$
I have just found out Airbus uses aluminium wiring in the A380 to save weight. However, I didn't see anything about whether all the wiring is aluminium, or if copper wiring is also used. What is the logic behind this, and do other aircraft manufacturers do the same? Does Airbus use aluminium wiring in aircraft produced since the A380 was introduced? Are there any risks associated with using aluminium wiring on aircraft?
airbus aircraft-physics
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
asked 10 hours ago
huyterganhuytergan
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
$endgroup$
$begingroup$
It's my understanding that most aircraft wiring is aluminum because it weighs less and is almost as conductive as copper.
$endgroup$
– FreeMan
10 hours ago
$begingroup$
Already asked and answered here: aviation.stackexchange.com/questions/61510/…
$endgroup$
– Therac
6 hours ago
$begingroup$
In smaller planes, AL has been used to connect the battery in the tailcone to the starter & other electronics in front of the pilot. That has worked properly for years, with the main thing being to properly terminate the AL in crimped connectors with the proper 'grease' (I don't know what it is) to prevent any galvanic corrosion. My plane has that, built in 1973 and still going strong.
$endgroup$
– CrossRoads
3 hours ago
add a comment |
$begingroup$
I have just found out Airbus uses aluminium wiring in the A380 to save weight. However, I didn't see anything about whether all the wiring is aluminium, or if copper wiring is also used. What is the logic behind this, and do other aircraft manufacturers do the same? Does Airbus use aluminium wiring in aircraft produced since the A380 was introduced? Are there any risks associated with using aluminium wiring on aircraft?
airbus aircraft-physics
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
asked 10 hours ago
huyterganhuytergan
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
$endgroup$
I have just found out Airbus uses aluminium wiring in the A380 to save weight. However, I didn't see anything about whether all the wiring is aluminium, or if copper wiring is also used. What is the logic behind this, and do other aircraft manufacturers do the same? Does Airbus use aluminium wiring in aircraft produced since the A380 was introduced? Are there any risks associated with using aluminium wiring on aircraft?
airbus aircraft-physics
airbus aircraft-physics
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
asked 10 hours ago
huyterganhuytergan
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
asked 10 hours ago
huyterganhuytergan
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
edited 10 hours ago
Juan Jimenez
7,6151 gold badge12 silver badges49 bronze badges
7,6151 gold badge12 silver badges49 bronze badges
asked 10 hours ago
huyterganhuytergan
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
asked 10 hours ago
huyterganhuytergan
162 bronze badges
asked 10 hours ago
huyterganhuytergan
162 bronze badges
162 bronze badges
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
New contributor
huytergan is a new contributor to this site. Take care in asking for clarification, commenting, and answering.
Check out our Code of Conduct.
$begingroup$
It's my understanding that most aircraft wiring is aluminum because it weighs less and is almost as conductive as copper.
$endgroup$
– FreeMan
10 hours ago
$begingroup$
Already asked and answered here: aviation.stackexchange.com/questions/61510/…
$endgroup$
– Therac
6 hours ago
$begingroup$
In smaller planes, AL has been used to connect the battery in the tailcone to the starter & other electronics in front of the pilot. That has worked properly for years, with the main thing being to properly terminate the AL in crimped connectors with the proper 'grease' (I don't know what it is) to prevent any galvanic corrosion. My plane has that, built in 1973 and still going strong.
$endgroup$
– CrossRoads
3 hours ago
add a comment |
$begingroup$
It's my understanding that most aircraft wiring is aluminum because it weighs less and is almost as conductive as copper.
$endgroup$
– FreeMan
10 hours ago
$begingroup$
Already asked and answered here: aviation.stackexchange.com/questions/61510/…
$endgroup$
– Therac
6 hours ago
$begingroup$
In smaller planes, AL has been used to connect the battery in the tailcone to the starter & other electronics in front of the pilot. That has worked properly for years, with the main thing being to properly terminate the AL in crimped connectors with the proper 'grease' (I don't know what it is) to prevent any galvanic corrosion. My plane has that, built in 1973 and still going strong.
$endgroup$
– CrossRoads
3 hours ago
$begingroup$
It's my understanding that most aircraft wiring is aluminum because it weighs less and is almost as conductive as copper.
$endgroup$
– FreeMan
10 hours ago
$begingroup$
It's my understanding that most aircraft wiring is aluminum because it weighs less and is almost as conductive as copper.
$endgroup$
– FreeMan
10 hours ago
$begingroup$
Already asked and answered here: aviation.stackexchange.com/questions/61510/…
$endgroup$
– Therac
6 hours ago
$begingroup$
Already asked and answered here: aviation.stackexchange.com/questions/61510/…
$endgroup$
– Therac
6 hours ago
$begingroup$
In smaller planes, AL has been used to connect the battery in the tailcone to the starter & other electronics in front of the pilot. That has worked properly for years, with the main thing being to properly terminate the AL in crimped connectors with the proper 'grease' (I don't know what it is) to prevent any galvanic corrosion. My plane has that, built in 1973 and still going strong.
$endgroup$
– CrossRoads
3 hours ago
$begingroup$
In smaller planes, AL has been used to connect the battery in the tailcone to the starter & other electronics in front of the pilot. That has worked properly for years, with the main thing being to properly terminate the AL in crimped connectors with the proper 'grease' (I don't know what it is) to prevent any galvanic corrosion. My plane has that, built in 1973 and still going strong.
$endgroup$
– CrossRoads
3 hours ago
add a comment |
1 Answer
1
active
oldest
votes
$begingroup$
While it is true that copper is 1.6 times more conductive than aluminum per volume,
Conductivity in $frac{mathrm{MS}}{mathrm{m}} = frac{mathrm{10^6}}{Ω,mathrm{m}}$:
- copper: 56
- aluminium: 36
$$frac{56}{36} = 1.56$$
aluminium is 2.1 times more conductive than copper per weight.
Density in $frac{mathrm{g}}{mathrm{cm^3}}$:
- copper: 8.96
- aluminium: 2.7
$$frac{36 cdot 8.96}{56 cdot 2.7} = 2.13$$
Another important metric concerns the cost. The conductivity per cost is 2.1 times higher for aluminium. Note that it is only coincidence that this is the roughly same factor as per weight. Metal prices are changing over time, the physical properties don't.
Base metal price in $frac{mathrm{US$}}{mathrm{lb}}$ (as of today):
- copper: 2.71
- aluminium: 0.81
$$frac{36 cdot 2.71}{56 cdot 0.81} = 2.14$$
Aluminium wiring is safe if it is sized and terminated correctly. In comparison with copper, aluminium is softer, shows more creep, and has 30% stronger thermal expansion.
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
$endgroup$
1
$begingroup$
That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
$endgroup$
– huytergan
9 hours ago
3
$begingroup$
"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
$endgroup$
– pericynthion
8 hours ago
1
$begingroup$
One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
$endgroup$
– niels nielsen
6 hours ago
1
$begingroup$
I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
$endgroup$
– Therac
6 hours ago
2
$begingroup$
@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
$endgroup$
– bogl
6 hours ago
|
show 5 more comments
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1 Answer
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1 Answer
1
active
oldest
votes
active
oldest
votes
active
oldest
votes
$begingroup$
While it is true that copper is 1.6 times more conductive than aluminum per volume,
Conductivity in $frac{mathrm{MS}}{mathrm{m}} = frac{mathrm{10^6}}{Ω,mathrm{m}}$:
- copper: 56
- aluminium: 36
$$frac{56}{36} = 1.56$$
aluminium is 2.1 times more conductive than copper per weight.
Density in $frac{mathrm{g}}{mathrm{cm^3}}$:
- copper: 8.96
- aluminium: 2.7
$$frac{36 cdot 8.96}{56 cdot 2.7} = 2.13$$
Another important metric concerns the cost. The conductivity per cost is 2.1 times higher for aluminium. Note that it is only coincidence that this is the roughly same factor as per weight. Metal prices are changing over time, the physical properties don't.
Base metal price in $frac{mathrm{US$}}{mathrm{lb}}$ (as of today):
- copper: 2.71
- aluminium: 0.81
$$frac{36 cdot 2.71}{56 cdot 0.81} = 2.14$$
Aluminium wiring is safe if it is sized and terminated correctly. In comparison with copper, aluminium is softer, shows more creep, and has 30% stronger thermal expansion.
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
$endgroup$
1
$begingroup$
That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
$endgroup$
– huytergan
9 hours ago
3
$begingroup$
"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
$endgroup$
– pericynthion
8 hours ago
1
$begingroup$
One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
$endgroup$
– niels nielsen
6 hours ago
1
$begingroup$
I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
$endgroup$
– Therac
6 hours ago
2
$begingroup$
@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
$endgroup$
– bogl
6 hours ago
|
show 5 more comments
$begingroup$
While it is true that copper is 1.6 times more conductive than aluminum per volume,
Conductivity in $frac{mathrm{MS}}{mathrm{m}} = frac{mathrm{10^6}}{Ω,mathrm{m}}$:
- copper: 56
- aluminium: 36
$$frac{56}{36} = 1.56$$
aluminium is 2.1 times more conductive than copper per weight.
Density in $frac{mathrm{g}}{mathrm{cm^3}}$:
- copper: 8.96
- aluminium: 2.7
$$frac{36 cdot 8.96}{56 cdot 2.7} = 2.13$$
Another important metric concerns the cost. The conductivity per cost is 2.1 times higher for aluminium. Note that it is only coincidence that this is the roughly same factor as per weight. Metal prices are changing over time, the physical properties don't.
Base metal price in $frac{mathrm{US$}}{mathrm{lb}}$ (as of today):
- copper: 2.71
- aluminium: 0.81
$$frac{36 cdot 2.71}{56 cdot 0.81} = 2.14$$
Aluminium wiring is safe if it is sized and terminated correctly. In comparison with copper, aluminium is softer, shows more creep, and has 30% stronger thermal expansion.
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
$endgroup$
1
$begingroup$
That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
$endgroup$
– huytergan
9 hours ago
3
$begingroup$
"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
$endgroup$
– pericynthion
8 hours ago
1
$begingroup$
One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
$endgroup$
– niels nielsen
6 hours ago
1
$begingroup$
I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
$endgroup$
– Therac
6 hours ago
2
$begingroup$
@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
$endgroup$
– bogl
6 hours ago
|
show 5 more comments
$begingroup$
While it is true that copper is 1.6 times more conductive than aluminum per volume,
Conductivity in $frac{mathrm{MS}}{mathrm{m}} = frac{mathrm{10^6}}{Ω,mathrm{m}}$:
- copper: 56
- aluminium: 36
$$frac{56}{36} = 1.56$$
aluminium is 2.1 times more conductive than copper per weight.
Density in $frac{mathrm{g}}{mathrm{cm^3}}$:
- copper: 8.96
- aluminium: 2.7
$$frac{36 cdot 8.96}{56 cdot 2.7} = 2.13$$
Another important metric concerns the cost. The conductivity per cost is 2.1 times higher for aluminium. Note that it is only coincidence that this is the roughly same factor as per weight. Metal prices are changing over time, the physical properties don't.
Base metal price in $frac{mathrm{US$}}{mathrm{lb}}$ (as of today):
- copper: 2.71
- aluminium: 0.81
$$frac{36 cdot 2.71}{56 cdot 0.81} = 2.14$$
Aluminium wiring is safe if it is sized and terminated correctly. In comparison with copper, aluminium is softer, shows more creep, and has 30% stronger thermal expansion.
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
$endgroup$
While it is true that copper is 1.6 times more conductive than aluminum per volume,
Conductivity in $frac{mathrm{MS}}{mathrm{m}} = frac{mathrm{10^6}}{Ω,mathrm{m}}$:
- copper: 56
- aluminium: 36
$$frac{56}{36} = 1.56$$
aluminium is 2.1 times more conductive than copper per weight.
Density in $frac{mathrm{g}}{mathrm{cm^3}}$:
- copper: 8.96
- aluminium: 2.7
$$frac{36 cdot 8.96}{56 cdot 2.7} = 2.13$$
Another important metric concerns the cost. The conductivity per cost is 2.1 times higher for aluminium. Note that it is only coincidence that this is the roughly same factor as per weight. Metal prices are changing over time, the physical properties don't.
Base metal price in $frac{mathrm{US$}}{mathrm{lb}}$ (as of today):
- copper: 2.71
- aluminium: 0.81
$$frac{36 cdot 2.71}{56 cdot 0.81} = 2.14$$
Aluminium wiring is safe if it is sized and terminated correctly. In comparison with copper, aluminium is softer, shows more creep, and has 30% stronger thermal expansion.
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
edited 1 hour ago
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
answered 10 hours ago
boglbogl
6,9992 gold badges30 silver badges45 bronze badges
6,9992 gold badges30 silver badges45 bronze badges
1
$begingroup$
That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
$endgroup$
– huytergan
9 hours ago
3
$begingroup$
"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
$endgroup$
– pericynthion
8 hours ago
1
$begingroup$
One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
$endgroup$
– niels nielsen
6 hours ago
1
$begingroup$
I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
$endgroup$
– Therac
6 hours ago
2
$begingroup$
@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
$endgroup$
– bogl
6 hours ago
|
show 5 more comments
1
$begingroup$
That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
$endgroup$
– huytergan
9 hours ago
3
$begingroup$
"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
$endgroup$
– pericynthion
8 hours ago
1
$begingroup$
One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
$endgroup$
– niels nielsen
6 hours ago
1
$begingroup$
I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
$endgroup$
– Therac
6 hours ago
2
$begingroup$
@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
$endgroup$
– bogl
6 hours ago
1
1
$begingroup$
That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
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– huytergan
9 hours ago
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That's great answer, I appreciate. "use copper where space is limited, and aluminium otherwise" Does that mean copper is usually preffered in fighter jets or UAVs regarding to space?
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– huytergan
9 hours ago
3
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"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
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– pericynthion
8 hours ago
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"There is no risk associated with using aluminium wiring." I think you need to expand on that a bit. Aluminium wiring in houses has a very bad reputation (and has been banned for new construction in the US for some time) due to fires caused by gradual growth of oxidization leading to increased resistance at connections. This can be prevented or mitigated but doing so isn't trivial.
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– pericynthion
8 hours ago
1
1
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One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
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– niels nielsen
6 hours ago
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One of the factors limiting power transmission in aircraft systems where weight must be minimized is the type of insulation coating the wires. If the wire jacketing can withstand high temperatures, then the size of the wire (for any given conductor material inside it) can be reduced. the increased I-squared-R losses heat the wire more but as long as the jacketing can take it, you're OK. this principle is commonly used in wiring for planes like fighter jets, where the weight of the wiring harness can be reduced by allowing it to run hotter.
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– niels nielsen
6 hours ago
1
1
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I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
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– Therac
6 hours ago
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I'd say there is quite a bit of risk associated with Al wiring. It just can be mitigated by being very thorough with it. For a long time, the rule was Al for thick cables and bus bars, Cu for most cables, as it's much easier to terminate. Only recently has Al been making more inroads.
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– Therac
6 hours ago
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@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
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– bogl
6 hours ago
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@pericynthion I modified the statement with respect to your comment. I don't know much about the aluminium wiring crisis in the US, but my limited understanding is that due to lack of better knowledge craftsmen installed aluminium as a 1:1 replacement for copper. They didn't account for the additional cross section required and/or using terminals suitable for this material. I don't know if there was a generation of planes that suffered from similar problems, but I am confident that aircraft manufactures learned the rules of aluminium wiring a long time ago.
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– bogl
6 hours ago
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show 5 more comments
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It's my understanding that most aircraft wiring is aluminum because it weighs less and is almost as conductive as copper.
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– FreeMan
10 hours ago
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Already asked and answered here: aviation.stackexchange.com/questions/61510/…
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– Therac
6 hours ago
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In smaller planes, AL has been used to connect the battery in the tailcone to the starter & other electronics in front of the pilot. That has worked properly for years, with the main thing being to properly terminate the AL in crimped connectors with the proper 'grease' (I don't know what it is) to prevent any galvanic corrosion. My plane has that, built in 1973 and still going strong.
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– CrossRoads
3 hours ago