Magnet wire aluminum alloy conductors and coil winding

Abstract

Aluminum alloys have been used increasingly as electrical conductor material in insulated magnet wire? the insulation may be a film coating or a separate tape, suitably applied. The type of insulation determines the wire manufacturing process including the temperature to which the magnet wire is subjected during its complete manufacturing process. This paper provides guidance on the behavior of various electrical conductor aluminum alloys at various temperatures to which such a magnet wire may be exposed during its manufacture, the product manufacturing process and the product life. That thermal behavior should be one of the factors influencing the choice of aluminum conductor alloy. This paper also describes the effect of aluminum conductor alloy on end product cost and performance; it provides data on coil winding effectiveness, material usage, and final coil dimensions, all as functions of aluminum magnet wire metallurgy.