MATERIALS n without compromising efficiency or reliability. The debate, therefore, is not a simple switch, but a more nuanced design decision based on each product’s operating environment and performance requirements. As attractive as aluminium has become, there are still applications where copper remains the only option. The challenge for designers is to identify where aluminium is a smart alternative and where copper is still essential. Hybrid windings A significant development emerging from the cost debate is the use of hybrid windings. These include copper-terminated aluminium conductors, copper-clad aluminium, or mixed-material winding arrangements that distribute current more efficiently and improve thermal behaviour. These hybrid approaches combine copper’s connectivity and durability with the economic benefits of aluminium, offering an appealing option for applications that sit between cost-driven and performancecritical design categories. The spike in copper prices has quickly become one of the most influential factors in transformer and choke design. While aluminium has always been present in some sectors – such as distribution transformers and large inductors – its adoption in specialised industrial and power-electronics applications is expected to accelerate. The conversation is now shifting from ‘Why would we use aluminium?’to ‘Why wouldn’t we consider it?’. The commercial arguments have changed dramatically, and the industry is having to catch up with that reality. With continued volatility expected in global copper markets, we are likely to see sustained interest in alternative winding materials. The long-term outcome may be a more diversified industry, where copper retains its position in premium performance applications, while aluminium – either alone or in a hybrid form – could become a mainstream option, rather than a fallback. Engineers, OEMs and specifiers need to revisit their material assumptions with fresh eyes, applying today’s economic realities rather than relying on historical norms. n How copper and aluminium compare for use as winding materials Follow us on LinkedIn @Drives & Controls Follow us X Drives&C Controls & rives Join us Facebo Drives & C on X @Drivesn Forthe D on ok Controls Controls latest news visit Controls the Driv www.driv ves & Controls we vesncontrols.com
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