Copper vs Aluminum Busbar: Which is More Suitable?

Copper is one of the oldest known conductive materials and is the most common conductive metal besides silver. The application of aluminum in the field of conductivity began in the 1960s. However, the inherent advantages of aluminum have also led to its rapid development in the field of conductivity.

This article provides a comparative analysis of conductive copper busbar and aluminum busbars to help you better understand their respective advantages, so that you can make the most favorable choice for yourself in future projects.

For both products, you can contact us to know more informationWelcome contact

8 Key Differences Between Copper and Aluminum Busbars

1. Conductivity and resistance of copper and aluminum

Copper is the international standard for conductivity, offering 100% or higher IACS values with advanced processing.

Despite aluminum's lower conductivity (62% of copper), its strong processing ability makes it a preferred choice for conductive products.

Winner: Copper √

2. Different Ampacity of copper and aluminum busbar

Ampacity refers to the maximum amount of electric current a conductor or busbar can carry before it becomes too hot and potentially unsafe. Copper and aluminum busbars are commonly used in electrical distribution systems, and their ampacity varies significantly due to differences in their electrical and thermal properties.

Thanks to their higher conductivity, copper busbars tend to have higher ampacity than aluminum busbars of the same dimensions. In practice, copper busbars’ conductivity allows them to carry more current without overheating.

Winner: Copper √

3. Corrosion resistance of copper and aluminum

Copper busbars exhibit good corrosion resistance, even forming a protective verdigris layer in rusted conditions.

Aluminum busbars have strong anti-corrosion properties but may require surface treatments in corrosive environments.

Winner: Copper √

4. Quality and strength of copper and aluminum metals

Copper provides high strength and rigidity, suitable for applications with demanding strength requirements.

Aluminum busbars, being lighter, find widespread use in weight-critical applications like aerospace and automotive lightweight trends.

Winner: Copper √

5. Different thermal expansion of copper and aluminum

Aluminum has a higher thermal expansion coefficient than copper. For this reason, aluminum busbars might expand and contract more with temperature changes, which can lead to unstable connections and even mechanical failures. Copper busbars, on the other hand, generally have longer lifespans and lower maintenance costs thanks to their superior corrosion resistance and mechanical strength.

Winner: Copper √

6. Different weight of copper and aluminum

Because aluminum is less dense than copper, aluminum fabrication delivers busbars that are lighter than copper ones of the same dimensions. Because copper busbars are heavier, they can be more difficult to transport, handle, and install.

Winner: Aluminum √

7. Cost comparison of copper conductive busbar and aluminum conductive busbar

Conductive copper remains the preferred choice for conductivity, but aluminum busbars offer cost savings due to lower processing costs and high recyclability.

Winner: Aluminum √

8. Environmental protection and sustainability

Both copper and aluminum are recyclable, but aluminum has a higher recovery rate (75%) and requires only 15% of the energy for recycling compared to copper.

Winner: Aluminum √

Chalco's integrated solution for conductive products-copper or aluminum or CCA?

Copper-Clad Aluminum Bus Bar

a third-gen conductor in power systemst……

Copper-clad aluminum CCA wire

Combining copper's conductivity, aluminum's lightweight……

Copper-aluminum Connecting Terminals

Widely used in distribution, transformers, and cable……

• Excellent Conductivity: The copper outer layer of CCA materials provides excellent conductivity, ensuring high electrical transmission efficiency, making it suitable for applications requiring high conductivity.
• Lightweight: Aluminum has a density that is only one-third of copper, making CCA materials much lighter than pure copper. This significantly reduces the weight of cables and wires, facilitating easier transportation and installation, especially in industries like aviation and automotive where weight reduction is critical.
• Cost-Effective: Aluminum is less expensive than copper, so the manufacturing cost of CCA materials is lower than that of pure copper. This makes it more economical for large-scale applications without significantly compromising performance.
• Good Mechanical Properties: CCA materials possess good strength and toughness, capable of withstanding considerable mechanical stress and tension, making them suitable for various demanding environments.
• Corrosion Resistance: The copper outer layer provides excellent corrosion resistance, protecting the aluminum core from oxidation and corrosion, thereby enhancing the material's durability and lifespan.
• Flexibility and Ease of Processing: CCA materials combine the solderability of copper with the flexibility of aluminum, making them easier to handle during manufacturing and processing. This makes them ideal for complex electrical designs and installations.

Through these advantages, copper-clad aluminum conductive materials have found widespread use in cables, wires, electronic components, and more, providing an economical, efficient, and high-performance conductive solution.Quick Quote

How to convert copper busbar sizes to aluminum for electrical projects while maintaining the same temperature rise

In electrical applications, the choice between copper and aluminum busbars often requires consideration of temperature rise differences. To substitute aluminum busbars for copper while maintaining the same temperature rise, adjustments to the aluminum busbar size must be made to account for its different conductivity. There are two common methods for making this conversion.

First Method: Increase the Width of the Aluminum Bar

By increasing the width of the aluminum bar by approximately 27%, the same temperature rise effect as a copper bar can be achieved. For example, a 5-inch x 1/4-inch aluminum bar is equivalent to a 4-inch x 1/4-inch copper bar. This method effectively increases the cross-sectional area, reducing resistive heating and enhancing heat dissipation.

Second Method: Increase the Thickness of the Aluminum Bar

Another approach is to increase the thickness of the aluminum bar by approximately 50%. For example, a 4-inch x 3/8-inch aluminum bar can match the temperature rise effect of a 4-inch x 1/4-inch copper bar. While this method also increases the cross-sectional area, changes in thickness have a smaller impact on heat dissipation, making it less effective than increasing the width.

In both conversion methods, the thermal skin effect must also be considered. This effect occurs under high current conditions, where the internal temperature of the conductor rises faster than the external temperature because the outer parts dissipate heat more efficiently. This leads to higher internal resistance and greater voltage drop, generating more heat. Therefore, when designing aluminum busbars, it is important to consider both size adjustments and the thermal skin effect to ensure system safety and stability.

If you have an electrical project or are unsure how to choose between copper and aluminum busbars, feel free to consult our professional busbar technology experts for assistance.Quick Quote

Chalco conductive busbar products