Copper vs Aluminum vs CCA: Which is More Suitable?

As industrial technology advances, copper-clad aluminum products are becoming more widely used in power, electronics, and construction industries, becoming a key market choice. Combining copper's excellent conductivity with aluminum's lightweight properties, they meet high performance standards while reducing costs. With improved manufacturing processes, the range and specifications of copper-clad aluminum products continue to grow, making them an ideal choice for various industries.

Currently, the common types of copper-clad aluminum products in the market include the following, which are also our key offerings:

Copper-clad aluminum wire
Copper-clad aluminum busbar
Copper-clad aluminum sheet plate
Copper-clad aluminum tube
Copper-clad aluminum strip
Copper-clad aluminum bar rod

In this article, we will explore the key differences between copper and aluminum, as well as the unique advantages of copper-clad aluminum, to help you make a more informed decision when selecting the right product.

8 Key Differences Between Copper and Aluminum

1. Conductivity and Resistance of copper and aluminum

Copper cladded aluminum (CCA) combines the high conductivity of copper with the lightweight properties of aluminum. While copper offers superior conductivity (100% IACS), CCA's conductivity is lower than pure copper but still efficient for many applications, making it a cost-effective alternative for lower-performance uses.

Winner: Copper √

2. Different Ampacity of copper and aluminum

Due to its higher conductivity, copper has a greater ampacity, allowing it to carry more current without overheating compared to CCA. CCA busbars can still handle significant current loads but may need larger sizes to match copper’s current carrying capacity in high-demand applications.

Winner: Copper √

3. Corrosion Resistance of copper and aluminum

Copper exhibits excellent corrosion resistance due to its natural protective verdigris layer. CCA, while offering some corrosion resistance, may require extra protection in highly corrosive environments, particularly where the aluminum core is exposed. Pure copper is better suited for long-term resistance to oxidation and wear.

Winner: Copper √

4. Strength and Durability of copper and aluminum

Copper is more rigid and stronger compared to CCA, which benefits from the lightweight properties of aluminum but sacrifices some mechanical strength. CCA’s aluminum core can also be more susceptible to mechanical stresses and deformations under extreme conditions, whereas copper maintains structural integrity under demanding loads.

Winner: Copper √

5. Thermal Expansion of copper and aluminum

Aluminum, as the core material of CCA, has a higher thermal expansion coefficient than copper. This can lead to instability in connections over temperature fluctuations, especially for CCA products. Copper’s lower expansion rate ensures more stable connections and a longer lifespan in varying temperature conditions.

Winner: Copper √

6. Weight difference of copper and aluminum

CCA benefits from aluminum’s lightweight characteristics, making it an ideal choice for weight-sensitive applications, such as aerospace or transportation. Copper, while heavier, provides superior performance but requires more effort for handling, installation, and transportation.

Winner: CCA √

7. Cost Comparison of copper and aluminum

Copper is more expensive due to its higher conductivity and manufacturing complexity. CCA, on the other hand, provides a lower-cost alternative by using aluminum as the core, offering a cost-effective solution without significantly sacrificing performance in many applications.

Winner: CCA √

8. Environmental Sustainability of copper and aluminum

Both copper and aluminum are recyclable, but CCA’s use of aluminum increases its sustainability, as aluminum has a higher recovery rate and requires significantly less energy to recycle compared to copper. This makes CCA a more environmentally friendly option in many cases.

Winner: CCA √

Explore Chalco's copper-clad aluminum products

Copper-clad Aluminum Wire

Combines copper's high conductivity with aluminum's lightweight, ideal for power transmission, communications, and cables.

Copper-clad Aluminum Busbar

Offers copper conductivity with aluminum's lightness, used in high-current applications like power distribution and substations.

Copper-clad Aluminum Sheet

Merges copper's conductivity with aluminum's lightness, commonly used in automotive, power, and construction industries.

Copper-clad Aluminum Tube

Used in heat exchangers and power distribution, providing high conductivity and corrosion resistance.

Copper-clad Aluminum Coil Strip

Ideal for electrical conductors and connectors, combining copper conductivity with aluminum's lightweight properties.

Copper-clad Aluminum Rod

Used in electrical connectors and busbars, offering high durability and conductivity with reduced weight.

Copper Clad Aluminum industry application and projct solutions

Chalco's integrated solution for power industry-copper or aluminum or CCA?

Considering the advantages of copper-aluminum products, copper-aluminum composites have become a key solution in the power industry. Combining copper's conductivity with aluminum's light weight, strength, and corrosion resistance, these products offer cost-effective, sustainable, and versatile solutions.

When to Use Copper Busbars	When to Use Aluminum Busbars	When to Use Copper-Clad Aluminum Busbars
High-Performance Systems: Ideal for power generation, transmission, and high-power electronics due to high conductivity. Critical Infrastructure: Suited for projects where reliability and longevity are crucial, like substations and data centers. Harsh Environments: Preferred in outdoor or corrosive environments for its high corrosion resistance. Low-Resistance Connections: Best for high-current applications, motor control centers, and distribution panels.	Cost-Sensitive Applications: Chosen for projects where cost is a key factor. Lightweight Applications: Ideal in aerospace, automotive, and portable electronics due to its lighter weight. Heat Dissipation: Better at dissipating heat, preventing overheating in thermal-sensitive applications. Flexible Applications: Easier to bend and manufacture, making it suitable for busway systems. Utility-Scale Power: Standard in large-scale power systems due to lower cost and suitability for high-voltage transmission.	Balanced Performance and Cost: Offers better conductivity than aluminum and is more cost-effective than copper. Moderate Corrosive Environments: Suitable for environments needing decent corrosion resistance. Weight-Conscious with High Conductivity: Ideal when weight savings are important, but higher conductivity is needed.

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……

Copper clad aluminum bus bar

CCA bus or bimetallic conductive bus, it is the third generation of "new energy-saving conductor materials".

Conductivity Scalability Reliability
6101 EC aluminum busbar T6, T61, T63, T64, T65

Containing magnesium and silicon, has high mechanical strength. Better anti creep than 1350.

Thermal stability Easy processing
1060 EC aluminum busbar T3, T4, T5, T6, T8

It is usually formed by extrusion or rolling, and has good processing performance.

High conductivity Corrosion resistance
1350 EC aluminum busbar H14, H16, H19

The minimum weight percentage is 99.5%, which is the material used for battery busbars.

Conductivity Thermal conductivity
6060 EC aluminum busbar T4, T5, T6

It can effectively transmit and distribute electricity, reducing energy loss and line power loss.

Lightweight Processability
6082 EC aluminum busbar T3, T4, T5, T6

It has high strength and hardness, while maintaining good conductivity.

Machinability High strength and rigidity
6061 EC aluminum busbar T4

6061 aluminum busbar has strong conductivity and is a universal material for most processing technologies.

Smooth surface Strong moisture resistance
6063 EC aluminum busbar T4, T5, T6, T52, T66

In high-power applications, it can help effectively dissipate heat, and reduce the risk of equipment overheating.

Strong plasticity Excellent heat dissipation

Chalco's CCA products for Electronics Industry

Copper-aluminum composites are ideal for electronic components, connectors, and cooling systems, thanks to their high conductivity, corrosion resistance, and light weight. They help improve device performance and durability while minimizing weight.

Chalco's CCA products for Automotive Industry

In the automotive industry, especially for electric vehicles, copper-aluminum composites reduce weight and improve power system efficiency, making them essential for battery management and power transmission in electric vehicles.

Chalco's CCA products for Heat Exchange Systems

Copper-aluminum composites are ideal for heat exchange systems, with copper providing excellent thermal conductivity and aluminum offering strength and reduced weight. These materials are widely used in air conditioners, heat exchangers, and cooling systems.

Advantages of Chalco Copper clad aluminum CCA products

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

Comprehensive Guide to Copper-Clad Aluminum (CCA) Products——Knowledge and Technical Specifications

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.

Reference Table of Specifications

Converting Copper to Aluminum using an Ampacity Chart
Ampacity Conversion Chart			Copper C110		30° C Rise	50° C Rise	65° C Rise	Aluminum 6101		30° C Rise	50° C Rise	65° C Rise
Flat Bar Size in Inches	Sq. In	Circ Mils Thousands	Weight Per Ft in Lb.	DC Resistance at 20° C, Microhms/Ft	60 Hz Ampacity Amp*			Weight Per Ft in Lb.	DC Resistance at 20° C, Microhms/Ft	60 Hz Ampacity Amp**
1/2*1	0.5	637	1.93	16.5	620	820	940	0.585	31	347	459	526
1/2*1 1/2	0.75	955	2.9	11	830	1100	1250	0.878	21	465	616	700
1/2*2	1	1270	3.86	8.23	1000	1350	1550	1.17	15	560	756	868
1/2*2 1/2	1.25	1590	4.83	6.58	1200	1600	1850	1.463	12	672	896	1036
1/2*3	1.5	1910	5.8	5.49	1400	1850	2150	1.755	10	784	1036	1204
1/2*3 1/2	1.75	2230	6.76	4.7	1550	2100	2400	2.048	9	868	1176	1344
1/2*4	2	2550	7.73	4.11	1700	2300	2650	2.34	8	952	1288	1484
1/2*5	2.5	3180	9.66	3.29	2050	2750	3150	2.925	6	1148	1540	1764
1/2*6	3	3820	11.6	2.74	2400	3150	3650	3.51	5	1344	1764	2044
1/2*8	4	5090	15.5	2.06	3000	4000	4600	4.68	4	1680	2240	2576

1/4*1/2	0.125	159	0.483	65.8	240	315	360	0.146	123	134	176	202
1/4*3/4	0.188	239	0.726	43.8	320	425	490	0.220	82	179	238	274
1/4*1	0.25	318	0.966	32.9	400	530	620	0.293	62	224	297	347
1/4*1 1/2	0.375	477	1.450	21.9	560	740	880	0.439	41	314	414	482
1/4*2	0.5	637	1.930	16.5	710	940	1100	0.585	31	398	526	616
1/4*2 1/2	0.625	796	2.410	13.2	850	1150	1300	0.731	25	476	644	728
1/4*3	0.75	955	2.900	11	990	1300	1550	0.878	21	554	728	868
1/4*3 1/2	0.875	1110	3.380	9.4	1150	1500	1750	1.024	18	644	840	980
1/4*4	1	1270	3.860	8.23	1250	1700	1950	1.170	15	700	952	1092
1/4*5	1.25	1590	4.830	6.58	1500	2000	2350	1.463	12	840	1120	1316
1/4*6	1.5	1910	5.800	5.49	1750	2350	2700	1.755	10	980	1316	1512

1/8*1/2	0.0625	79.6	0.241	132	153	205	235	0.073	247	86	115	132
1/8*3/4	0.0938	119	0.362	87.7	215	285	325	0.110	164	120	160	182
1/8*1	0.125	159	0.483	65.8	270	360	415	0.146	123	151	202	232
1/8*1 1/2	0.188	239	0.726	43.8	385	510	590	0.220	82	216	286	330
1/8*2	0.25	318	0.966	32.9	495	660	760	0.293	62	277	370	426
1/8*2 1/2	0.312	397	1.210	26.4	600	800	920	0.365	49	336	448	515
1/8*3	0.375	477	1.450	21.9	710	940	1100	0.439	41	398	526	616
1/8*3 1/2	0.438	558	1.690	18.8	810	1100	1250	0.512	35	454	616	700
1/8*4	0.5	636	1.930	16.5	900	1200	1400	0.585	31	504	672	784

1/16*1/2	0.0312	39.7	0.121	264	103	136	157	0.037	494	58	76	88
1/16*3/4	0.0469	59.7	0.181	175	145	193	225	0.055	327	81	108	126
1/16*1	0.0625	79.6	0.242	132	187	250	285	0.073	247	105	140	160
1/16*1 1/2	0.0938	119	0.362	87.7	270	355	410	0.110	164	151	199	230
1/16*2	0.125	159	0.483	65.8	345	460	530	0.146	123	193	258	297
Source: Copper Development Organization; Aluminum Association
Note: Ratings depend upon configuration, air flow, ambient temp, etc. The values depicted are an approximation. Controlled testing is always required to validate.
Other considerations Forming the busbar (aluminum has a tendency to crack with very tight radius) Electroplating the busbar (white rust on aluminum, oxidation is an issue with aluminum) Configuration of the busbar (vertical or horizontal configuration)

	Copper	AL 6101	AL 1350	AL 6061	AL 6063	AL 1050	AL 1060	AL 1070
Electrical Conductivity (%IACS)	100%	50% - 55%	61% - 62%	40% - 43%	52% - 56%	61%	61%	62%
Specific resistance (ohmscir/mil ft) (20℃ ref)	10.6	18.52

Chalco can provide you the most comprehensive inventory of aluminum products and can also supply you customized products. Precise quotation will be provided within 24 hours.

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