Aluminum Transformer

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State-of-the-Art Stock & Custom Aluminum Transformer Manufacturer Offering Top Quality at Wholesale Prices

Aluminum Transformers

Call TEMCo today for delivering leading industry products that will supply your electrical needs and help sustain your business functions, such as ordering a aluminum transformer for a new building or power expansion.  Call us today at 510-490-2187. 

Aluminum Transformer Differences

It may seem odd to start off a discussion of aluminum transformers with extolling the virtues of copper transformers.  It is doubly so, because aluminum transformers are the predominant choice for users in North America.  Aluminum transformers would not be as popular as they are without being useful and being able to "hold their own" against their one other competitor.  We want to assure the customer that aluminum transformers do have their useful advantages.  Though TEMCo stresses that copper is traditionally the number one choice in so far as optimum quality and serviceability is concerned, we do also carry, build and sell quality aluminum transformers. 

Aluminum Transformer Characteristics (vs. Copper)

Cost: The first issue is initial cost.  This is the primary reason for ordering an aluminum transformer over a copper one.  One might expect that since copper is usually a significant percentage higher in cost than aluminum that that fact alone would outweigh other considerations.  But in larger transformers the overall cost ends up as a negligible difference between aluminum and copper.  However, when the winding to other materials ratio changes, as it does in smaller transformers, the cost becomes a more significant factor.

Labor: A reliable aluminum contact requires different and more stringent handling and connection practices than copper.

Shipping: The larger distribution and transmission transformers are not produced on-site. They must be built and then shipped.  Aluminum transformers require a significant increase in size to accommodate the extra volume of wire.  An aluminum winding has to have a larger cross-sectional sized to compensate for the reduced conductivity and tensile strength compared to copper.  This makes very large capacity aluminum transformers much larger than copper transformers and therefore harder; even prohibitive to ship.  This must be taken into account when determining what will be installed, and where.

Connectivity: The internal connections must be durable and long-lasting.  Typical utility and substation transformers are expected to last for 40 to 50 years or more.  Copper has a better reputation for remaining corrosion free and maintaining tight connections.  Also, copper oxides and other permutations of copper encountered are more conductive than aluminum oxides.  However, once a layer of aluminum has oxidized, it does not continue to do so to any degree.  And connections within aluminum transformers are either welded or, as are copper, brazed with silver or tin.  Copper cable to aluminum wound transformer connections are usually made with tin plated aluminum lugs.  They have proven over decades of use to be effective and reliable.

Internal Stresses:  Copper retains its winding position more easily than aluminum.  It is denser and tougher and moves less when heated.  Aluminum will expand almost one-third more than copper of same diameter under similar temperature changes.  Proper hardware connections at joints will correct for this, but there is also the issue of the windings creeping or moving during heating.  However, since aluminum is used with a much larger diameter to compensate for its lower conductivity, the difference in its tensile strength and other factors become much less important.  

Summation:

Relative quality of Aluminum vs. Copper: While copper is an entirely different conductive material with a superior performance when considered next to an aluminum conductor of the same cross section, the negative factors fall away or diminish when a larger diameter aluminum wire is used.  It is true that aluminum will move more and respond to heating more where connections and windings are concerned, but successful techniques within the capabilities of our trained and experienced professionals have been developed to address these issues. 

Space vs. Cost Factors: The one adverse factor that is not diminished by this compensation via larger diameter wires actually becomes magnified.  Aluminum transformers of very large capacities are limited by the size they will take up, if for no other reason than they become impossible to move to the installation site. 

When space is not a factor with smaller transformers, then cost becomes a more important factor.  Since the ratio of winding material costs to other material costs is more significant in the smaller transformers, aluminum will be more cost-effective in the initial expense of manufacturing.  Additionally, weight makes a difference.  One very common application of this is in pole transformers.  They are very often aluminum wound so as to reduce overall weight and make them more friendly for mounting high on poles.

When space is a consideration, even in the smaller transformer, then cost takes a back seat and copper transformers are recommended. 

Production considerations: While there are real life differences that may make aluminum less desirable than copper in some aspects, technology is constantly moving forward and new techniques in addressing such issues tend to diminish the differences.  Today, In the right context, an aluminum transformer can be the right choice!

Highest Quality Aluminum Transformers

Call TEMCo with your specific needs. TEMCo’s technical sales department has many years of applications experience providing design and engineering assistance for all types of aluminum transformer installations.

Call Our Aluminum Transformer Specialists Today!

 *Custom Aluminum Transformer Voltage Combinations Available*

Contact our team at TEMCo Transformer at 510-490-2187 to get your quote, place your order and arrange for shipping.

TEMCo Transformer Manufacturer Distribution: The Custom Aluminum Transformer Manufacturer Supplier of Choice for Electricians and Manufacturers.

TEMCo Transformer Manufacturer Distribution: High Quality, Efficient, Fast Turnaround of Custom Aluminum Transformers Manufactured to your Specs!