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ConnectorSupplier.com: Design Considerations When Terminating Aluminum Wire

It may be necessary to replace copper wiring with aluminum in automotive applications to reduce vehicle weight and achieve the aggressive future fuel-economy standards, but design engineers must be mindful of the significant differences between aluminum and copper wire terminations.

Aluminum wiring has been used for many years in several different industries. Utility companies have successfully used aluminum wire for the purposes of electrical transmission in power grids; the aircraft industry has successfully used aluminum wiring in power applications. Now the automotive industry is replacing copper wires with aluminum. The primary reasons for this conversion are to reduce costs and vehicle weight in order to achieve the future fuel economy standards.

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