Aluminum Hookup Wire

jsa_ind · 11th January 2007, 02:54 PM

Hi All,

I am looking for a web purchase of 24 & 35 AWG ideally Teflon insulated hookup wire, if not other insulations are also welcome.

Thanks folks !

jsa_ind

XEAGLEKEEPER · 11th January 2007, 03:54 PM

Teflon coated wire is the only type of hookup wire that is used in the F-15 aircraft...A little trivia. I would prefer to use it.I have not seen any with aluminum conductor though.Usually it is silver coated copper. The teflon is a little more difficult to strip off . I used a electric wire stripper when I was in the "Force" and working on avionics equipment.

Zero Cool · 11th January 2007, 06:22 PM

there is a guy on eBay selling surplus navy wire in various sized and lengths. all teflon and silver coated copper.

I have been thinking of buyings some for various amp projects.

he has 30ga to 10ga from what i have seen.

ebay id navships

Zc

AndrewT · 12th January 2007, 09:42 AM

Hi,
is the weight saving of significance to your proposed use?

Copper is about three times heavier but about 60% of resistance.
There is a significant weight saving when the cross-section is adjusted to match voltage loss (resistance). However the fatter aluminium conductor will run a little cooler.

How are you planning to connect the aluminium, you can forget all the conventional copper type fixings. Solder does not work and wire wrap doesn't either. A mechanical fixing must cut through the insulating oxide surface and the gas tight joint must stop all future oxidation. The mechanical deformation will reduce the fatigue life at the joint and may lead to premature cracking and failure.
Which grade of aluminium will you be using?

You'll gather that unless you are flying, or in some competitive motorsports' arena then I do not recommend aluminium.

XEAGLEKEEPER · 12th January 2007, 10:40 AM

Andrew
I believe JSA just assumed the silver coated copper was aluminum. Or Im giving him the benefit of the doubt.

Dave

jsa_ind · 12th January 2007, 10:56 AM

No Sir, I was wishing to have pure insulated aluminium wire...if possible.....though I am losing hope right now !!

Nordic · 12th January 2007, 11:00 AM

You are aware that aluminum oxide (the layer that forms on outside due to exposure to oxygen) is used as a dielectric....? i.e. it doesn't conduct....for long

I think makeing thin alu wire is a problem in the sense that it is brittle and can't be stretched into thiner and thinner wires like copper is...

XEAGLEKEEPER · 12th January 2007, 11:27 AM

Aluminum ? So much for doubt. Guess I stand corrected. LOL Cause I.m going to have to agree with Andrew and Nordic.I wouldnt waste my time with aluminum.

Nixie · 12th January 2007, 11:41 AM

Well, why do you want aluminum?

jsa_ind · 12th January 2007, 12:23 PM

Guys you are right bad idea ! I wished to expriment on a JPS Lab clone.......
Back to the drawing board I guess !!
Thanks for all your inputs !

Jsa_ind

11th January 2007, 02:54 PM	#1
jsa_ind diyAudio Member Join Date: May 2005 Location: Orlando	Aluminum Hookup Wire Hi All, I am looking for a web purchase of 24 & 35 AWG ideally Teflon insulated hookup wire, if not other insulations are also welcome. Thanks folks ! jsa_ind

11th January 2007, 03:54 PM	#2
XEAGLEKEEPER diyAudio Member Join Date: Jan 2006 Location: central Iowa	Teflon coated wire is the only type of hookup wire that is used in the F-15 aircraft...A little trivia. I would prefer to use it.I have not seen any with aluminum conductor though.Usually it is silver coated copper. The teflon is a little more difficult to strip off . I used a electric wire stripper when I was in the "Force" and working on avionics equipment. __________________ Ret. USAF... AKA- Avionic * Solder slinger for hire...*

12th January 2007, 09:42 AM	#4
AndrewT diyAudio Member Join Date: Jul 2004 Location: Scottish Borders	Hi, is the weight saving of significance to your proposed use? Copper is about three times heavier but about 60% of resistance. There is a significant weight saving when the cross-section is adjusted to match voltage loss (resistance). However the fatter aluminium conductor will run a little cooler. How are you planning to connect the aluminium, you can forget all the conventional copper type fixings. Solder does not work and wire wrap doesn't either. A mechanical fixing must cut through the insulating oxide surface and the gas tight joint must stop all future oxidation. The mechanical deformation will reduce the fatigue life at the joint and may lead to premature cracking and failure. Which grade of aluminium will you be using? You'll gather that unless you are flying, or in some competitive motorsports' arena then I do not recommend aluminium. __________________ regards Andrew T.

12th January 2007, 10:40 AM	#5
XEAGLEKEEPER diyAudio Member Join Date: Jan 2006 Location: central Iowa	Andrew I believe JSA just assumed the silver coated copper was aluminum. Or Im giving him the benefit of the doubt. Dave __________________ Ret. USAF... AKA- Avionic * Solder slinger for hire...*

12th January 2007, 11:27 AM	#8
XEAGLEKEEPER diyAudio Member Join Date: Jan 2006 Location: central Iowa	Aluminum ? So much for doubt. Guess I stand corrected. LOL Cause I.m going to have to agree with Andrew and Nordic.I wouldnt waste my time with aluminum. __________________ Ret. USAF... AKA- Avionic * Solder slinger for hire...*


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11th January 2007, 06:22 PM	#3
Zero Cool Audio Junkie diyAudio Member Join Date: Sep 2004 Location: MN	there is a guy on eBay selling surplus navy wire in various sized and lengths. all teflon and silver coated copper. I have been thinking of buyings some for various amp projects. he has 30ga to 10ga from what i have seen. ebay id navships Zc

12th January 2007, 10:56 AM	#6
jsa_ind diyAudio Member Join Date: May 2005 Location: Orlando	No Sir, I was wishing to have pure insulated aluminium wire...if possible.....though I am losing hope right now !!

12th January 2007, 11:00 AM	#7
Nordic diyAudio Member Join Date: Sep 2005	You are aware that aluminum oxide (the layer that forms on outside due to exposure to oxygen) is used as a dielectric....? i.e. it doesn't conduct....for long I think makeing thin alu wire is a problem in the sense that it is brittle and can't be stretched into thiner and thinner wires like copper is...

12th January 2007, 11:41 AM	#9
Nixie Banned Join Date: Jan 2006 Location: Vancouver, BC	Well, why do you want aluminum?

12th January 2007, 12:23 PM	#10
jsa_ind diyAudio Member Join Date: May 2005 Location: Orlando	Guys you are right bad idea ! I wished to expriment on a JPS Lab clone....... Back to the drawing board I guess !! Thanks for all your inputs ! Jsa_ind

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