Switching from copper to aluminium in cars

real_aurgathor

Ferrari and BMW join Tesla, China in switch from copper to cheaper aluminium.

Ferrari and BMW are rolling out new models featuring lightweight, cost-effective aluminium wiring, accelerating a shift away from copper, the dominant material in electric wiring since the invention of the electric battery two centuries ago.

The decisions follow similar moves by Tesla and Chinese EV makers and reflect a broader industry trend forecast to affect around 2% of global copper demand ‌this year, according to JPMorgan.

https://www.reuters.com/business/autos-transportation/ferrari-bmw-join-tesla-china-switch-copper-cheaper-aluminium-2026-06-30/

Aluminium is not only much cheaper, but it’s also lighter, although it has some minor issues, making it less forgiving than copper when making connections.

Substitution of aluminium for copper has come in waves over two decades, but record copper prices in late January, peaking close to $15,000 per metric ton, added weight to the case for switching to aluminium.

robxr4ti

real_aurgathor What a terrible idea. We will rue the day this began.

Somewhat-Reticent

real_aurgathor less forgiving

Classic Understatement

Thane_Bitter

real_aurgathor Before: Replace module, verify operation. Estimated time to replace rear brake light module 0.25 hours.

Soon: Replace module, replace wiring harness, replace sub harness, pack ungodly amounts of antiox into connectors X though …. perform full load test and image with thermo camera. Estimated time to replace rear brake light module 5 hours.

Disposable vehicle, you might have the right to have it repaired, you will not be able to afford doing so.

I do agree with a number of real_aurgathor points, its been used and for the most costly copper parts on a car without much issue (though since its relatively new there is no long term data over how well these things age). Another plus is that unlike the traditional high current circuits used in the pass to run incandescent lights, LEDSs do not necessarily pull as much current so its wiring can be reduced in capacity, plus the use of in car networks has cut down on the amount of control wiring needed, devices just need power and comms rather than much more higher capacity copper wires shunting power around to make a window open or close via a mechanical switch.

InternetJeff

robxr4ti What a terrible idea. We will rue the day this began.

When I was young we lived in a house that was wired with aluminum. By the time I was a teenager we were experiencing many of the widespread issues caused by aluminum wiring. Connections would heat up and outlets and switches had to be replaced. As part of that replacement you had to put this goop on the terminals, and you had to inspect the fixtures periodically. Eventually they came out with special fixtures, outlets, and switches for homes with aluminum wiring. But by then my Dad had enough and ripped out the aluminum and replaced it with copper wiring. When eventually moved, other houses is still having aluminum wiring had all kinds of issues being sold.

InternetJeff

Oh, nothing can go wrong here.

Due to “cost concerns” aluminum wiring was used in US homes in the early 70’s due to a price inversion compared to copper wiring. By the end of the 70’s it was abandoned, but the aluminum wire left in place led to many issues. Aluminum wiring oxidizes more than copper, especially at connection points. Aluminum wire contracts and expands due to heating more than copper, again this is more prone to cause problems especially at connection points. Aluminum is also more prone to fatigue and cracking due to vibration, which is much more common in an automotive environment. Aluminum wiring also tends to creep and deform at terminal block connections. And you cannot just use conventional terminals/splices with aluminum wire, as special aluminum-rated components ($$) must be used.

Other than all that, everything should go well.

px_eliezer_

InternetJeff Due to “cost concerns” aluminum wiring was used in US homes in the early 70’s due to a price inversion compared to copper wiring. By the end of the 70’s it was abandoned, but the aluminum wire left in place led to many issues.

My house (and neighborhood) is one such.

John_deSouza

InternetJeff Oh, nothing can go wrong here

Anyone getting an aluminum wired car should make sure that it’s an electric car to fully experience the second order effects! Ha!

robxr4ti

InternetJeff an interesting solution is copper coated aluminum. I have it in my home.

real_aurgathor

I was curious how long would it take for someone to bring aluminium house wiring. Didn’t have to wait long. 😉

In any case, that was around 50 years ago, so engineers had plenty of time to come up with solutions to address the issues experienced back then.

The purpose of engineering is to apply various principles to create safe, efficient, cost effective and innovative solutions, systems, and technologies. Given the expected demand and projected supply, copper prices are likely to continue to increase in the foreseeable future and replacing some of the copper with the much cheaper aluminium is one possible solution to that.

I presume aluminium wiring is used only where there’s lots of current, and in those cables the copper is usually factory terminated already with some kind of connector like this:

I shall note that most of the high powered transmission lines nowadays use aluminium in some shape or form, usually around a central steel cable that provides strength.

robxr4ti

real_aurgathor aluminum wiring used in cars or electronics is very difficult to solder (if at all) and is very difficult to work with due to lack of durability. I’ve worked with it before. No fun. What a great way to make unreliable cars even less reliable.

real_aurgathor

robxr4ti aluminum wiring used in cars or electronics is very difficult to solder (if at all) and is very difficult to work with due to lack of durability.

As I’ve already mentioned, engineering was invented to solve these issues.

Tesla and Chinese EV automakers made aluminium wiring viable by leveraging advanced harness domain controllers, copper-clad aluminum (CCA) conductors, anti-corrosive coatings and mechanical clamping designed to withstand thermal expansion. and specialized bimetallic welding. These innovations overcome aluminium’s inherent oxidation issues, dropping vehicle wiring weight by up to 50%.

https://www.linkedin.com/pulse/automotive-lightweighting-revolution-how-aluminum-conductors-jl5uc

Conclusion
Aluminum conductors have transitioned from “feasibility exploration” to “large-scale adoption” in automotive applications. While connection technologies and standardization remain challenges, relentless demands for lightweighting and cost reduction will drive innovation. Advances in materials, manufacturing, and recycling systems may establish aluminum as the “new normal” for vehicle electrical systems, underpinning global carbon neutrality goals.

https://mexicobusiness.news/automotive/news/automakers-shift-aluminum-wiring-copper-prices-rise

Tesla pioneered the use of aluminum wiring in modern passenger vehicles with the launch of the Model Y in 2019 and later expanded its use in the Cybertruck.

😉

Sparkchaser

robxr4ti aluminum wiring used in cars or electronics is very difficult to solder

How many “wire” connections in a car are soldered, I don’t know, but have never seen one.

As for homes, I think soldering is a no no for copper connections per NEC. I read that many years ago, since I come from a “solder it” environment (65+ years). Don’t know how it is now.

My sister has an aluminum wired house and I fixed a few problems she had. Finally convinced her to get a company that deals with the problem and they updated all the connections to the Al wiring. They specialize in it since there seem to be so many homes built in her area with Al wiring. Once the terminations are updated the problems go away.

anjorni

robxr4ti this… might be part of their plan

Somewhat-Reticent

robxr4ti aluminum wiring used in cars or electronics is very ~~difficult~~ different to solder

Soldering aluminum is not the same as soldering copper. It’s different.
Takes different materials and methods. Few are familiar with this.
(Welding likewise.)

robxr4ti

real_aurgathor While what you posted is interesting none of it addresses the fact that it is difficult to solder repair aluminum wiring which will be necessary regardless of how durable it is. Honestly I don’t care which manufactures use it, it’s a terrible idea.

real_aurgathor

real_aurgathor Tesla pioneered the use of aluminum wiring in modern passenger vehicles with the launch of the Model Y in 2019

I just realized that the above quote is apparently incorrect since European carmakers started to use Al wiring much earlier than that. They first began using aluminium wiring for select applications (such as large battery cables) around the mid-2000s to cut vehicle weight. Widespread adoption across electrical harnesses and high-voltage systems began in 2011 when BMW introduced it in their 1 Series.

Somewhat-Reticent

robxr4ti it’s a ~~terrible~~ challenging idea

Best let someone else be Beta Tester, eh?

JanJ

Ask the people who lived in noble homes with aluminum wiring……. How it went with aluminum wiring!

InternetJeff

JanJ Ask the people who lived in noble homes with aluminum wiring……. How it went with aluminum wiring!

That is a very timely observation. Perhaps anyone following this thread who lives in a mobile home might render an opinion.

real_aurgathor

Sparkchaser How many “wire” connections in a car are soldered, I don’t know, but have never seen one.

Soldering is highly frowned upon in general automotive wiring for a number of reasons.
In general, connectors are usually crimped on, which is essentially a cold weld if done properly.

robxr4ti

Sparkchaser sooner or later wires need to be repaired especially in the rust belt. The only permanent way to repair wires is with solder, As usual, it’s about saving manufacturers a buck while costing the end user a ton.

JanJ

Our house has copper wires. As does our garage and 20KW generator That is good enough for me!

HFB1217

In the early 1980’s and the late 70’s Aluminum, wiring was just starting to be used for main power home lines and inside homes on Cape Cod with the cape’s Salt Air environment with in a short while there were major issues with corrosion of connections as there was no recommendations for the use of corrosion protection compounds. There were at the least part power failures. internal home component failures, reduced power outputs as well as home power box fires. Aside from the other factors the load carrying ratings for Aluminum wires are lower than copper for the same gauge wiring. I was doing a DYI house building and after careful research I opted to use copper for the main power line and throughout the house the cost was not significantly higher and was exceed by the increased safety factor and load carrying carrying of copper. Specialized Aluminum comparable components were never even thought to be needed or conceived of at the time. The eventual recommendation of the time became slather every connection point with corrosion reduction compound.

So I say and Think COPPER Yes Aluminum No

Still the Automotive switching to Aluminum is cheaping out and in places where the environment has higher corrosion potential it could become a major safety problem. Just like what the automotive industry values is cost cutting regardless of their safety and the obligation to its customers. Think Air Bags, Exploding Gas tanks,, Fords Rotting Doors, and Ralph Nader’s Unsafe at Any Speed.
Safety and Reliability V/S Actuarial Profits

Somewhat-Reticent

HFB1217 Safety and Reliability V/S ~~Actuarial~~ Bean-Counter Profits

Actuaries work for Insurance.
They would argue against, due to said risk factors.
OTOH,
many “accountants” are Bean-Counters that do no Due Diligence.

Sparkchaser

real_aurgathor In general, connectors are usually crimped on, which is essentially a cold weld if done properly.

This is one thing I’ve noticed on many connector applications. Many time the correct tool is not used because “it’s so expensive” and the user does not want to spend $$$$ for it.

robxr4ti

real_aurgathor frowned on by whom? It’s the only permanent form of connection. Crimps and splices are not reliable and highly technique sensitive.