Copper vs Aluminum Cable: Which Is Better?

By Jianyun Cable – Professional Manufacturer of Quality Electrical Cables

The choice between copper and aluminum conductors is one of the most important decisions in electrical design and installation. Both materials are widely used in power cables, building wire, overhead lines, and industrial applications – but each has distinct advantages and trade-offs. This 2025 in-depth comparison explores copper vs aluminum cable in detail: conductivity, cost, weight, corrosion resistance, safety, installation, and real-world applications – helping engineers, contractors, and buyers make informed decisions.

1. Introduction: Copper vs Aluminum – The Eternal Debate

Copper has long been the “gold standard” for electrical conductors due to its superior conductivity and reliability. Aluminum, however, has gained significant market share thanks to lower cost and lighter weight – especially in large feeders, service entrances, and utility lines. The “better” choice depends on your project’s specific requirements: budget, load, environment, code compliance, and long-term performance goals.

2. Key Differences at a Glance

3. Electrical Conductivity & Performance

Copper has approximately 61% higher electrical conductivity than aluminum (100% IACS vs 61% IACS). This means:

• A copper conductor can carry the same current with a smaller cross-section (≈60% smaller size)
• Or, for the same size, copper has lower power loss (I²R heating)
• Copper allows longer cable runs with acceptable voltage drop

4. Cost, Weight & Installation Comparison

Aluminum is 3.3 times lighter than copper and typically 2–3 times cheaper per kg. For large feeders or long-distance lines, aluminum reduces structural load and installation cost significantly. However, aluminum requires larger conductor sizes to match copper’s ampacity, which can offset some savings.

5. Corrosion Resistance, Safety & Longevity

Copper forms a stable, self-protecting oxide layer and is highly resistant to corrosion. Aluminum also forms a protective oxide, but it is more prone to galvanic corrosion (especially at terminations with copper lugs) and requires anti-oxidant compound + proper torque. Copper connections are more forgiving and have fewer long-term failure risks.

6. Copper vs Aluminum Cable – Side-by-Side Comparison

7. When to Choose Copper vs Aluminum

Choose Copper when:

• Smaller conductor sizes are preferred
• High reliability & long life are critical
• Indoor or corrosive environments
• Residential/commercial branch circuits
• Code requires copper (some jurisdictions)

Choose Aluminum when:

• Large feeders or service entrances (≥4/0 AWG)
• Cost savings are priority
• Weight reduction is important (overhead, long runs)
• Utility distribution lines
• Modern AA-8000 series aluminum with proper terminations

8. Final Verdict: Which Is Better?

There is no universal “better” conductor – it depends on your project:

• Copper is superior in conductivity, reliability, corrosion resistance, and long-term performance – ideal for most building wiring and critical applications.
• Aluminum wins on cost and weight – making it the preferred choice for large feeders, utility lines, and cost-sensitive projects when properly installed (using AA-8000 series and anti-oxidant compound).

For high-quality copper and aluminum power cables – low voltage, medium voltage, armored, LSZH, fire-resistant – with full international compliance and expert technical support, contact Henan Province Jianyun Cable Co., Ltd. – your trusted partner for reliable conductor solutions.