Foil strip for electrical coil application ranges from 0.0006 to 0.0059 in. Several aluminum alloys can be used to meet the minimum industry requirements for strip conductor, but alloy 1350 (99.50% aluminum) is generally the low purity limit employed for this application.
Slitting is closely controlled to assure smooth, substantially burr-free edges and strip-size availabilities are in capacities exactly equivalent to those of standard copper wire sizes.
In varying degrees, for different electrical applications, the following advantages of aluminum foil for coil winding are typical:
Depending upon the market, significant material savings, as compared with conventional wire windings, are affected through the use of the convolute-wound aluminum coils. In some instances, savings have been as high as 50%.
Actual operating temperatures of an electrically-equivalent, aluminum foil coil are from 15 to 20 degrees Fahrenheit cooler than a copper wire wound unit;
Internal hot spots usually encountered in wire windings are substantially eliminated through the use of aluminum foil;
Lower cost insulation materials are generally permissible for foil coils as compared with those demanded by wire, because foil has a substantially lower turn-to-turn voltage drop (difference in potential);
Aluminum Foil Strip Conductor