Al99.

5 Aluminum Wire
Al99.5
Aluminum Wire
General Description Features
ELEKTRISOLA enameled aluminum wire is mainly  Low density allows coil weight reduction
used as an electrical conductor wherever coils are  Rapid heat dissipation
in motion. Because of the low density of aluminum,
the coil weight can be reduced to one third of a
similar copper coil. This weight advantage allows Applications
for easier and more efficient acceleration of the
moving part, resulting in performance increases
 VCM coils for HDD actuator
such as: reduced access times of hard disk drives  Voice coils (e.g. headphones)
and improved sound quality & sensitivity for  High-Fidelity speakers
speakers and voice coils. For these applications,  Induction heaters
self-bonding aluminum wire are mainly used.  Others

Electrical Characteristics (Note 1)

Min Typ Max
Symbol Parameter (Note 3) (Note 2) (Note 3) Units
 Conductivity 36.0 S*m/mm²
 Resistivity 0.0278 Ω*mm²/m
 Thermal coefficient of resistance 3800 4000 4200 10E-6/K

Mechanical Characteristics (Note 1)

Min Typ Max
Symbol Parameter (Note 3) (Note 2) (Note 3) Units

T Tensile strength 120 130 150 N/mm²

 Y 1% Yield strength at 1% 80 90 100 N/mm²

 Elongation 5 20 35 %

BPP Bending proof performance (Note 4) 20 %

Physical Characteristics (Note 1)

Min Typ Max

Symbol Parameter (Note 3) (Note 2) (Note 3) Units
 Density 2.7 kg/dm³

October 2009 1 www.elektrisola.com

 Note 1: Unless otherwise specified, all limits are guaranteed for annealed and enameled wire at T A = 20°C and measured
according international standard IEC 851 as far as applicable.

AL99.5 Aluminum Wire

Note 2: Typical Values represent the most likely parametric norm.
Note 3: All limits are guaranteed by testing or statistical analysis.
Note 4: BPP tests are conducted with a 0.100mm hard drawn bare wire according ELEKTRISOLA internal specification.
The value specifies the Time To Fracture (TTF) compared to copper (100%) under these test conditions.

Typical Performance Characteristics

Tensile strength vs. elongation
(Diameter: 0.100mm)

160
Tensile strength [N/mm²]

140
120
100
80
60
40
20
0
0 5 10 15 20 25 30
Elongation [%]

BANNED SUBSTANCES COMPLIANCE

ELEKTRISOLA FEINDRAHT AG certifies that the products and packing materials meet the provision from the European
Union for the Restriction of certain Hazardous Substances (RoHS) and the directive for Waste from Electrical and
Electronic Equipment (WEEE).

ELEKTRISOLA FEINDRAHT AG Telephone +41 (0)41 487 77 00
Hauptstrasse 35, PO Box 177 Fax +41 (0)41 487 78 00
CH - 6182 Escholzmatt E-Mail info@elektrisola.ch
Switzerland Internet www.elektrisola.ch
Sister Companies: ELEKTRISOLA Dr. Gerd Schildbach, Germany
ELEKTRISOLA GmbH, Italy
ELEKTRISOLA Inc., USA
ELEKTRISOLA Sdn. Bhd., Malaysia
ELEKTRISOLA SA, México
ELEKTRISOLA Hangzhou, China

October 2009 2 www.elektrisola.com

 Annex A

AL99.5 Aluminum Wire

Electrical Resistance
The limits of electrical resistance are calculated according to IEC standard 317-0-3 Annex C.1 “Method for the
calculation of linear resistance” for aluminum wire and for smaller diameters they are derived from IEC
standard 317-0-1 Annex C.1 for copper wire and are restricted by a factor of 2.

Nom. AWG Min Nominal Max Nom. AWG Min Nominal Max
Diameter Diameter
[mm] [Ω/m] [Ω/m] [Ω/m] [mm] [Ω/m] [Ω/m] [Ω/m]
0.0098 58 332.8 369.8 406.8 0.0420 18.18 20.13 22.09
0.0101 313.3 348.2 383.0 0.0430 17.34 19.21 21.07
0.0109 57 269.0 298.9 328.8 0.0437 16.79 18.60 20.40
0.0113 250.3 278.1 306.0 0.0440 45 16.57 18.34 20.12
0.0120 222.0 246.6 271.3 0.0450 15.84 17.54 19.24
0.0125 56 204.6 227.3 250.0 0.0460 15.16 16.78 18.41
0.0130 55.5 189.1 210.2 231.2 0.0470 44.5 14.63 16.08 17.52
0.0135 55 175.4 194.9 214.4 0.0480 14.03 15.41 16.80
0.0140 163.1 181.2 199.3 0.0490 13.46 14.79 16.12
0.0145 54.5 152.0 168.9 185.8 0.0500 44 12.93 14.21 15.48
0.0155 54 133.0 147.8 162.6 0.0520 43.5 11.95 13.13 14.32
0.0160 124.9 138.7 152.6 0.0530 11.51 12.64 13.78
0.0165 53.5 117.4 130.5 143.5 0.0550 43 10.68 11.74 12.80
0.0170 110.6 122.9 135.2 0.0560 10.31 11.33 12.34
0.0175 53 104.4 116.0 127.6 0.0580 9.607 10.56 11.51
0.0180 98.65 109.6 120.6 0.0600 42.5 9.076 9.865 10.65
0.0185 52.5 93.39 103.8 114.1 0.0620 8.500 9.239 9.978
0.0190 88.54 98.38 108.2 0.0630 42 8.232 8.948 9.664
0.0195 52 84.06 93.40 102.7 0.0650 41.5 7.606 8.406 9.330
0.0200 79.91 88.79 97.67 0.0670 7.178 7.912 8.756
0.0210 51.5 72.48 80.53 88.59 0.0680 6.977 7.681 8.489
0.0215 69.15 76.83 84.52 0.0700 41 6.600 7.248 7.990
0.0220 51 66.04 73.38 80.72 0.0710 6.423 7.045 7.756
0.0230 50.5 60.42 67.14 73.85 0.0740 5.932 6.486 7.115
0.0240 55.49 61.66 67.83 0.0750 40.5 5.781 6.314 6.919
0.0245 50 53.25 59.17 65.09 0.0780 40 5.361 5.838 6.376
0.0250 51.14 56.83 62.51 0.0800 5.106 5.549 6.049
0.0260 49.5 47.28 52.54 57.79 0.0830 39.5 4.756 5.155 5.604
0.0270 43.85 48.72 53.59 0.0850 4.542 4.916 5.334
0.0275 49 42.27 46.96 51.66 0.0880 39 4.247 4.586 4.964
0.0280 40.77 45.30 49.83 0.0900 4.067 4.385 4.739
0.0290 48.5 38.01 42.23 46.45 0.0930 38.5 3.816 4.106 4.428
0.0300 35.52 39.46 43.41 0.0950 3.662 3.935 4.237
0.0310 48 33.26 36.96 40.65 0.100 3.315 3.552 3.812
0.0320 31.22 34.68 38.15 0.101 38.0 3.252 3.482 3.734
0.0330 47.5 29.45 32.61 35.78 0.106 37.5 2.960 3.161 3.381
0.0340 27.74 30.72 33.70 0.110 2.755 2.935 3.133
0.0350 47 26.18 28.99 31.80 0.112 2.660 2.831 3.019
0.0360 24.75 27.40 30.06 0.113 37 2.614 2.781 2.964
0.0370 46.5 23.43 25.94 28.46 0.115 2.526 2.686 2.859
0.0380 22.21 24.60 26.98 0.118 36.5 2.402 2.551 2.712
0.0381 46.1 22.09 24.47 26.84 0.120 2.325 2.466 2.620
0.0390 46.0 21.09 23.35 25.62 0.125 2.147 2.273 2.410
0.0400 20.04 22.20 24.35 0.126 36 2.114 2.237 2.371
0.0410 45.5 19.08 21.13 23.18 0.130 1.988 2.102 2.224

October 2009 3 www.elektrisola.com

 Annex A

AL99.5 Aluminum Wire

Electrical Resistance (Continued)
Nom. AWG Min Nominal Max Nom. AWG Min Nominal Max
Diameter Diameter
[mm] [Ω/m] [Ω/m] [Ω/m] [mm] [Ω/m] [Ω/m] [Ω/m]
0.132 1.930 2.038 2.155 0.268 29.5 0.4754 0.4945 0.5146
0.134 35.5 1.874 1.978 2.090 0.270 0.4685 0.4872 0.5069
0.138 1.769 1.865 1.968 0.280 0.4361 0.4530 0.4708
0.140 1.720 1.812 1.911 0.286 29 0.4182 0.4342 0.4510
0.141 35 1.696 1.786 1.883 0.290 0.4069 0.4223 0.4385
0.149 34.5 1.522 1.600 1.683 0.295 0.3934 0.4081 0.4235
0.150 1.503 1.578 1.660 0.300 0.3806 0.3946 0.4094
0.159 34.0 1.340 1.405 1.474 0.301 28.5 0.3781 0.3920 0.4066
0.160 1.324 1.387 1.455 0.315 0.3456 0.3579 0.3708
0.169 33.5 1.189 1.244 1.302 0.319 28 0.3371 0.3490 0.3615
0.170 1.175 1.229 1.286 0.335 0.3061 0.3165 0.3274
0.179 33 1.062 1.108 1.158 0.339 27.5 0.2990 0.3090 0.3196
0.180 1.050 1.096 1.145 0.345 0.2888 0.2984 0.3084
0.189 0.9541 0.9943 1.037 0.350 0.2807 0.2899 0.2996
0.190 32.5 0.9442 0.9838 1.026 0.355 0.2729 0.2818 0.2911
0.200 0.8535 0.8879 0.9242 0.360 27 0.2640 0.2740 0.2846
0.202 32 0.8369 0.8704 0.9057 0.375 0.2436 0.2526 0.2620
0.210 0.7753 0.8053 0.8370 0.380 26.5 0.2373 0.2460 0.2550
0.212 31.5 0.7609 0.7902 0.8211 0.383 0.2336 0.2421 0.2510
0.220 0.7073 0.7338 0.7617 0.390 0.2254 0.2335 0.2420
0.222 0.6948 0.7206 0.7478 0.400 0.2144 0.2220 0.2299
0.224 0.6826 0.7078 0.7343 0.402 26 0.2123 0.2198 0.2276
0.225 31 0.6707 0.7015 0.7343 0.420 0.1947 0.2013 0.2083
0.230 0.6423 0.6714 0.7022 0.425 0.1902 0.1966 0.2033
0.236 0.6106 0.6377 0.6664 0.427 25.5 0.1885 0.1948 0.2014
0.239 0.5956 0.6218 0.6495 0.450 0.1699 0.1754 0.1811
0.240 30.5 0.5908 0.6166 0.6440 0.453 25 0.1677 0.1731 0.1787
0.250 0.5452 0.5683 0.5927 0.475 0.1527 0.1574 0.1624
0.253 30 0.5325 0.5549 0.5785 0.481 24.5 0.1489 0.1535 0.1583
0.260 0.5047 0.5254 0.5473 0.500 0.1379 0.1421 0.1464
0.265 0.4861 0.5057 0.5265 0.508 24 0.1331 0.1376 0.1423

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