Power transmission and distribution form the backbone of modern infrastructure, with power cables serving as its vital components. Among various cable materials, aluminum alloy cables have gained significant prominence in both overhead and underground applications due to their unique advantages. This article provides an in-depth exploration of aluminum alloy power cables, covering their types, characteristics, applications, and selection criteria, offering electrical engineers and professionals a comprehensive reference.

Imagine how renewable energy from wind turbines and solar panels would reach households without an efficient power transmission network. Aluminum alloy power cables play a crucial role in the energy transition, ensuring economical and safe electricity delivery to every corner of society.

Aluminum alloy power cables use aluminum alloy conductors for electricity transmission and distribution. Compared to traditional copper-core cables, they offer lighter weight, lower cost, and superior corrosion resistance while meeting power transmission requirements. Based on installation methods, they're categorized into overhead and underground cables.

These cables serve three primary functions in power systems:

1. Power Transmission: Delivering high-voltage electricity from power plants to distribution networks
2. Power Distribution: Distributing electricity to residential, commercial, and industrial users
3. Power Supply: Providing reliable electricity to various electrical devices

Cable design considers voltage rating, current capacity, and operating temperature to ensure stable performance. Typically featuring stranded aluminum alloy conductors to reduce resistance and enhance flexibility, these cables use insulation materials like XLPE or PVC to prevent current leakage.

• AAC (All Aluminum Conductor): Pure aluminum strands with good conductivity but lower mechanical strength
• ACSR (Aluminum Conductor Steel Reinforced): Aluminum with steel core for enhanced strength, ideal for long-distance lines
• AAAC (All Aluminum Alloy Conductor): Higher strength and corrosion resistance than pure aluminum
• ABC (Aerial Bundled Cable): Insulated cables for urban distribution networks

• XLPE Cable: Cross-linked polyethylene insulation with excellent electrical and thermal properties
• PVC Cable: Cost-effective for low-voltage applications
• MIC (Mineral Insulated Cable): Fire-resistant for hazardous environments
• MC (Metal Clad Cable): Armored for mechanical protection

• Conductivity: 61% of copper's conductivity but significantly lighter
• Durability: Excellent corrosion resistance through natural oxide layer formation
• Lightweight: 30% of copper's density, reducing installation costs
• Safety: Non-toxic, non-combustible, with proper insulation
• Compatibility: Works with standard connectors and can interface with copper cables

These cables serve diverse sectors:

• Power transmission networks (ACSR for long-distance transmission)
• Renewable energy systems (wind and solar farms)
• Industrial and commercial facilities
• Residential buildings (especially in coastal areas)
• Electric vehicle charging infrastructure

Key factors for proper cable selection:

1. Voltage rating exceeding system requirements
2. Current capacity matching maximum load
3. Operating temperature suitable for environment
4. Proper installation method (overhead/underground)
5. Environmental conditions (corrosion, flammability)
6. Compliance with regional standards (GB/T in China, UL in US)

Proper practices include:

• Following manufacturer specifications
• Maintaining proper bending radius
• Using appropriate connectors
• Regular insulation resistance testing
• Periodic inspection for damage or corrosion

Development focuses on:

• Higher-strength aluminum alloys
• Advanced insulation materials
• Smart cables with integrated sensors
• Eco-friendly manufacturing processes

Aluminum alloy power cables remain indispensable in modern power systems. Understanding their properties and proper selection ensures reliable electricity distribution. As technology advances, these cables will continue evolving to support smarter, more sustainable power infrastructure.