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Applications of Enamelled Aluminium Wire & Enamelled Copper Wire

Enamelled Aluminium Wire or Enameled Copper Wire is a wire coated with a thin layer of enamel (varnish) insulation to prevent the wire surfaces from being in a short circuit when wound into coils. Magnetic flux is created when current flows through the coil. Aluminum Enameled Wire and Copper Enamelled Winding Wire are used mainly in the construction of motors, electromagnets, transformers and inductors. For ease of manufacturing inductive components like transformers and inductors, most of these wires can be soldered.

Enameled Aluminum Wire or Enamelled copper wire, also called "Magnet Wire," is widely used in various Electrical Applications due to its superior Electrical, Thermal and Mechanical Properties. Enameled Aluminium Wire /Enameled Copper Wire are insulated by coating it with enamel of different temperature class. Enamelled Aluminum Wire /Enamelled Copper Wire are primarily used in three types of applications - in transformers to transform one kind of electrical energy into other kinds. Aluminum Enameled Wire and Copper Enameled Winding Wire are used in motors to transform electrical energy into mechanical energy. Enamelled Aluminium Winding Wire /Enamelled Copper Winding Wire are also used in generators to transform mechanical energy into electrical energy.

Enameled Aluminum Magnet Wire and Enamelled Copper Magnet wire are used as the wire in electromagnets that use electricity to generate a magnetic field. Enameled Rectangular or Flat Aluminium Wire and Enameled Rectangular or Flat Copper Wire /Strip is wrapped in a tight coil. When an electric charge is applied, the wires generate the magnetic field. Flat Enamelled Aluminium Wire and Flat Enamelled copper wire have a wide variety of applications, including use in automobiles, motors, transformers and industrial machineries. Round Enameled Aluminium Wire and Round Enameled copper wire are also found in smaller devices and home appliances, such as computers, televisions etc.

Like other wire, Aluminium & Copper Enamel Magnet Wire is classified by diameter (AWG number or SWG) or area (square mili meters), temperature class, and insulation class.

Breakdown voltage of Aluminium Enamelled Winding Wire or Copper Enamelled Winding Wire depends on the thickness of the covering, which can be of 3 types: Grade 1, Grade 2 and Grade 3. Higher grades have thicker insulation and thus higher breakdown voltages.

The temperature class indicates the temperature of the wire where it has a 20,000 hour service life. At lower temperatures the service life of the wire is longer (about a factor 2 for every 10 C lower temperature). Common temperature classes are 105 C, 130 C, 155 C, 180 C and 220 C.

Advantage of Enamelled Aluminium /Enamelled Copper Round & Flat Winding Wire


One of the primary properties that make Enamelled Aluminium Wire and Enamelled copper wire desirable for wide applications is the thin enameling insulation. Transformers, motors and generators are all machines based on the coil, which is a device that generates magnetic fields and electrical currents using large coils of wire. The smaller these devices are, the stronger they are. Because Enameled Aluminum Magnet Wire and Enameled copper Magnet Wire is insulated by a thin coat of enamel instead other types of thicker insulation like paper, fibre glass, mica etc. As Enamel Aluminum Wire or Enamel Copper Wire takes up less space in coil formation so it makes more effective and compact coils with higher efficiency.


Enameled Aluminium Winding Wire and Enameled copper Winding wire are widely used in electric devices because of their conductivity. Aluminium Enameled Wire and Copper Enameled wire are meant to carry electrical currents. Specially, Enamel Copper Magnet Wire has less resistance than almost any other insulated wires. This means that generators using enamel copper wires will produce more electricity than generators using most other substances. Coils of Motors made of Enamel Copper Winding Wire will produce more motion. Transformers made of Enamel Aluminium Wire or Enamel Copper Wire will lose less energy.

Resistance to Corrosion

The third feature of enameled copper wire / enamelled aluminum wire that make them so attractive for use in these devices is its resistance to corrosion. Enamelled Aluminum & Copper Magnet Wire is the material of choice for use in electrical circuits, as it lasts for a long time.

The mechanical, electrical and chemical characteristics of enamelled aluminum magnet wire differ from those of copper magnet wire because of the inherent differences in the conductor materials. These differences are reflected in certain test procedures and/or performance requirements for aluminum enameled magnet wire, such as elongation, adherence and flexibility, heat shock, scrape resistance, continuity and thermal endurance.

The advantage of aluminum enameled winding wire is light weight. This product is widely used in electrical tools, ballasts, automotive electronics, refrigerator and air conditioner compressor motors, television sets, electric stove, microwave ovens, various transformers, and other kinds of electronic coil motors, electrical appliances.

Enamelled Aluminium magnet wire is sometimes used for large transformers and motors, but because of its lower electrical conductivity, an aluminium enameled wire must have 1.6 times the cross sectional area as a copper wire to achieve comparable DC resistance. Smaller diameter magnet wire usually has a round cross section. Thicker Aluminum Magnet Wire is often square or rectangular (with rounded corners) to permit more efficient use of available winding space.

Modern Enamelled Aluminium Magnet Wire or Enameled Copper Magnet Wire typically uses one to three layers of polymer film insulation, often of two different compositions, to provide a tough, continuous insulating layer. Magnet wire insulating films use (in order of increasing temperature range) polyvinyl formal or Formvar (PVF), polyurethane, polyamide (PUW), polyester (PEW), polyester-polyimide (EIW), polyamide-polyimide (or amide-imide) (AI-EIW), and polyimide (AIW). Polyimide insulated magnet wire is capable of operation at up to 250C. The insulation of thicker square or enamelled rectangular aluminium or copper magnet wire is often augmented by wrapping it with a high-temperature polyimide or fiberglass tape, and completed windings are often vacuum impregnated with an insulating varnish to improve insulation strength and long-term reliability of the winding.

Other types of insulated conductors such as fiber glass insulated copper / aluminium round & flat wires with varnish, nomex insulated copper / aluminium round & flat wires, kraft paper insulated copper / aluminium round & flat wires, mica insulated copper / aluminium round & flat wires, kapton insulated copper / aluminium round & flat wires, and polyester film insulated copper / aluminium round & flat wires are also widely used across the world for various applications like motors, transformers and reactors.

Various Applications of Enamelled Aluminium Wire & Copper Enamelled Wire

Dual Coated Enamelled Aluminium Wires /Copper Wires are suitable for all "H + " (220C and 200C) Class and above applications such as dry type transformers, stator winding fractional and integral H.P motors, D.C Field and Armature windings, Motors for Hermetic grade, Hand tools, Chemicals Industries, Furnaces and high Torque, continuous rated, all Home appliances machine motors, Auto electrical, coil application-varnished or unvarnished. Enameled Aluminum Wire or Enameled Copper Wire of Hermetic Grade has Excellent suitability for refrigeration and air conditioning systems.

Single Coated Wires are suitable for all "H","F" and "B" Class application such as dry type transformers, stator winding fractional H.P. motors, D.C field and Armature windings. Polyester coated wires have very good chemical resistance and compatible with all general purpose impregnating varnishes including high temperature modified phenolic polyester and others which do not contain the reactive solvent.