The subject of using aluminum wire in a hybrid motor was raised.
Because of its greater resistivity, aluminum wiring requires larger conductors than copper. For instance, instead of 14 AWG (American wire gauge) for most lighting circuits, aluminum wiring would be 12 AWG on a typical 15 ampere circuit, though local building codes may vary.
Several electrically conductive metals are lighter than copper, but since they require larger cross sections to carry the same current, they are unacceptable when limited space is a major requirement. Aluminum has 61% of the conductivity of copper. The cross sectional area of an aluminum conductor must be 56% larger than copper for the same current carrying capability. The need to increase the thickness of aluminum wire restricts its use in several applications, such as in small motors and automobiles. The motor windings would need to be more than half again larger.
Tensile strength measures the force required to pull an object such as rope, wire, or a structural beam to the point where it breaks. The tensile strength of a material is the maximum amount of tensile stress it can take before breaking.
Copper’s higher tensile strength (200-250 N/mm2 annealed) compared to aluminum is another reason why copper is used extensively in the building industry. Copper’s high strength resists stretching, neck-down, creep, nicks and breaks, and thereby also prevents failures and service interruptions.