Electronics Repair (sci.electronics.repair) Discussion of repairing electronic equipment. Topics include requests for assistance, where to obtain servicing information and parts, techniques for diagnosis and repair, and annecdotes about success, failures and problems.

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using http://www.powerstream.com/Wire_Size.htm

is there a functional difference, other factors ie metal purity equal,

between 8-12-14 gauge wire having 10 strands and 25 strands ?

does covering each copper strand with aluminum coating increase conductivity ?

or increase conductivity eliminating corrosion ....


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On Friday, January 6, 2017 at 9:52:54 AM UTC-5, wrote:

SNIPPAGE


a) Wire conductivity, irrespective of material, is a function of surface area and gauge amongst other factors. So, if 14-gauge wire is then divided into strands, the final product with the most strands will have the most surface area, and so by some factor greater conductivity.

b) Using material conductivity hierarchy, the most conductive material wants to be on the surface. Aluminum is a much poorer conductor than copper. All other things being equal, aluminum coated copper will be a poorer conductor than copper-coated aluminum (or steel: c.f. CopperWeld).

c) Corrosion is a factor, but not much of one. Alumina (AKA Aluminum Oxide) is an excellent insulator, as well as being quite inert. As aluminum wire acquires an oxide coating very nearly immediately upon exposure to air, that will reduce conductivity on the immediate surface of the wire. But as that coating is only a very few nanometers thick, the effect is near-zero overall. Copper oxides and sulfates as well as various other 'salts' are variously conductive, but also can be rectifiers, so there will be some effect on overall conductivity in the presence of these materials. BUT, copper is not a very active metal, so oxidation under normal atmospheric and environmental conditions is low and slow. Similar to Aluminum, but for different reasons.
d) Electrolysis is always a factor when dissimilar metals are forced into a conductive connection in the presence of oxygen or other oxidizers. For an interesting experiment, take an ordinary 16D nail, wrap a bit of copper wire around it, and place it in a glass of ordinary tap water. In an adjacent glass place a similar nail, no copper. Then a bit of copper, no nail. Do the same with an aluminum wire bonded to a copper wire (mere wrapping may not insure sufficient connectivity for electrolysis to take place. Copper clad materials generally do not suffer as there is very limited surface area exposed.

Enjoy!

Peter Wieck
Melrose Park, PA
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On 2017/01/06 7:17 AM, wrote:
On Friday, January 6, 2017 at 9:52:54 AM UTC-5, wrote:

SNIPPAGE


a) Wire conductivity, irrespective of material, is a function of surface area and gauge amongst other factors. So, if 14-gauge wire is then divided into strands, the final product with the most strands will have the most surface area, and so by some factor greater conductivity.


At 60 Hz in copper, the skin depth is about 8.5 mm, slightly thicker
than gauge 0.
You are talking about skin effect which is only starts to show above a
few kilohertz, otherwise the raw diameter of the wire is what carries
the current. Multi-strand wire (such as power cords, or speaker wire) is
convenient as it flexes, but it carries no more current than an
equivalent solid core wire at frequencies under around 10kHz. For
transmission towers where the outer diameter of the wire is much larger
that 8.5mm dia, then uses multi-stranded wire to get around it.


b) Using material conductivity hierarchy, the most conductive material wants to be on the surface. Aluminum is a much poorer conductor than copper. All other things being equal, aluminum coated copper will be a poorer conductor than copper-coated aluminum (or steel: c.f. CopperWeld).


If you are comparing wire coated with aluminum vs a copper wire of the
same diameter as the coated, then yes, the plain copper would conduct
more current.


c) Corrosion is a factor, but not much of one. Alumina (AKA Aluminum Oxide) is an excellent insulator, as well as being quite inert. As aluminum wire acquires an oxide coating very nearly immediately upon exposure to air, that will reduce conductivity on the immediate surface of the wire. But as that coating is only a very few nanometers thick, the effect is near-zero overall. Copper oxides and sulfates as well as various other 'salts' are variously conductive, but also can be rectifiers, so there will be some effect on overall conductivity in the presence of these materials. BUT, copper is not a very active metal, so oxidation under normal atmospheric and environmental conditions is low and slow. Similar to Aluminum, but for different reasons.


Of course corrosion will show up as a problem at connection points, but
rarely does it matter for regular wire. Battery leakage though was a big
problem with electronics designed in the 70s to 90s - but that mostly
affect circuit boards and the connectors to them. Battery and salt are
factors for wire corrosion in vehicles.

d) Electrolysis is always a factor when dissimilar metals are forced into a conductive connection in the presence of oxygen or other oxidizers. For an interesting experiment, take an ordinary 16D nail, wrap a bit of copper wire around it, and place it in a glass of ordinary tap water. In an adjacent glass place a similar nail, no copper. Then a bit of copper, no nail. Do the same with an aluminum wire bonded to a copper wire (mere wrapping may not insure sufficient connectivity for electrolysis to take place. Copper clad materials generally do not suffer as there is very limited surface area exposed.


Interesting. Thanks. The results probably depend on the hardness of your
water...


Enjoy!

Peter Wieck
Melrose Park, PA


Indeed, have a good day!

John :-#)#

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On Friday, January 6, 2017 at 2:32:01 PM UTC-5, John Robertson wrote:

At 60 Hz in copper, the skin depth is about 8.5 mm, slightly thicker
than gauge 0.
You are talking about skin effect which is only starts to show above a
few kilohertz, otherwise the raw diameter of the wire is what carries
the current. Multi-strand wire (such as power cords, or speaker wire) is
convenient as it flexes, but it carries no more current than an
equivalent solid core wire at frequencies under around 10kHz. For
transmission towers where the outer diameter of the wire is much larger
that 8.5mm dia, then uses multi-stranded wire to get around it.


In the words of the prophet: Yabbut!! (Yes, but!)

Most discussions around wire material and types wind up, at least at some point, around speaker wire discussions. Hence the reference to surface area being an advantage. Speaker wires commonly carry in the multi-kHz frequencies.

For normal household use the difference will be negligible, and in some specific conditions actually favor solid conductors. And to be a tiny bit snarky: "There is a formula for that".

My specific choice for speaker wire is #12 19-strand THHN wire chucked and twisted in a drill for easier handling. Quite manageable and extremely tough.

Peter Wieck
Melrose Park, PA
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they just flip out

electrical current, here 12v+ DC in an auto primary wire does not seek the least obstructive path that is at the interface of copper n aluminum cladding ?



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wrote:


using http://www.powerstream.com/Wire_Size.htm

is there a functional difference, other factors ie metal purity equal,

between 8-12-14 gauge wire having 10 strands and 25 strands ?



** Yes, stranded wire is far more flexible.


does covering each copper strand with aluminum coating increase
conductivity ?



** Aluminium wire is often coated in copper, not the other way around.

It improves conductivity and most importantly makes it possible to solder the ends.

Sometimes it is passed off as being pure copper to the unwary.



..... Phil


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On Friday, January 6, 2017 at 9:01:07 PM UTC-5, Phil Allison wrote:
wrote:


using http://www.powerstream.com/Wire_Size.htm

is there a functional difference, other factors ie metal purity equal,

between 8-12-14 gauge wire having 10 strands and 25 strands ?



** Yes, stranded wire is far more flexible.


does covering each copper strand with aluminum coating increase
conductivity ?



** Aluminium wire is often coated in copper, not the other way around.

It improves conductivity and most importantly makes it possible to solder the ends.

Sometimes it is passed off as being pure copper to the unwary.



.... Phil



accessed the specs via 4 lines of ID codes.....copper inside, aluminum coating outside, 25 strands Ga 12 has a mil spec rating

difficult scraping the silver off with a new utility blade


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wrote:





does covering each copper strand with aluminum coating increase
conductivity ?



** Aluminium wire is often coated in copper, not the other way around.

It improves conductivity and most importantly makes it possible to
solder the ends.

Sometimes it is passed off as being pure copper to the unwary.




accessed the specs via 4 lines of ID codes.....copper inside,
aluminum coating outside, 25 strands Ga 12 has a mil spec rating


** Kindly post in plain English - not pure gibberish like the above.

I have never heard of Aluminium clad Copper wire and neither has Google.

Where have you ?


..... Phil

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Ralph Mowery wrote:



I got some wire of 16 and 12 guage to use for 12 volt power wiring. It
may have been called speaker wire. A red and black pair.
The wire turned out to be aluminuim with a coating of copper.

I have seen some coax where the center conductor is aluminum with a
coating of copper, but this is for use at radio frequencies where the
skin effect is very much in effect.


** Copper clad aluminium wire ( aka CCA ) is commonly used for loudspeaker voice coils - enamel coated of course.

The advantage is lower weight compared to pure copper, leading to more dBs per watt.


..... Phil
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"The advantage is lower weight compared to pure copper, leading to more dBs per watt. "

Depends on the application, the advantage might be negligible. The mass will certainly matter more at higher frequencies, so these big massive cones on speakers in sound reinforcement bass bins might not benefit quite so much as say a woofer in a decent quality two way home speaker.

I also have heard of copper clad aluminum wire for other purposes and usually it is to save money. One instance it is wires strung from telephone poles. Alot of that is copper clad steel for the tensile strength, again because of cost but not just the cost of the copper, they can put up longer spans and have to set less poles.

I can't think of much reason for aluminum clad copper.
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A quantity of aluminum tineed or clad (?)
Material online but not specifically answering my question beyond the general rules of surface conduction.

An absence, in a brief surface read, led to a conclusion there's not a serious difference tween copper m aluminum clad copper. An original patent sez there is a layer of silver molecules between...in 1956, WE.

And the advantage is the AL clad wire is less reactive to insulation at higher temps.

Last question: when soldered is the joint as conductive as copper solder copper ?

Silver melts streams off solder joins copper copper with a low % aluminum.

I used the new aluminum clad wire giving a less conductive result but there are other available reasons for the result so a redo. Maybe a direct conparison.
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no, in the 1930's rubber insulation decayed against copper so cladding was produced. Aluminum cladding ( I read this last night ) did not adhere to copper but the Westinghouse patent covering copper with silver produced a functioning AL outer layer .....for lower temps on the surface or greater resistance to degradation from outside heat sources...I'm not sure which or both.

Thus, with a fine multiple strand wire there is more conductivity, less degradation more flex with a smaller space occupation. Maybe more effective bundling ?

that's what the material suggests. I read the answer to my question of not flowing thru less resistance toward the center of a copper wire with a thicker AL cladding as the outer areas of conductivity are geometrically larger supplying more free electrons in this Cu AL apparently topping more conductive copper below.

now tell me why that wire is more resistive ? as per common knowledge.
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wrote:


"The advantage is lower weight compared to pure copper, leading to
more dBs per watt. "


Depends on the application, the advantage might be negligible.


** So what? If make no odds then makers use plain copper.

JBL have been using aluminium wire on their instrument speakers for many decades to increase efficiency. CCA is easier to work with and solder.



..... Phil
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In article ,
" wrote:

On Friday, January 6, 2017 at 9:52:54 AM UTC-5, wrote:

SNIPPAGE


a) Wire conductivity, irrespective of material, is a function of surface area
and gauge amongst other factors.


It's mostly a function of cross-section area at DC. As frequency rises
and skin effect begins to be important, surface area starts to matter,
so more, finer strands might be better, *but only if the individual
strands are insulated from each other*.

Isaac
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On Saturday, January 7, 2017 at 11:21:52 PM UTC-5, isw wrote:
In article ,
" wrote:

On Friday, January 6, 2017 at 9:52:54 AM UTC-5, wrote:

SNIPPAGE


a) Wire conductivity, irrespective of material, is a function of surface area
and gauge amongst other factors.


It's mostly a function of cross-section area at DC. As frequency rises
and skin effect begins to be important, surface area starts to matter,
so more, finer strands might be better, *but only if the individual
strands are insulated from each other*.

Isaac


explain cross section electron availability for an aluminum/silver/copper wire or aluminum/copper where cladding cross section is thin ?



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" wrote:
On Friday, January 6, 2017 at 2:32:01 PM UTC-5, John Robertson wrote:

At 60 Hz in copper, the skin depth is about 8.5 mm, slightly thicker
than gauge 0.
You are talking about skin effect which is only starts to show above a
few kilohertz, otherwise the raw diameter of the wire is what carries
the current. Multi-strand wire (such as power cords, or speaker wire) is
convenient as it flexes, but it carries no more current than an
equivalent solid core wire at frequencies under around 10kHz. For
transmission towers where the outer diameter of the wire is much larger
that 8.5mm dia, then uses multi-stranded wire to get around it.


In the words of the prophet: Yabbut!! (Yes, but!)

Most discussions around wire material and types wind up, at least at some
point, around speaker wire discussions. Hence the reference to surface
area being an advantage. Speaker wires commonly carry in the multi-kHz frequencies.

For normal household use the difference will be negligible, and in some
specific conditions actually favor solid conductors. And to be a tiny bit
snarky: "There is a formula for that".

My specific choice for speaker wire is #12 19-strand THHN wire chucked
and twisted in a drill for easier handling. Quite manageable and extremely tough.

Peter Wieck
Melrose Park, PA


Some notes on speaker wire.

https://passlabs.com/press/speaker-c...e-or-snake-oil

Greg
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The page would not load for me, but I got this to say. I don't buy this snake oil ****. As long as the gauge is thick enough to allow good damping and not lose signal you are good to go.

As far as I can tell, the best speaker wire would be solid, like Rpmex that is in a casing which will force the two leads to run parallel.

Nelson Pass designs little three watt amplifiers n **** like that, there is no appreciable magnetic field. Audiophiles swear by them though. They also like single ended triode tube amps. This is where you take a 6L6 or 1 6550 per channel and rock the house with five watts. They replace perfectly good capacitors with super expensive ones which supposedly sound better.

He is obviously pandering to those who do not know electronics. Float your scope and the DUT, put the scope probe across any coupling cap in there and if all you see is DC it is good enough for the job. Same with filters, if all you see is DC it is good enough. I mean they do the cap job on single ended amps.

In some cases you might get a little more oomph out of a class AB amp upping the value of the main filters but you are not getting more power. All you get is more time at your dynamic headroom point before the voltages drop to the steady state power point. Same **** a few milliseconds later.

I have indeed heard the difference when speaker wires are of insufficient gauge, but it was an extreme demonstration.. fifty feet of zip cord that was maybe 28 gauge or something. Not much fatter than telephone wire.
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In article ,
says...

The page would not load for me, but I got this to say. I don't buy this snake oil ****. As long as the gauge is thick enough to allow good damping and not lose signal you are good to go.

As far as I can tell, the best speaker wire would be solid, like Rpmex that is in a casing which will force the two leads to run parallel.

Nelson Pass designs little three watt amplifiers n **** like that, there is no appreciable magnetic field. Audiophiles swear by them though. They also like single ended triode tube amps. This is where you take a 6L6 or 1 6550 per channel and rock the house with five watts. They replace perfectly good capacitors with super expensive ones which supposedly sound better.

He is obviously pandering to those who do not know electronics. Float your scope and the DUT, put the scope probe across any coupling cap in there and if all you see is DC it is good enough for the job. Same with filters, if all you see is DC it is good enough. I mean they do the cap job on single ended amps.

In some cases you might get a little more oomph out of a class AB amp upping the value of the main filters but you are not getting more power. All you get is more time at your dynamic headroom point before the voltages drop to the steady state power point. Same **** a few milliseconds later.

I have indeed heard the difference when speaker wires are of insufficient gauge, but it was an extreme demonstration.. fifty feet of zip cord that was maybe 28 gauge or something. Not much fatter than telephone wire.



When they can sell about 6 feet of wire to go from the equipment to a
wall socket for over $ 100 , it proves they will buy most anything.

That wire must be some oxygen free, special insulated wire or some such
snake oil coated. There is no way the wire of the same gauge is going
to be noticed when there is probaly over 50 feet of cheep wire from the
socket to the breaker box of the house and hard telling how many miles
of even cheaper made wire to the power company.
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Phil Allison wrote:

Ralph Mowery wrote:



I got some wire of 16 and 12 guage to use for 12 volt power wiring. It
may have been called speaker wire. A red and black pair.
The wire turned out to be aluminuim with a coating of copper.

I have seen some coax where the center conductor is aluminum with a
coating of copper, but this is for use at radio frequencies where the
skin effect is very much in effect.


** Copper clad aluminium wire ( aka CCA ) is commonly used for loudspeaker
voice coils - enamel coated of course.

The advantage is lower weight compared to pure copper, leading to more dBs
per watt.

Yes, that is definitely one place where it makes sense!
The wire in my Magneplanar speakers is made that way, although it isn't a
coil.

Jon
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isw wrote:


ISTR that the problem was mostly that electricians couldn't be bothered
to learn the new techniques and so on that were mandatory to install the
stuff safely. It was only when it was installed just like Cu that it was
prone to overheating.

If the wrong wire terminal combination is installed, then your house WILL
burn down, guaranteed! If you use the right CO/ALR fittings EVERYWHERE,
then over time you will STILL develop poor connections. You can go around
and tighten all the terminals in your breaker box and outlets and switches
every ten years or so. But, it is STILL a risk, even with all the right
parts, as the wire just keeps creeping out from under the terminals. And,
of course, some people wired up their houses with those incredibly awful
poke the wire in the hole switches and outlets, which even with all copper
wire make poor connections after a few years.

Jon


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On Tuesday, January 10, 2017 at 11:38:54 AM UTC-8, Jon Elson wrote:
isw wrote:


[about aluminum house wiring]

ISTR that the problem was mostly that electricians couldn't be bothered
to learn the new techniques and so on that were mandatory to install the
stuff safely.


If the wrong wire terminal combination is installed, then your house WILL
burn down, guaranteed! If you use the right CO/ALR fittings EVERYWHERE,
then over time you will STILL develop poor connections.


I've seen poor connections with copper wire, too; many industrial plants
are wired with heavy aluminum (I've done some of it). I don't know about CO/ALR
specifically, but there ARE effective ways to use aluminum wiring.
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Ralph Mowery wrote:

I have seen some coax where the center conductor is aluminum with a
coating of copper, but this is for use at radio frequencies where the
skin effect is very much in effect.


CATV coax (RG-59, RG-6, RG-11) uses a STEEL center conductor for
strength, not aluminum. The figure eight version for drops hs an added
stainless steel messenger wire. .500", .750" and larger trunk cables use
aluminum to reduce the weight, but the .750" and larger trunk lines have
to be able to handle 30A on the center conductor. .500" is only used to
feed line extenders or line taps, and needs to be able to carry 15A.
CATV line equipment is typically powered by 60 VAC modified sine wave
from a large pole or pad mounted CVT, but some early 12 channel hardware
was powered by 30VAC modified sine wave power supplies. This was mostly
obsolete by the '70s.



--
Never **** off an Engineer!

They don't get mad.

They don't get even.

They go for over unity! ;-)
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On Fri, 6 Jan 2017 18:18:32 -0800 (PST), wrote:

On Friday, January 6, 2017 at 9:01:07 PM UTC-5, Phil Allison wrote:
wrote:


using
http://www.powerstream.com/Wire_Size.htm

is there a functional difference, other factors ie metal purity equal,

between 8-12-14 gauge wire having 10 strands and 25 strands ?



** Yes, stranded wire is far more flexible.


does covering each copper strand with aluminum coating increase
conductivity ?



** Aluminium wire is often coated in copper, not the other way around.

It improves conductivity and most importantly makes it possible to solder the ends.

Sometimes it is passed off as being pure copper to the unwary.



.... Phil



accessed the specs via 4 lines of ID codes.....copper inside, aluminum coating outside, 25 strands Ga 12 has a mil spec rating

difficult scraping the silver off with a new utility blade


More likely to be coated with silver, particularly if mil spec.

RL
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On Sat, 7 Jan 2017 14:43:12 -0800 (PST), wrote:

no, in the 1930's rubber insulation decayed against copper so cladding was produced. Aluminum cladding ( I read this last night ) did not adhere to copper but the Westinghouse patent covering copper with silver produced a functioning AL outer layer .....for lower temps on the surface or greater resistance to degradation from outside heat sources...I'm not sure which or both.

Thus, with a fine multiple strand wire there is more conductivity, less degradation more flex with a smaller space occupation. Maybe more effective bundling ?

that's what the material suggests. I read the answer to my question of not flowing thru less resistance toward the center of a copper wire with a thicker AL cladding as the outer areas of conductivity are geometrically larger supplying more free electrons in this Cu AL apparently topping more conductive copper below.

now tell me why that wire is more resistive ? as per common knowledge.


AlSi coatings are used for environmental protection. They will not
improve surface conductivity directly, but can preserve conductivity
of the coated material and assist to reduce corrosion.

I've never seen it offered for copper. Perhaps you can offer a
reference or link to the material you're refering to?

Aluminum is more resistive by volume than copper (less resistive by
weight).....so is unlikely to be used to reduce skin resistance of a
copper conductor directly, in the short term.

RL


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On 1/10/2017 10:09 AM, Ralph Mowery wrote:

That wire must be some oxygen free, special insulated wire or some such
snake oil coated. There is no way the wire of the same gauge is going
to be noticed when there is probaly over 50 feet of cheep wire from the
socket to the breaker box of the house and hard telling how many miles
of even cheaper made wire to the power company.


For the definitive answer from an electrical engineer, see the answer by
Bill Shymanski
https://groups.google.com/forum/?hl=...al/eWXk4BjP-rM
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On 1/7/2017 10:24 PM, isw wrote:
In article ,

The only aluminum wire is used as power lead-ins to houses, as it is much
cheaper than copper. They did use aluminum wire INSIDE houses in the US
around 1966-1968, and it burned a lot of houses down, due to the cold flow
of aluminum weakening the contact force.


ISTR that the problem was mostly that electricians couldn't be bothered
to learn the new techniques and so on that were mandatory to install the
stuff safely. It was only when it was installed just like Cu that it was
prone to overheating.


The problem is only for 15 and 20 amp branch circuits. Larger wire is
used often without problems.

Around 1965 the price of copper went through the roof and aluminum
started to be used on 15 and 20A circuits. Failed connections and fires
resulted, and in 1971 UL pulled the listing on that aluminum wire and
the aluminum rating for devices like switches and receptacles. New
standards soon followed. The new aluminum wire was harder, and devices
had a CO/ALR (Revised) rating.

The CPSC had extensive testing done on aluminum connections. That
testing found that the aluminum oxide surface insulating layer caused
much of the problem - the actual metal-metal contact could be quite
small. Installations done "properly" could still fail. The probability
of a failure was just higher for aluminum than copper. Even though
there is a new alloy, most of the wire actually installed is the "old
technology" stuff. "Backstab" device connections were never listed for
use with aluminum.

If someone is working with this 15 & 20A wire there is a good paper on
connections at:
http://www.kinginnovation.com/pdfs/R...Fire070706.pdf
It is written by the engineer that supervised the testing for the CPSC.
Use of antioxide pastes is generally recommended.

The best connectors are
http://www.kinginnovation.com/produc...cts/alumiconn/
They have a screw connection that likely breaks through surface oxides.
(Connections for large wires also deform the wire.)


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AND THE WIRE IS...

Consolidated

14(41)UL 1007/1569 105C CSA TR64 30C FT1 BLUE


for example, other spools state differently but same batch MO
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On Tuesday, January 10, 2017 at 11:38:54 AM UTC-8, Jon Elson wrote:
isw wrote:


[about aluminum house wiring]

ISTR that the problem was mostly that electricians couldn't be bothered
to learn the new techniques and so on that were mandatory to install the
stuff safely.


If the wrong wire terminal combination is installed, then your house WILL
burn down, guaranteed! If you use the right CO/ALR fittings EVERYWHERE,
then over time you will STILL develop poor connections.


Covering the aluminum leads with anti-corrosive material (noalox) before attaching to copper or brass terminals helps.
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In article ,
says...

AND THE WIRE IS...

Consolidated

14(41)UL 1007/1569 105C CSA TR64 30C FT1 BLUE


for example, other spools state differently but same batch MO


PLL lock just out of reach ?

jamie



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