A strategic choice: Changing from copper to aluminium in HVAC&R and automotive applications
Aluminium is increasingly used in heating, ventilation, air conditioning and refrigeration (HVAC&R), automotive and several other industries as a replacement for copper, which is more expensive.
The global energy transition is driving an exponential growth in the demand for materials used to conduct electricity and heat. This has led to a strategic exploration of copper to aluminium substitution, where aluminium's unique characteristics present a compelling case for modern manufacturing.
This is not about one material being better than the other, but about choosing the right material for the right application in order to achieve specific goals like reducing cost, increasing performance and lowering the embedded carbon footprint of the materials.
Aluminium, a versatile and abundant metal, is an excellent alternative. With its lightweight nature, high conductivity, and infinite recyclability, it is well suited for a modern industrial landscape focused on efficiency and decarbonization. The current market conditions also offer an economic incentive to explore a material shift to aluminium.
Optimizing performance and cost
Transitioning to aluminium is a reengineering process, not a simple swap. For applications like HVAC&R, manufacturers can redesign components to leverage aluminium's properties.
“In order to successfully adopt aluminium, you need to redesign the shape, for example, replacing copper tubes with micro-channel extrusions, and re-engineer the system. But once you get through all that, customers don’t go back to using copper and stick with aluminium,” Lionel Chapis, Senior Vice President of Hydro Precision Tubing, told Fastmarkets.
Using micro-channel extrusions can create heat exchangers that are both lighter and more cost effective to produce. By thoughtfully redesigning products to take advantage of aluminium's strengths, companies can achieve better performance at a lower cost.
The benefits of aluminium substitution are also evident in the automotive industry. A key advantage of aluminium is its lightweight nature, which is critical for maximizing battery range and overall vehicle efficiency.
Aluminium battery cables reduces the amount of wired weight in electric, hybrid and fossil fuel powered vehicles. The battery cables are extruded solid aluminium rods that offer significant advantages in material, weight and cost for the electrical systems in cars.
Partnering for a more responsible future
For companies operating in a modern industrial landscape, the case for exploring copper to aluminium substitution is a strategic one. It requires redesigned systems and affects many parts of the production chain and also the service offering and maintenance when the product is in use.
While these hurdles can seem challenging, partnering with an expert can streamline the process. Hydro have a long history of helping manufacturers navigate these complexities to achieve their goals for lower cost, better performance and enhanced environmental responsibility.