Electrical/Electronic Architecture

Delphi Aluminum Cable Systems include a cost-effective, lightweight wiring alternative that offers up to 48 percent mass reduction compared to traditional copper core cable. Approximately one kilogram of aluminum can replace 2 kilograms of copper, providing equal conductivity.

Delphi Aluminum Cable Systems enable improved fuel economy due to mass savings and lighter, easier vehicle assembly, while reducing the susceptibility to copper commodity volatility. Aluminum cable is larger than copper cable due to the greater cross section of aluminum required, yet it achieves the same conductivity. The insulation is lighter in weight than conventional insulations, further enhancing the weight reduction potential of Delphi's aluminum cable.

A range of aluminum cable sizes are available, depending on the intended application:

• Primary cable — 0.75 to 2.5mm²
• Power/battery cable — 3.0 to 85.0 mm²

Delphi Aluminum Cable Systems feature advanced materials such as halogen free ultra thin-wall insulation, which provides exceptional pinch and abrasion resistance to enable a volume reduction compared to thin-wall cable. Delphi's high strength, high conductivity aluminum alloy provides up to 46 percent higher break strength than pure aluminum cable.

Delphi continues to expand its portfolio of aluminum cable related products and processes. A portfolio of aluminum-capable terminals is also available. Advanced processes include automated crimp termination technology and innovative corrosion protection solutions.

Benefits

• Reduced weight lowers harness mass and helps improve vehicle fuel economy
• Achieving the same conductivity, aluminum is half the weight of copper
• Ultra thin-wall insulation helps to offset the larger cross section required by aluminum
• Reduced volume enables bundle size reduction, reduces the space needed for cable, and improves packaging opportunities
• Eliminates copper, which costs more than aluminum, enhancing the cost-effectiveness of wire assembly
• Reduced susceptibility to commodity market fluctuations
• Aluminum prices are historically more stable (less variation on a percentage basis) when compared to copper prices
• Various insulation materials are available with aluminum core
• Lead-free PVC (polyvinyl chloride)
• Halogen free, heavy metal free
• Performs well in an ultra thin-wall configuration, helping to offset the diameter gain required by aluminum to maintain the same conductivity as copper
• Complies with ISO 6722-2 (International Organization for Standardization)
  
• Proven termination performance and corrosion protection
• In-house aluminum cable manufacturing
• Proven, production ready manufacturing assembly processes, including automation
• Aluminum cable integration into the standard electrical/electronic system

Typical Applications

Delphi Aluminum Cable Systems can be used in primary cable or power/battery cable applications. Contact Delphi for further information about your specific application requirements.

Delphi Aluminum Cable

Availability

Manufacturers can contact Delphi for information regarding:

• Samples
• Test results
• Application guidelines
• Aluminum compatible terminals
• Fleet vehicle testing

Performance Advantages

Many thousands of kilometers of Delphi's copper clad aluminum core cable and aluminum solid core cable can be found on roads around the world in proven applications. This development and manufacturing experience enables Delphi to continue to meet customer expectations for material cost reduction, weight reduction, robustness, reliability, and minimized complexity.

Delphi offers a complete line of wiring and cable to meet the demanding requirements for many applications, including engine compartments, interior and chassis wiring harnesses. In addition to Delphi Aluminum Cable Systems, other offerings include the following:

• 0.13 mm² Cable
• Battery Cable
• Halogen Free Thin-Wall & Ultra Thin-Wall Cable
• PVC Primary Cable
• XLPE (cross-linked polyolefin) Primary Cable