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Aluminum Cable, Lightweight Performer

Delphi Aluminum Cable provides weight reduction and equivalent electrical performance when compared to copper cable.

Losing weight can be difficult ... just ask the designers working on vehicle platforms where every extra gram affects fuel economy, manufacturing, and costs. Automotive manufacturers want to lose weight in their vehicles without having to sacrifice anything. Delphi Aluminum Cable can save up to about 4 lbs (1.8 kg) on a typical vehicle without compromising electrical performance or disrupting production. That can add up to a 48 percent weight reduction when compared to copper core cable.

"Delphi continues to develop additional products and processes to help meet customer expectations for material cost and weight reductions, robustness, reliability, and less complexity," said Stefaan Vandevelde, president, global Electrical/Electronic (E/E) Distribution Systems, Delphi Packard Electrical/Electronic Architecture. "All of our wiring systems are designed to support these global trends."

Aluminum Can

Delphi Aluminum Cable can — and does — perform as well as copper core cable ... without the added weight and cost. "Delphi Aluminum Cable is an excellent alternate choice for primary cable applications," said Steve Duca, director, global engineering and operations, Delphi Packard E/E Architecture. "With our unique aluminum core alloy, cable manufacturing process, and state-of-the-art crimping technology, Delphi Aluminum Cable is well suited for use in passenger compartments and other locations in the vehicle."

A lightweight alternative to traditional copper core cable, Delphi Aluminum Cable offers up to a 48 percent weight reduction. Consider that approximately 1/2 lb (227 g) of aluminum can replace 1 lb (454 g) of copper. That means about 4 lbs (1.8 kg) of weight can be trimmed from a typical vehicle.

Vehicle platform weight reduction with Delphi Aluminum Cable results in:

Improved fuel economy
Lighter, easier vehicle assembly
Cost efficiencies

Cost Conscious


	Delphi Aluminum Cable is a cost-effective, lighter weight alternative to copper core cable.

It's clear that Delphi customers save money by using less material weight with Delphi Aluminum Cable. However, another important cost factor to keep in mind is the price of aluminum compared to copper. Aluminum prices have historically been more stable (less variation on a percentage basis) than copper. Using Delphi Aluminum Cable helps OEMs reduce their susceptibility to commodity market fluctuations.

Gain Performance

Delphi Aluminum Cable reduces weight and costs without reducing performance. OEMs can count on Delphi to provide a "performance heavyweight" that meets their requirements for conductivity, strength, regulatory compliance, and sustainability.

"One of the goals at Delphi is to help our customers balance their need to economize on every level with their market mandate to continually improve quality and performance," said Vandevelde. "Our aluminum cable is a smart and relatively simple way to achieve that balance in their cable requirements. With the choice of various insulation materials, including lead-free PVC (polyvinyl chloride) and halogen free ultra thin-wall insulation, Delphi Aluminum Cable gives our customers 'performance plus.'"

With Delphi Aluminum Cable, manufacturers will gain:

Conductivity. To achieve the same conductivity as copper core cable, Delphi Aluminum Cable requires approximately half the weight.
Compliance. Delphi Aluminum Cable will help meet customers' regulatory requirements, including ISO-6722 (primary cable focus), LV112-2 (battery cable focus), and USCAR-23 (for cable).
Durability. Delphi's ultra thin-wall insulation provides superior pinch and abrasion resistance with aluminum as well as copper.
Recyclability. Aluminum is easily recycled at appropriate facilities worldwide.
Robustness. Delphi Aluminum Cable provides both stable electrical performance and good mechanical performance.

Delphi Knows Aluminum Cable

Delphi has designed and manufactured aluminum cable since its initial development in 1969 with the production of copper-clad aluminum core cables. In 1974, the company introduced aluminum solid core cables to the automotive market. In those 40 years, Delphi has manufactured approximately 900,000,000 meters of aluminum cable and 35,000,000 meters of copper-clad aluminum cable, both of which have been proven in a variety of vehicle applications.

"With our extensive experience, we can offer high-quality, lightweight aluminum cable for real-world applications," said Duca. "OEMs require significant weight reduction and fuel economy improvement, and Delphi Aluminum Cable is one more way that Delphi is helping our customers reach their goals."

Many Options

Delphi offers a complete line of wiring and cable to meet demanding requirements for many applications, including engine compartments and interior and chassis wiring harnesses. In addition to aluminum cable, Delphi has an extensive product portfolio that includes:

Read more about Delphi's complete cable offerings at delphi.com.