The resistance of rare earth aluminum alloy cables is equivalent to that of copper cables, and they are significantly superior to copper cables in ductility, bendability and conductive efficiency, enabling rare earth aluminum alloy power cables to replace copper cables. The main material cost of rare earth aluminum alloy cables is lower than that of copper-core cables. In addition, their excellent mechanical properties such as bend resistance and creep resistance facilitate easy installation and greatly reduce construction costs, cutting the overall cost by approximately 30% compared with copper cables.
I. Performance and Standards
Rare earth aluminum alloy power cables have equivalent resistance to copper cables and outperform copper cables notably in ductility, bendability and conductive efficiency, enabling them to serve as a viable replacement for copper cables. In accordance with current national codes including GB 50217-2018 Standard for Design of Cables in Electric Power Engineering, GB 51348-2019 Standard for Electrical Design of Civil Buildings, and GB/T 31840-2025 National Standard for Aluminum Alloy Power Cables, rare earth aluminum alloy power cables are fully qualified to substitute copper cables in practical applications.
II. Economic Efficiency
For cables of the same length, rare earth aluminum alloy cables incur lower main material costs than copper-core cables. Benefiting from superior mechanical properties such as excellent bendability and creep resistance, they simplify installation and slash construction expenses, cutting the overall life-cycle cost by approximately 30% compared with copper cables.
III. Electrical Performance
The conductivity of rare earth aluminum alloy reaches 62%–62.5% IACS. After cable size conversion, its electrical performance matches or surpasses that of copper cables, and far exceeds pure aluminum and ordinary aluminum alloy cables. When the cross-sectional area of a rare earth aluminum alloy cable is 1.5 times that of a copper cable, the two deliver identical electrical performance, including equivalent current-carrying capacity, voltage drop and thermal stability. Therefore, replacing copper cables with rare earth aluminum alloy cables of appropriate specifications can fully satisfy safe electrical operation requirements while delivering superior energy efficiency. Actual tests verify an energy-saving effect of roughly 0.95%–7.41%. Third-party authoritative institutions have tested the electrical properties of rare earth aluminum alloy cables, confirming they outperform the world’s most advanced imported aluminum alloy cables. These cables feature low resistance, minimal power loss and stronger power transmission capacity.
IV. Superior Mechanical Properties vs. Copper and Aluminum
A cable’s mechanical performance is primarily determined by its conductor material. Elongation, fatigue resistance and springback performance are core indicators for evaluating conductor mechanical properties.
- Elongation: Copper conductors generally require an elongation rate of 25%, while pure aluminum conductors only achieve 0.5%–2.0%. After specialized processing, rare earth aluminum alloy conductors attain an elongation rate above 25% — far higher than pure aluminum, exceeding copper and delivering greater flexibility.
- Fatigue Resistance: Rare earth aluminum alloy boasts far better fatigue resistance than pure aluminum and even outperforms copper. Metal fatigue tests reveal pure aluminum has poor fatigue performance, a major root cause of operational accidents. Thanks to its unique material characteristics, rare earth aluminum alloy cables fundamentally eliminate such hidden hazards and greatly enhance operational safety.
- Low Springback: Rare earth aluminum alloy cables exhibit low springback. After stress relief under natural conditions, their springback angle is merely 60% that of copper cables, with zero material memory effect, making installation safer and more convenient than copper cables.
V. Comparable Creep Resistance and Connection Performance to Copper
The proprietary alloy formula and heat treatment process of rare earth aluminum alloy drastically mitigate metal creep under heat and pressure. Alloying elements such as iron are incorporated during high-temperature processing to form a high creep-resistant matrix, securing stable connections between cables and electrical terminals. Even under current overload conditions, the crimped joints with terminals remain tight without loosening or elevated contact resistance. They deliver the same stable and reliable electrical connectivity as copper cables and equipment, ensuring safe power operation.
VI. Superior Corrosion Resistance to Copper
Rare earth aluminum alloy cables feature outstanding general corrosion and seawater corrosion resistance, extending service life. Added alloy components purify the metal matrix, raise purity, fill surface defects, refine grain structures and reduce segregation, eliminating localized corrosion caused by microscopic inhomogeneity and drastically boosting conductor corrosion resistance. The designed service life of rare earth aluminum alloy cables exceeds 40 years, versus 30 years for copper cables. Additionally, they offer numerous advantages over copper cables: lighter weight (40%–60% of copper cable weight), energy conservation, low carbon emissions and lower overall costs.
VII. Energy Conservation and Emission Reduction to Support China’s Low-Carbon Development
Widespread adoption of this alloy material slashes smelting energy consumption and cuts carbon dioxide emissions by over 50%, aligning with China’s national dual-carbon strategic goals.
VIII. High Anti-Theft Performance
Copper carries high residual economic value, leading to frequent copper cable theft that causes substantial financial losses and severe safety risks. In contrast, aluminum-based cables are rarely targeted by thieves, offering superior on-site anti-theft security and strong practicality for construction sites.
IX. Significance of Promoting Rare Earth Aluminum Alloy Cables
Wires and cables are regarded as the “blood vessels and nerves” of the national economy, widely deployed across all civilian and military sectors. China is copper-deficient: over 65% of domestic copper resources are consumed in cable manufacturing, and more than 70% of copper supply relies on imports, with copper ore reserves approaching depletion. Substituting copper with rare earth aluminum alloy carries profound strategic significance for safeguarding sustainable supply of copper raw materials. It also drastically reduces capital investment in national infrastructure and power grid construction, yielding immeasurable economic and social benefits.
X. Intellectual Property Protection
Guangdong Tengyuantong Cable Co., Ltd. holds invention patents including:
- A Rare Earth High-Iron Aluminum Alloy Cable and Its Preparation Method
- A High-Strength, High-Conductivity and High-Stability Rare Earth Aluminum Alloy Cable and Its Preparation Method
- A Rare Earth Aluminum Alloy Cable
4 .A Rare Earth High-Iron Aluminum Alloy Fire-Resistant Cable and Its Preparation Method
Notably, the invention patent titled A Rare Earth High-Iron Aluminum Alloy Cable and Its Preparation Method has been verified through retrieval by a national first-class search institution under the Ministry of Science and Technology as the sole patent of its kind in China, with no equivalent similar patents. Guangdong Tengyuantong Cable Co., Ltd. is the only legally qualified domestic manufacturer of rare earth aluminum alloy cables, fully protected and supported by independent intellectual property rights.