aluminium magnet wire 28awg
- Electrical Performance Specifications
28 AWG aluminum enameled wire is a special type of conductor with an insulating enamel coating on the surface of the aluminum conductor. Its bare wire diameter is approximately 0.32 mm (the diameter increases slightly to 0.35-0.38 mm after enameling), offering the dual advantages of lightweight construction and superior insulation performance. Compared to traditional copper wire, aluminum has only 30% of the density of copper, resulting in a 50% weight reduction for the same conductive cross-sectional area, significantly reducing energy consumption in weight-sensitive fields such as aviation and new energy vehicle motors.
| Parameter categories | Specification Name | Standard value/range | unit | Remark |
| Basic Specifications | AWG number | 28 | – | American Wire Gauge |
| Basic Specifications | Conductive materials | EC Grade Aluminum | – | Lightweight materials, low density |
| Basic Specifications | Nominal D | 0.320 | mm | Core dimension parameters when manufacturing coils |
| Basic Specifications | Nominal cross-sectional area | 0.0810 | mm² | Affecting current carrying capacity |
| Electrical performance | Resistivity (Aluminum) | 2.82 x 10-8 | Ω⋅m | Inherent properties of materials |
| Electrical performance | DC resistance (20℃) | about 340 | Ω/km | resistance per kilometer of conductor |
| Electrical performance | Breakdown voltage | Depending on the insulation class | V | Dielectric strength of insulating film |
| Electrical performance | Maximum operating temperature | 130, 155, 180, 200, 220 | ℃ | The heat resistance rating determines the maximum allowable operating temperature of the coil. |
II. Core Advantages:
1. Lightweight Design: Aluminum has a much lower density than copper. Using aluminum enameled wire can significantly reduce the overall weight of the final product, which is crucial for aerospace, portable devices, and power tools.
2. Superior Cost-Effectiveness: The relatively low cost of aluminum helps reduce production costs and enhance product competitiveness.
3. Good Conductivity: Although its conductivity is slightly lower than copper, with proper design, aluminum enameled wire can meet the electrical performance requirements of most applications.
4. Ease of Processing: High-quality enameled wire has good flexibility and abrasion resistance, facilitating handling and shaping on high-speed winding machines.
III. Diameter and Insulation Film Thickness of 28 AWG Aluminum Enameled Wire
1. Bare Conductor Diameter (D): According to AWG standards, the nominal diameter of 28 AWG bare aluminum conductor is approximately 0.320 mm. 2. Insulation Film Thickness (T): The Core of Winding Wire Performance The outer insulating film of enameled wire is crucial for ensuring the coil’s withstand voltage, moisture resistance, heat resistance, and abrasion resistance. According to the International Electrotechnical Commission (IEC) or national standards (such as China’s GB standard), the insulation class of enameled wire is typically divided into:
Grade 1 (Thin): Suitable for applications with the most compact size requirements but relatively low withstand voltage requirements.
Grade 2 (Thick): The most common standard insulation, providing a good balance between withstand voltage and mechanical properties.
Grade 3 (Extra Thick): Suitable for applications requiring high withstand voltage or higher mechanical strength and abrasion resistance.
28 AWG aluminum enameled wire insulation film thickness:
| Insulation class | Single-sided thickness of insulating varnish film( μm ) | Complete outer diameter ( mm ) | Main Features |
| Grade 1 | About 10 – 15 μm | About 0.34 – 0.35 | Suitable for high-density windings |
| Grade 2 | About 15 – 20 μm | About 0.35 – 0.36 | Most commonly used, balancing performance |
| Grade 3 | About20 – 25 μm | About0.36 – 0.37 | Enhanced pressure resistance and abrasion resistance |
Note: Actual thickness may vary slightly depending on the manufacturer, insulation material (e.g., polyurethane, polyesterimide), and specific standards.
IV. Main Application Areas:
1. Electronic Components and Equipment
Small Transformers and Adapters: Used in step-down transformers and switching power supply transformers in electronic devices and chargers, especially in cost-sensitive applications.
Various Inductors/Chokes: Used for circuit filtering, energy storage, and choking.
Relays and Solenoid Valve Coils: Used in actuators in control circuits; the lightweight properties of aluminum wire reduce the overall weight of relays or valve bodies.
2. Micromotors and Precision Machinery
Micromotors/Microfabrication Machines: Widely used in consumer electronics such as drones, model toys, small fans, and electric toothbrushes. 28 AWG wire diameter is suitable for high-turn-count windings within limited space.
Precision Instrument and Meter Coils: Such as sensor coils, electromagnetic instrument panel coils, etc., requiring small size and light weight.
3. Home Appliances and Consumer Electronics
Small Appliance Coils: Such as low-power motor coils in exhaust fans and power tools.
Speakers/Voice Coils: In some headphones or small speakers, the lightweight properties of aluminum wire help improve the response speed of the voice coil.
4. Automotive and Industrial Applications (Low-Power Segment)
Small Coils in Automotive Electronics: For example, electromagnetic coils in vehicle sensors and small control units.
Low-Power, Non-Continuously Used Motors: Aluminum enameled wire may be used to reduce costs in low-power industrial equipment or tools where efficiency requirements are less stringent.
28 AWG aluminum enameled wire is an excellent solution for achieving lightweight and cost-effectiveness in modern electronic component design. By precisely controlling its bare conductor diameter and insulation film thickness, manufacturers can produce coil products with stable and reliable performance. Choosing the appropriate insulation class is key to optimizing coil withstand voltage and lifespan.