The topic of "aluminum replacing copper" has been discussed for over 20 years, but it has not been widely adopted. The industry has previously followed a "treating the symptoms rather than the root cause" approach, making adjustments only in terms of structure and thickness, without fundamentally addressing the issue through positive research and development.
The aluminum-for-copper substitution technology faces two core challenges: creep and electrochemical corrosion. The creep issue of aluminum, which has not been resolved for many years, directly affects the quality and lifespan of vehicles. Electrochemical corrosion is another significant challenge; once aluminum wires undergo electrochemical corrosion, the result is not rust but rather material loss.
In the industry, the commonly used 1xxx series aluminum suffers from creep and has weak mechanical strength. The 6xxx series aluminum, on the other hand, experiences high-temperature failure, with its mechanical strength drastically decreasing above 125°C, posing a risk of fracture in high-voltage wire harnesses over long-term use.
The transition in materials also greatly impacts production efficiency. Material conversion involves adjustments in numerous processes, which can affect manufacturing efficiency and add extra costs.
03The Path to Breakthrough 2025: Solving Long-Standing Industry Challenges
In 2025, a long-standing technical challenge that has plagued the industry for years was finally overcome. This breakthrough was achieved through the integration of three key forces: advanced materials, advanced processes, and a diverse ecosystem.
Advanced Materials:
Atomic-level designed aluminum alloys fundamentally addressed the issues of creep failure at high temperatures and electrochemical corrosion when connected with copper. The new aluminum alloy maintains stable mechanical properties at 180°C, with creep performance approaching that of pure copper.
Digital R&D:
Digital research and development became a critical technological support. The R&D team integrated knowledge graphs, computational simulations, machine learning, and digital twin technologies to build a specialized artificial intelligence (AI) application model. This model consolidated years of material data and massive external data, enabling it to quickly recommend alloy formulations and process routes, significantly reducing the R&D cycle.
Innovative Processes:
At the process level, innovations were also made. Traditional crimping techniques used for copper materials faced issues such as unstable resistance when applied to aluminum. Therefore, welding was adopted as an alternative to crimping.
04 Ecosystem Win-Win:
"Going it alone cannot solve systemic problems." The breakthrough in aluminum substitution for copper technology is attributed to the collaborative innovation of leading enterprises across the industrial chain. This cooperative model is referred to as "ecosystem co-creation," bringing together top companies from various segments including materials, equipment, connectors, and wiring harnesses, to achieve a technological closed loop and rapid implementation. Innovation requires breaking down boundaries. Each company has its own strengths, and some solutions that are common knowledge to professionals in one field can be the key to solving problems in another.
05The commercialization of aluminum substitution for copper technology will bring about significant economic and social benefits.
Upon full-scale promotion, each vehicle can reduce its copper usage by approximately 10 kilograms, leading to a 10% cost reduction and notable weight decrease. Based on the current growth rate of new energy vehicle sales, this technology is expected to open up a market space of 36 to 48 billion yuan for new low-voltage wire harness materials. Additionally, it can reduce carbon dioxide emissions by about 8.5 million tons annually. The replacement of copper with aluminum will effectively alleviate the strategic risk associated with China's high dependence on imported copper resources, promoting the transformation of the industrial chain towards resource conservation and environmental friendliness.
06Future Prospects
Currently, aluminum as a copper substitute is undergoing validation in several major automakers and Tier 1 suppliers, with mass production expected to be achieved by the end of 2026. After technological breakthroughs, the application scenarios will expand to more areas such as high-voltage wiring harnesses and high-speed, high-frequency cables. By 2030, the penetration rate of aluminum in automotive wiring harnesses is projected to reach 65%.
This transition not only reduces the manufacturing cost per vehicle by approximately 800-1200 yuan but also promotes the upgrade of the industrial chain towards resource conservation and environmental friendliness, aligning deeply with the national "dual carbon" strategic goals. The substitution of aluminum for copper will effectively alleviate the strategic risk of China's high dependence on external copper resources. Based on the current growth rate of new energy vehicle sales, this technology is expected to open up a market space of 36 to 48 billion yuan for new materials in low-voltage wiring harnesses.
Mass production is anticipated to be realized by the end of 2026, and by 2030, the penetration rate of aluminum in automotive wiring harnesses could reach 65%. This transformation will drive the automotive manufacturing industry from being "resource-dependent" to "technology-driven," injecting new momentum into the global development of the new energy vehicle industry.
