Xiaomi SU7 charging harness problem, aluminium wire is really not as good as copper wire repair? Xiaomi SU7 charging harness using aluminium wire triggered the controversy of ‘whether it is not as good as copper wire repair’, the core lies in the differences between the physical characteristics of aluminium and copper on the repair process, cost and long-term reliability of the integrated impact.
The core differences between aluminium and copper wires are reflected in electrical conductivity, mechanical strength and corrosion resistance. Copper conductivity is better, in the same cross-sectional area of the current carrying capacity is stronger, and better ductility. Aluminium is due to high resistivity, need to increase the cross-sectional area to achieve the same conductive effect, and brittle texture, frequent bending prone to metal fatigue.
Aluminium and copper coefficient of thermal expansion, thermal conductivity differences, direct welding due to the melting point of the different contact surfaces easily lead to welding, and aluminium surface is prone to the formation of oxidation layer, further increasing the welding resistance. The aluminium strip is embedded in the copper groove and then cold-pressed composite, which retains the electrical conductivity and welding stability of copper, so that there is no need to distinguish between the materials during maintenance, and the composite terminal can be operated directly.
Aluminium wire is lightweight, lower transport and installation costs, and aluminium resources are abundant, the price fluctuation is less than copper, which indirectly reduces the procurement cost of maintenance materials. For new energy vehicles, the lightweight to the range of the improvement can reduce the battery loss triggered by the maintenance needs, forming a comprehensive cost advantage.
Aluminium wire maintenance requires professional equipment and training, but this is a problem of technical popularity, not a defect of the material itself. As the new energy vehicle industry promotes the application of aluminium wires, the relevant maintenance technology has formed a standardised process, which can be mastered by professional maintenance personnel through training.
Xiaomi SU7 charging harness problems, aluminium wire is really not as good as copper wire repair? Aluminium wire is not as good as copper wire repair, the difficulty of repair stems from the material characteristics of the process requirements, the feasibility of repairing aluminium wire has been similar to copper wire. The industry trend is towards technology optimisation rather than material regression. The application of aluminium wires in new energy vehicles is essentially a balancing act between performance, cost and sustainability.
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