An Overview of Aluminum Windings and Their Manufacturing Technologies in Electrical Machines

Due to its lower density and reduced cost, aluminum is increasingly adopted as a substitute for copper in lightweight and cost-effective winding applications. Its superior manufacturability further facilitates the realization of unconventional winding geometries, which contribute to enhanced loss suppression and improved cooling performance. To offer deeper insights, this paper aims to provide a comprehensive review of aluminum windings in electrical machines, with a particular emphasis on their benefits in loss reduction and cooling enhancement. A comparative analysis of material properties of aluminum and copper is first conducted, followed by a summary of their unique effects on loss suppression and cooling performance. Finally, advanced manufacturing technologies and industrial applications of aluminum windings are briefly outlined. Moreover, a critical discussion is included to address their current limitations and highlight future development opportunities.