So why is high tensile aluminum alloy the best choice for high current mechanical connectors & lugs (screw type)?
Aluminum alloy connectors costs about 25% that of copper connectors and can be used with both aluminum and copper wire (“dual rated”). Aluminum is easier to machine and can be extruded in complex design shapes including hollows with outside profiles which are different from the internal profiles. Cooling fins may be provided readily in aluminum extrusions but not generally in copper profiles which have to utilize even wall thickness tubing.
