Reliability testing of aluminum magnet wire connections for hermetic motors

Economic considerations not withstanding, aluminum magnet wire for hermetic motors offers other advantages. For example, there is evidence of better resistance to long-term aging when organic insulations are applied to aluminum wire. It is common experience that aluminum wire winds easier once proper tensions are adjusted. Springback characteristics which are inherently less in aluminum wire allow for better coil conformation and more efficient use of available space. These advantages partially offset the lower conductivity values of aluminum wire. Historically, however, the primary drawback in using aluminum magnet wire has been in the development of a process to insure that reliable connections could be made.