Aluminum Winding Wire

Winding wire is a key conductor used in coils for motors, transformers, relays, inductors, and new energy systems. Made from copper or aluminum and coated with insulating materials like enamel, paper, or glass fiber, it ensures stable electrical and mechanical performance.

As a core material in energy conversion, its quality directly affects system efficiency, heat management, and durability. Chalco, leveraging its aluminum expertise, offers a full range of copper, aluminum, enameled, and high-temperature winding wires—serving everything from microelectronics to heavy-duty industrial systems.

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Selection guide by industry/application

Chalco winding wire product specifications and introduction

Winding round wire diameter range: 7-36 GUAGE (0.2mm-15.0mm)

Winding flat wire size range: the widest flat wire can reach 3.5mm

Chalco enameled winding wire insulation material types: PEW (polyester), EIW (polyesterimide), AIW (polyimide), PI (radiation high temperature resistant); paper insulation; glass fiber insulation; three-layer insulation

Chalco enameled winding wire coating thickness grades: Grade 1 / Grade 2 / Grade 3 (thin to thick), suitable for different slot filling ratios

Cable reel: PT25, PT30, PT35, PT60, PT90, PT200, PT270 wooden reels, each with a maximum load of 150kg. Conical reels or other reels are available, and the models can be customized according to customer requirements.

Chalco winding wire industry standards and testing basis

• IEC 60317 / IEC 60264 – International Electrotechnical Commission standards for magnet wire and winding conductors
• GB/T 7672, GB/T 7095, GB/T 11022 – Chinese National Standards
• Customer-specified standards – Benchmarking solutions can be provided according to special certification systems such as UL, VDE, JIS, etc.

Chalco winding wire product type introduction

Chalco provides a full range of winding wire products to meet the diverse needs of electromagnetic winding systems, covering multiple dimensions from basic conductor materials to high-performance insulation structures. Whether it is a high-efficiency motor, high-voltage transformer or high-temperature/submersible environment, we can provide performance-matched, stable and reliable winding conductor solutions.

Copper winding wire — high conductivity, high heat resistance

Copper winding wire is one of the most widely used winding materials in motors, transformers and other equipment. It is particularly suitable for applications with extremely high requirements for conductivity, current density and thermal stability. Chalco provides multiple specifications of bare copper wire and enameled copper wire to adapt to complex operating environments such as high speed, high temperature and high vibration.Quick Quote

It supports delivery in loose discs, small spools or large rolls, suitable for batch automatic winding process.

Structure type: Round copper wire and flat copper wire can be supplied, and customized SWG/AWG wire diameter is supported

Insulation treatment: PEW, EIW, AIW, double paint layer or unpainted bare conductor are optional

Typical Applications: motor winding copper wire, transformer winding wire

Product advantages:

• The conductivity is as high as 99.9%, and the energy loss is small
• Excellent mechanical strength, suitable for high-speed winding and precision coils
• Uniform paint layer, suitable for automatic winding equipment

Aluminum winding wire —— lightweight, low cost, high cost performance

Aluminum alloy winding wire is a high-quality alternative to copper wire. It has the advantages of light weight, low cost, and good processing flexibility. It is widely used in weight- and cost-sensitive equipment such as compressors, electric fans, small motors, and distribution transformers. Chalco provides bare aluminum wire and enameled aluminum wire in various specifications to meet various process and structural design requirements.Quick Quote

It supports 1kg to 200kg reel delivery and can be used for automated batch coil winding.

Structural type: Round aluminum wire, flat aluminum wire, support 30~36 SWG or non-standard customization

Insulation treatment: PEW, EIW, composite heat-resistant enamel coating; or provide bare aluminum conductor for subsequent insulation treatment

Typical applications: fan winding wire, aluminum winding wire for transformer, submersible motor winding

Product advantages:

• 1/3 the density of copper, enabling lighter winding and optimized equipment design
• Cost-effective, ideal for large-scale industrial manufacturing
• Strong paint adhesion and consistent insulation for automated winding
• Surface pre-treatment available for improved soldering or crimping performance

Copper clad aluminum winding wire — lightweight & conductive

Copper clad aluminum winding wire (CCA) has aluminum as the core and copper as the cladding layer. It has good conductivity and extremely high cost performance. It is a commonly used winding material in fan motors, home appliance transformers, high-frequency coils, etc. Chalco provides a variety of copper layer ratios and insulation type combinations to meet the electrical and mechanical needs of different systems.Quick Quote

With Chalco's superior manufacturing capabilities and customizable options, our copper clad aluminum wires provide optimal conductivity, lightweight benefits, and excellent cost control for demanding industrial applications.

Structure type: round or flat CCA conductor, common copper cladding ratio is 10%, 15%, 20%

Insulation form: PEW, EIW and other high temperature enameled structures are available, suitable for automatic winding

Typical applications: fan winding wire, speaker coil, power transformer secondary winding

Advantages and features:

• The density is much lower than pure copper, and the weight reduction is obvious
• Excellent cost control, suitable for high-volume non-high-load applications
• Excellent welding and peeling properties, compatible with existing processing lines

Enameled winding wire——insulated and suitable for automatic winding

Enameled wire is the most widely used type of winding wire. The surface of the conductor is covered with one or more layers of uniform insulating paint film, and can be directly used for winding coils without additional treatment. Chalco provides enameled wires with various conductor materials (copper/aluminum) and different heat resistance grades and structures, suitable for various electromagnetic devices such as motors, transformers, inductors, relays, etc.Quick Quote

The product is compatible with automated winding equipment and can be delivered in small spools or high- precision layer-wound large rolls.

Structure type: round wire/flat wire, supports Grade 1/2/3 paint thickness, wire diameter covers the full range of AWG/SWG

Insulation treatment: Supports various paint film types such as PEW, EIW, AIW, PI, etc., with thermal ratings ranging from 130°C to 220°C

Typical Applications: enameled copper wire for motor coil, transformer winding, inductor & choke coil

Product advantages:

• Uniform insulation with strong voltage and thermal shock resistance
• Supports high-speed winding, minimizing breaks
• High-temp wires for inverters, drives, industrial power
• Functional wires: chemical, radiation resistance, self-adhesive.

Paper covered winding wire — ideal for high voltage oil-immersed systems

Paper-covered winding wire is a traditional insulated wire structure used in medium and high voltage transformers and reactors. It usually uses copper or aluminum conductors and is covered with one or more layers of high-strength electrical paper or crepe paper. It has excellent impregnation performance and dielectric strength. This product is widely used in key parts such as the main winding of oil-immersed transformers, inter-turn insulation of reactors, and tap switching.Quick Quote

Chalco can provide a variety of paper types, layers and coating forms according to the winding structure and oil-paper system requirements to meet IEC or GB standard requirements.

Structure type: Bare copper/aluminum conductor covered with electrical paper, crepe paper, composite paper, optional single/double/multi-layer structure

Supporting insulation system: suitable for oil-immersed insulation, gas insulation, electrical impregnation system

Typical applications: paper insulated winding wire for oil-immersed transformers, reactor winding conductor

Product advantages:

• High electrical strength and voltage resistance for medium/high voltage windings
• Paper absorbs oil well, enabling deep impregnation for stable insulation
• Flexible, ideal for large coils with good thermal expansion matching
• Smooth surface, suitable for automatic wrapping and slot filling

Glass fiber covered winding wire — high temperature resistance, high strength

Glass fiber covered wire is made of high-temperature glass fiber coated on the surface of copper or aluminum conductor and cured by resin. It has excellent heat resistance, mechanical protection ability and surface protection performance. It is widely used in dry-type transformers, reactors, electric furnaces and large motors and other occasions with extremely high requirements on temperature and mechanical stress.Quick Quote

Chalco can provide single or multi-layer glass fiber braided structure to meet various insulation requirements of IEC and GB standards.

Structure type: bare copper/aluminum conductor + single/double layer glass fiber braid + thermosetting resin treatment

Heat resistance: insulation level can reach 200~220℃, short-term temperature resistance> 260℃

Typical applications: fiberglass insulated winding wire for dry-type transformers, electric furnaces, high-temp reactors

Product advantages:

• High mechanical strength with excellent tensile, impact, and abrasion resistance
• Stable insulation thickness, good heat aging; ideal for high-frequency start equipment
• Suitable for dry insulation systems; can replace some enameled wires, enhancing thermal safety
• Supports custom thickness, multilayer coatings, and special curing processes

Specialty winding wire——high frequency, high voltage, miniaturized electromagnetic system

In addition to conventional structures, Chalco also provides a series of functional winding wires for special application scenarios, suitable for high-tech barrier equipment such as high-frequency transformers, micro coils, industrial power modules and new energy electric drives. This type of wire has structural advantages such as multi-layer insulation, high flexibility, high-frequency loss control, and self-adhesion properties, and is widely used in occasions with extremely high requirements for electrical performance and size integration.Quick Quote

Main types:

• Litz Wire: Multiple strands of enameled wire are braided and twisted to reduce skin effect and high-frequency loss. It is suitable for high-frequency induction heating, resonant circuits, radio equipment, etc.
• Triple insulated wire: Three layers of insulation structure with different dielectrics, replacing traditional isolation windings, can realize small volume high voltage isolation system
• Self-bonding wire: The surface has hot-melt or electric self-adhesive properties, which simplifies the coil structure and improves the winding stability
• Highly flexible/radiation-resistant wire: suitable for special scenarios in medical equipment, rail transportation, and aerospace

Chalco winding wire product technical parameters

The winding wire products provided by Chalco strictly follow international and industry standards, from wire diameter tolerance to insulation grade, from paint layer structure to thermal stability, to ensure that each batch of winding wire can be stably used in efficient and high reliability electromagnetic systems.Quick Quote

Thermal grade coverage: 130℃, 155℃, 180℃, 200℃, 220℃, customizable up to 240℃

Thermal shock test: 155℃~300℃, suitable for industrial frequent start-stop or high-power systems

Breakdown voltage: up to 7 kV, meeting the safety requirements of high-voltage electromagnetic systems

Mechanical properties reference:

• Tensile strength: 70–90 N/mm²
• Elongation: 15%–48%
• Wear resistance: >67.75 N
• Scratch resistance(Grade 1:1.95 N, Grade 2:3.15 N)

Chalco winding wire product application and cooperation field

Focusing on the key needs in the field of electromagnetic equipment manufacturing, Chalco provides winding wire material solutions for various equipment types such as transformers, motors, fans, submersible pumps, etc., helping customers improve electrical efficiency, structural integration and system reliability.

Transformer winding wire | Withstands voltage, heat and structural plasticity

Transformer winding wires must meet the requirements of electrical insulation strength, thermal stability and forming processability. Especially in dry, high-frequency and oil-immersed systems, it is crucial to reasonably match the wire structure.Quick Quote

• Flat copper/aluminum winding wire (for dry main winding)
• Paper wrapped winding wire (for oil immersed power transformers)
• Triple insulation structure winding wire (for isolation transformers, switching power supplies)

Motor winding wire | High-speed operation and heat resistance

As the main application field of winding wire, motors are widely distributed in industries such as industrial drives, household appliances, and automotive electric drive systems. Typical working conditions require the wire to have high conductivity, excellent mechanical strength, and compatibility of the insulation system with automatic winding equipment.Quick Quote

• Copper enameled winding wire (suitable for industrial motors, variable frequency motors)
• Aluminum winding wire (suitable for lightweight design such as air-conditioning compressors and small motors)
• Self-adhesive copper winding wire (suitable for compact, low-power motors)

Winding wire for fans and household appliances | Lightweight economy and automated processing requirements are equally important

Small motor products such as household appliances, fans, and rice cookers have multiple requirements for winding wires during mass production, including lightweight, insulation consistency, and automatic winding efficiency.Quick Quote

• Aluminum enameled winding wire (suitable for large-volume products such as fans and electric blowers)
• Copper enameled winding wire (suitable for export brand home appliances or occasions with higher durability requirements)
• Self-adhesive winding wire (improves winding density and reduces external bonding process)

Submersible pumps and high temperature coils | Insulation stability assurance in hot and humid environments

Submersible pumps, electric heating coils, reactors and other equipment are mostly used in harsh working conditions of high humidity, high heat and high electric field. The winding wire must not only carry current but also have long-term insulation resistance.Quick Quote

• Glass-fiber covered copper winding wire (for dry submersible motors and electric heating systems)
• Paper-wrapped winding wire (for oil-immersed submersible pumps, voltage regulators)
• High temperature grade enameled winding wire (AIW/PI, suitable for frequent starting or high load operation)

Production capacity and quality assurance

As a professional winding wire material manufacturer, Chalco has a complete integrated manufacturing system. From metal conductor casting, wire drawing, coating, painting, curing to high-speed winding and forming, the whole process is strictly controlled to achieve stable, efficient and traceable product output.

Complete production process control

Raw material guarantee: 9.5mm high-quality copper/aluminum metal rods are selected and processed through multiple wire drawing dies to the target wire diameter to ensure stable conductivity.

Multi-layer painting system: The mold coating machine supports the superposition of multiple layers of insulating paint film, with a thickness range of 60~450μm, which is uniform and stable.

High temperature curing process: using advanced infrared oven with precise temperature control, the paint film will not crack at up to **350℃**, ensuring the consistency of heat resistance level.

Automatic lubrication system: Patented lubricant layer improves surface smoothness and significantly reduces wear and jamming during automatic winding.

Precision winding equipment: high-speed tension-controlled winding machine, supports coil forming in the range of 5kg to 200kg, can adjust tension/speed/angle, and is suitable for various bobbin structures and assembly processes.

Multiple line type support and finished product forms

Chalco can produce winding conductors with various cross-sections according to customer drawings or process requirements, which are widely used in various electromagnetic structures:

Round winding wire: standard single-core conductor, suitable for most motors and small transformers

Square winding wire: used for equipment with high space utilization requirements and compact structure

Flat winding wire: suitable for directional winding applications such as dry-type transformers and low-inductance coils

Multi-strand composite structure (Litz stranded wire, etc.): Reduce high-frequency loss and optimize skin effect

Supports customization of spools: cylindrical, conical, horizontal and other structures are available, with a maximum load of 200kg. The packaging is moisture-proof and shock-proof, suitable for domestic and overseas transportation.

Full process testing and quality traceability

Each batch of winding wires is fully tested according to the standards before leaving the factory to ensure the consistency of the electrical performance, mechanical performance and thermal stability of the products:

• Factory inspection report:
• Raw material certification
• Paint film thickness and uniformity test
• Breakdown voltage, dielectric loss test
• Elongation, tensile strength and elasticity tests
• Solvent resistance and thermal shock resistance evaluation

The highly automated production process and strict quality control system enable Chalco winding wire to have high consistency, high durability and batch stability, helping customers improve system performance and safely implement engineering projects.

Price reference and purchasing suggestions

Conductor selection recommendations:

• Strict performance requirements → Pure copper winding wire is preferred
• Weight sensitive / cost-constrained → Aluminum or CCA wire recommended

Insulation structure recommendations:

• High frequency occasions → Litz structure/ self-adhesive wire is recommended
• High temperature environment → AIW and PI winding wires are preferred

Thermal level selection:

• Industrial motor: 155℃~180℃
• Submersible pump, electric heating ring: above 200℃
• Electronic transformer: 220~240℃ grade enameled structure is optional

Want to know the most suitable wire for your equipment? Chalco technical engineers can provide you with personalized selection suggestions and sample matching solutions. Please click Quick Quote to contact us.

Answers to core questions about the selection and use of winding wire

How to choose copper wire and aluminum wire in winding applications?

Copper winding wire has higher conductivity and mechanical strength, and is suitable for high-performance or long-term operation equipment; aluminum wire is lighter and more cost-effective, and is suitable for light-load equipment such as fans and small motors. If you want to strike a balance between conductivity and cost, you can also choose copper-clad aluminum (CCA) winding wire as an alternative.

What thermal ratings do you offer for your enameled winding wire?

Chalco can provide enameled winding wires with 130℃, 155℃, 180℃, 200℃, 220℃ and 240℃ grades, corresponding to B, F, H, C, HC insulation grades respectively. We also support customization of different paint film structures (PEW, EIW, AIW, PI) to meet different environmental requirements.

What types of winding wire structures can you make?

We can produce round, square, flat, Litz structure, stranded and other winding wires, support copper, aluminum, copper clad aluminum conductors, as well as enameled, paper-wrapped, glass fiber-wrapped and other insulation forms, adapting to various structural requirements such as transformers, motors, induction coils, etc.

Can you provide samples or small batch customization?

Yes. We support customized proofing services for parameters such as wire diameter/structure/insulation, with flexible minimum order quantity, suitable for testing or development verification. Samples are usually delivered within 3-7 days.

Can winding wire products be accompanied by a test report?

Each batch of factory products can provide:

• Raw material chemical composition report
• Film thickness, insulation breakdown, voltage test
• Tensile strength, elongation, thermal shock and other test data

We also support third-party testing and certification cooperation.

Do you support export business? How are the packaging and shipping methods?

Support export. We can provide wooden reels (cylindrical/conical), carton/pallet packaging that meet international transportation specifications according to customer requirements, and have experienced sea and air shipping processes. Export countries include Germany, India, Vietnam, UAE, etc.