Sumitomo Electric – Aluminium Wire Harness

As the demand for the reduction of CO2 emissions from automobiles is ever increasing, lightweight wiring harnesses  have been in high demand. Effective weight reduction can be expected by replacing conventional copper electric wires  with aluminum electric wires. However, aluminum wires have several drawbacks such as low electrical conductivity, low tensile strength, and poor workability, as well as a strong insulating oxide film on the surface and galvanic corrosion. To  solve these problems, we have developed an aluminum alloy conductor with improved electrical conductivity, tensile strength, and workability. We also developed a unique serration terminal structure that maintains low contact resistance and sufficient wire retention force even under a thick oxide layer. We also established an anti-corrosion technology that prevents galvanic corrosion by molding the crimped joint of the terminal.

This paper from Sumitomo Electric explains respective solutions in detail. More Information.
Keywords: aluminum wire, crimping, wiring harness, automobile, anti-corrosion.