A Detailed Examination of Material Choices for Windings in Dry-Type Transformers

Dry-type transformers are commonly used in a range of applications, from power distribution to industrial sectors. One of the most important factors in transformer design is the selection of conductor material, with copper and aluminum being the main options. This study aims to compare copper and aluminum windings in dry-type transformers for the first time according to the Turkish TEDAŞ MLZ specifications, focusing on their performance, efficiency, and weight. The study also examines how electrical losses and physical characteristics affect the efficiency, size, weight, and reliability of transformers. Interestingly, in dry-type transformers, using copper windings doesn't provide any clear technical advantage over aluminum unless there are specific power needs. Moreover, copper's coefficient of thermal expansion is less compatible with resin than that of aluminum. By providing these insights, the research will assist transformer designers and power providers in making informed material choices.