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Reliable Copper-to-Aluminum Connection Solution
Lower cost. Safer CU-AL connections.
Home / Copper to Aluminum Connection
Key Benefits
Why Use Aluminum Cables in Solar Projects?
With rising copper prices and increasing cable theft risks, aluminum cables are becoming the preferred choice for utility-scale solar projects.
Lower Cost
Up to 30–50% lower cost than copper
Easy Installation
Lightweight, easier installation
Theft Resistant
Lower theft risk due to lower scrap value
Utility-Scale Ready
Suitable for large-scale PV plants
Integrated Aluminum Cable Connection System
Engineered as a complete system to eliminate installation errors and ensure consistent connection quality.
Built for Reliable CU-AL Connections
TÜV Certified System
Aluminum conductor PV cables comply with TÜV 2PfG 2642 (1500V) and 2954 (2000V) standards, supported by a TÜV-certified connector portfolio for proven safety and compliance.
Superior Corrosion Protection
Multi-layer plating structure combined with patented 3SETP coating technology delivers outstanding resistance in harsh environments.
Innovative CU-AL-CU Structure
Unique “copper–aluminum–copper” design combines the conductivity of copper with the cost advantages of aluminum, ensuring optimal performance and reduced material cost.
Ultra-Low Contact Resistance
≤ 0.3 mΩ contact resistance enables stable performance under high current loads.
Break-Resistant Design
Solid-state Cu-Al friction welding ensures zero thermal damage and superior mechanical integrity.
25-Year Long-Term Stability
Validated through rigorous multi-stage testing for proven durability and reliability over time.
Why Choose SUNKEAN
Advanced Manufacturing Capability
Strict Quality Control
Global Project Experience
Pre-Assembled CU-AL Harness for Fast Installation
Pre-assembled design eliminates complex on-site connections, reducing installation time and minimizing failure risks.
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Factory pre-assembled copper-to-aluminum connection
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Flexible aluminum cable length for different project needs
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Ready-to-use connection for fast and easy installation
Engineered for Durability & Performance
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Trusted by Solar Projects Globally
PV Las Violetas (Chile)
· 852 sets CU-AL connectors deployed
· 51 km aluminum cable installed
Reduced cable costs while ensuring stable long-term performance
PV Los Quilos (Chile)
· 1,481 sets CU-AL connectors deployed
· 112 km aluminum cable installed
Improved installation efficiency with reliable copper-aluminum connections
Chile Solar Farm
· 6,000 sets CU-AL connectors deployed
· 120 km aluminum cable installed
Enabled large-scale deployment with consistent connection quality
Why is aluminum used to replace copper?
FAQ on Copper to Aluminum Connection
How much cost savings can SUNKEAN’s copper-to-aluminum connection solution deliver?
Compared to a full-copper system, this solution reduces costs by up to 58%. In a 1 GW PV power plant project, the savings can exceed USD 2,750,000.
How is SUNKEAN's copper-to-aluminum conversion harness designed to ensure stability and safety?
The harness uses a "copper–aluminum–copper" structure: copper conductors on both ends with an aluminum conductor in the middle, plus a plastic connector housing. It supports high currents and allows quick on-site crimping at the aluminum end for simplified installation.
What welding process is used for the copper-to-aluminum joint, and how reliable is it?
The connection adopts friction welding (solid-state bonding), which operates at low temperatures to minimize thermal damage to the cable. Over 25 years, conductivity degradation is less than 0.5%. The tensile strength is verified through pull and impact testing.
How does the copper-to-aluminum connector maintain corrosion resistance in harsh environments?
The joint surface is protected by a three-layer gradient structure: diffusion layer, chemical nickel plating layer, and hot-dipped tin anti-oxidation layer. An electroplating hole design ensures uniform coating. In a 96-hour 5% salt spray test, no corrosion occurred in the contact area.
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