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What if I use an aluminium primary coil for a Tesla transformer?
It will weigh less than if copper or silver.
Because Tesla coil application may involve both heat and vibration in an air (and maybe ozone) environment, the electrical connections to the aluminum need care. Wherever the aluminum is connected to copper (or other different metalic) conductors, it should be treated the same as if it were a junction from aluminum home power wiring to an old device terminal screw or to a copper wire. Mainly that means coating with an anti-oxidation compound and securely tightening the connection.
The goal is to avoid the intermetalic connection increasing its resistance.
(A) Aluminum is relatively soft, and can ‘cold-flow’ out of a joint under the pressure of the connection, that may reduce the area of the contact, and thus the current carrying capability.
(B) The metalic surface of aluminum promptly forms an oxide layer when exposed to oxygen in air and the oxide is an insulator so the connection can degrade with time & temperature if not protected.
The Tesla primary is the higher current winding so contact resistance is undesired.
Because Tesla coil application may involve both heat and vibration in an air (and maybe ozone) environment, the electrical connections to the aluminum need care. Wherever the aluminum is connected to copper (or other different metalic) conductors, it should be treated the same as if it were a junction from aluminum home power wiring to an old device terminal screw or to a copper wire. Mainly that means coating with an anti-oxidation compound and securely tightening the connection.
The goal is to avoid the intermetalic connection increasing its resistance.
(A) Aluminum is relatively soft, and can ‘cold-flow’ out of a joint under the pressure of the connection, that may reduce the area of the contact, and thus the current carrying capability.
(B) The metalic surface of aluminum promptly forms an oxide layer when exposed to oxygen in air and the oxide is an insulator so the connection can degrade with time & temperature if not protected.
The Tesla primary is the higher current winding so contact resistance is undesired.
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