Enamelled Round Aluminium Winding Wires Manufacturers & Suppliers in Mumbai, India.

What is an Enamelled Aluminium Winding Wire?

An enamelled aluminium winding wire is an aluminium conductor coated with a thin layer of electrical insulation (enamel). This enamel allows the wires to be wound tightly in coils without short-circuiting, while also withstanding high temperatures, chemical, and mechanical stress.

These wires are used in electromagnetic applications—primarily motors, transformers, generators, and inductors where electrical current is passed through coiled wire to create magnetic fields.

Key Features:

Lightweight Composition: Aluminium is ~33% lighter than copper, making these wires ideal for compact, portable devices and transport applications.
High Thermal Resistance: Available in Class B (130°C), F (155°C), and H (180°C) temperature ratings.
Cost-Efficient: Substantially cheaper than copper with minimal trade-off in performance.
Excellent Dielectric Strength: The enamel insulation prevents breakdown and supports high-voltage applications.
Corrosion Resistance: Special enamel coatings ensure long-term resistance to oxidation and moisture.
Solderable and Durable: Compatible with automated winding and thermal soldering processes.

Types of Enamelled Round Aluminium Winding Wires and their Applications

PROPERTY	Type Class	PVA 105	(PU+Polyamide) 130	PE 130	Mod. PE 155	(PE+Polyamide) 155	(PU+Bonding) 155	PEI 180	(PEI+Polyamide) 180	(PEI+Bonding) 180	DC(PE+PAI) 200	(PI) 220
STANDARD		- Part 17 MW 15A	MW 28A	Part 9	Part 5 Part 5	MW 24A	IS 13730-35 IEC 60317-35	Part 15 MW 30C	MW 76A	IS 13730-37 IEC 60317-37	Part 25 MW 35C / 73C	MW 74A
SIZE (MM)		1.00	1.00	1.00	1.00	1.00	1.00	1.00	1.00	1.00	1.00	1.00
COVERING	Grade	G2	G2	G2	G2	G2	G2	G2	G2	G2	G2	G2
ELONGATION (%)	IS/IEC Min NEMA Min BIC Value	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30	12 20 30
FLEXIBILITY (No Crack)	IS/IEC NEMA BIC	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D	3×D 10%+3D 1×D
ABRASION (N)	IS/IEC- Min. NEMA- Min. SICValue	4.7/5.6 590/690 8.1/8.8	4.4/5.2 590/690 ,; 6.8/7.6	4.4/5.2 - 6.8/7.6	4.5/5.3 590/690 6.8/7.6	4.5/5.3 .. 590/690 6.8/7.6	4.4/5.2 - 6.8/7.6	4.6/5.45 590/690 7.0/7.8	4.6/5.45 590/690 7.0/7.8	4.6/5.45 - 7.0/7.8	4.7/5.6 590/690 8.1/8.8	4.4/5.2 590/690 6.8/7.6
BDV (V)	IS/IEC Min NEMA Min BIC	5000 4275 8000	5000 3825 8000	5000 - 8000	5000 5700 8000	5000 3825 8000	5000 - 8000	5000 5700 8000	5000 3850 8000	5000 - 8000	5000 5700 8000	5000 4275 8000
RANGE	SWG	4–36	4–36	4–36	4–36	4–36	19–36	4–36	4–36	16–36	4–36	4–36
APPLICATIONS		Transformers, motors, fans, domestic appliances.	Low friction motors, high-speed windings.	B-class motors, fans, armature winding.	F-class motors, hand tools.	Improved thermal & mechanical strength motors.	Self-bonding coils, relays, audio coils.	H-class motors, compressors.	180°C motors, chemical & industrial uses.	Self bonding high-speed machines.	W-class motors, alternators, solenoids.	Extreme thermal & mechanical applications.

Diameters, Increase in Diameters, and Resistance of Enamelled Round Aluminium Winding Wires based on IS 13730-0-1

SWG	Nominal Conductor Diameter	Conductor Tolerance ± (mm)	Grade 1		Grade 2		Grade 3		Conductor Resistance at 20°C For 1 meter (ohms)
SWG	(mm)	Conductor Tolerance ± (mm)	Min. Increase (mm)	Max. Overall (mm)	Min. Increase (mm)	Max. Overall (mm)	Min. Increase (mm)	Max. Overall (mm)	Nominal	Maximum	Minimum
4	5.893	0.059	0.054	5.986	0.098	6.034	0.146	6.079	0.001023	0.001033	0.001012
5	5.385	0.054	0.052	5.478	0.096	5.526	0.144	5.571	0.001225	0.001238	0.001213
6	4.877	0.049	0.050	4.970	0.094	5.018	0.142	5.063	0.001493	0.001509	0.001478
7	4.470	0.045	0.049	4.561	0.092	4.607	0.138	4.651	0.001777	0.001796	0.001759
8	4.064	0.041	0.048	4.155	0.091	4.197	0.137	4.245	0.002150	0.002173	0.002128
9	3.658	0.037,,	0.047	3.746	0.089	3.791	0.134	3.834	0.002654	0.002682	0.002627
10	3.251	0.033	0.046	3.336	0.086	3.380	0.130	3.422	0.003360	0.003396	0.003325
11	2.946	0.029	0.045	3.029	0.084	3.072	0.127	3.112	0.004092	0.004136	0.004049
12	2.642	0.026	0.043	2.722	0.081	2.764	0.123	2.803	0.005087	0.005143	0.005034
13	2.337	0.023	0.042	2.415	0.079	2.455	0.119	2.493	0.006502	0.006573	0.006433
14	2.032	0.020	0.041	2.108	0.077	2.147	0.116	2.184	0.008600	0.008696	0.008508
15	1.829	0,018	0.040	1.903	0.075	1.941	0.113	1.977	0.010615	0.010735	0.010501
16	1.626	0.016	0.039	1.698	0.073	1.735	0.110	1.770	0.013431	0.013618	0.013285
17	1.422	0.014	0.038	1.492	0.071	1.528	0.107	1.562	0.017562	0.017765	0.017366
18	1.219	0.012	0.035	1.285	0.067	1.318	0.100	1.350	0.023898	0.024180	0.023627
19	1.016	0.010	0.034	1.080	0.065	1.113	0.098	1.144	0.034401	0.034819	0.03400
20	0.914	0.009	0.034	0.976	0.063	1.008	0.095	1.038	0.042508	0.043034	0.042003
21	0.813	0.008	0.032	0.872	0.060	0.902	0.090	0.931	0.053726	0.054404	0.053074
22	0.711	0.007	0.030	0.766	0.056	0.795	0.085	0.822	0.070247	0.071160	0.069369
23	0.610	0.006	0.027	0.659	0.050	0.684	0.075	0.708	0.095434	0.096399	0.094507
24	0.559	0.006	0.025	0.605	0.047	0.629	0.071	0.652	0.113643	0.114999	0.112338
25	0.508	0.005	0.025	0.554	0.047	0.578	0.071	0.601	0.137606	0.139553	0.135737
26	0.457	0.005	0.024	0.501	0.045	0.523	0.067	0.544	0.170033	0.172135	0.168012
27	0.417	0.005	0.022	0.458	0.042	0.480	0.064	0.500	0.204217	0.207181	0.201373
28	0.376	0.005	0.021	0.417	0.040	0.435	0.060	0.454	0.251182	0.255504	0.247045
29	0.345	0.004	·0.020	0.382	0.038	0.401	0.057	0.418	0.298350	0.302438	0.294425
30	0.315	0.004	0.019	0.349	0.035	0.367	0.053	0.384	0.357885	0.363600	0.352407
31	0.295	0.004	0.019	0.329	0.035	0.347	0.053	0.364	0.408057	0.415297	0.401128
32	0.274	0.004	0,018	0.306	0.033	0.323	0.050	0.339	0.473003	0.482412	0.464019
33	0.254	0.004	0.018	0.286	0.033	0.303	0.050	0.319	0.550424	0.562685	0.538748
34	0.234	0.004	0.017	0.265	0.032	0.281	0.048	0.296	0.648534	0.664798	0.633099
35	0.213	0.003	0.015	0.241	0.029	0.255	0.043	0.269	0.782718	0.797456	0.768631
36	0.193	0.003	0.014	0.219	0.027	0.232	0.039	0.245	0.953345	0.974177	0.933498

Type of Enamelled Aluminium Winding Wires

. Polyester (PE 130)

General-purpose enamelled wire for dry-type transformers and motors
Used in B-class applications
Heat resistance: 130°C

. Modified Polyester (Mod. PE 155)

Enhanced insulation for higher thermal stability
Used in F-class motors, domestic appliances, and hand tools
Heat resistance: 155°C

. Polyester-Imide (PEI 180)

High thermal endurance
Used in H-class motors, hand tools, and chemical industry applications
Heat resistance: 180°C

. Dual Coated: Polyester-Imide + Polyamide-Imide (DC PEI+PAI 200)

Excellent heat and chemical resistance
Suitable for encapsulated coils and continuous-duty motors
Heat resistance: 200°C

. Polyvinyl Acetal (PVA 105)

Good mechanical, chemical, and electrical properties
Designed for high-speed winding in small motors, coils, and relays
Heat resistance: 105°C

. Polyester overcoated with polyamide (PE + Polyamide 155)

Low coefficient of friction; suitable for fine winding
Used in small motors and instrument coils
Heat resistance: 155°C

. Polyurethane overcoated with Polyamide (PU + Polyamide 130)

High solderability with mechanical protection
Used in high-speed winders and small motors
Heat resistance: 130°C

. Polyester-Imide overcoated with Polyamide (PEI + Polyamide 180)

Designed for maximum thermal and mechanical durability
Ideal for demanding applications requiring high endurance
Heat resistance: 180°C

. Polyester-Amide-Imide (PI 220)

Self-bonding insulation with a very high temperature class
Used in coils requiring bonding without external adhesives
Heat resistance: 220°C

. Self-Bonding: Polyester-Imide + Bonding Layer (PEI + Bonding 180)

Solderable and thermoplastic bonding
Suitable for self-supported coils in TVs, electronics, & voice coils
Heat resistance: 180°C
Bonding temperature: 170–180°C

. Self-Bonding: Polyurethane + Bonding Layer (PU + Bonding 155)

Self-bonding and solderable
Used in relays, small motors, & telecommunication coils
Heat resistance: 155°C
Bonding temperature: 170–180°C

Common Applications of Enamelled Aluminium Wires

Enamelled aluminium wires are an industry standard in the following

. Electric Motors

Widely used in pumps, fans, washing machines, air conditioners, compressors, and industrial machinery.
Known as aluminium winding wire for motors, these wires help reduce motor weight and cost.

. Power and Distribution Transformers

Withstand high voltage and heat conditions.
Their thermal endurance makes them ideal for continuous operation in transformers.

. Enamelled Aluminium Magnet Wire

Used in electromagnetic fields to create inductance in coils.
Popular in radios, telecommunication devices, speakers, and medical equipment

. Automotive and EV Systems

Automotive alternators and electric vehicle (EV) motors benefit from lightweight windings, increasing vehicle efficiency/li>

. Household Appliances & Electronics

Motors, relays, and solenoids in domestic appliances depend on these wires for smooth performance.

Benefits in Real-World Applications

Material Cost Savings: Replacing copper with aluminium in a 100 kW motor saves significant raw material cost without major design changes.
Energy Efficiency: Lighter motors reduce energy consumption in vehicles and appliances.
Space-Saving Design: More compact windings for tightly packed devices.
Sustainable Manufacturing: Aluminium extraction and recycling are less resource-intensive compared to copper.

FAQ Section – People Also Ask

What are Enamelled Round Aluminium Winding Wires used for?

Enamelled Round Aluminium Winding Wires are primarily used in motors, transformers, generators, inductors, relays, and electronic devices where electrical insulation and magnetic properties are essential.

What is the difference between enamelled copper and aluminium wire?

Copper wire offers higher conductivity, but aluminium is lighter and more economical. For cost-sensitive and weight-specific applications, enamelled aluminium electrical wire is often preferred.

Are aluminium magnet wires reliable for motors?

Yes, aluminium winding wire for motor use is industry-standard today, particularly in HVAC, automotive, and small appliance motors, thanks to improved insulation and processing technology.

What is the temperature rating of enamelled aluminium wire?

Depending on the enamel type, temperature ratings range from 130°C to 220°C, complying with IS and IEC thermal class standards.

Can I replace copper wire with aluminium in my application?

Yes, but design adjustments may be necessary for conductivity and diameter. Consult with manufacturers to ensure compatibility.