Electrical – Tesla Coil/Slayer Exciter : Aluminium or Copper wire

archigh voltageresonancetesla-coil

I was making a slayer exciter recently and I ran out of copper while winding the secondary up, with a goal of 1300 turns..
I ran out of Cu wire, but I do have a lot of aluminium(37 AWG) wire(enamelled) laying around…
Can I use that instead?
My guess is it should work, although aluminium is a bit less conductive, but I need some help from experts or anyone who has better knowledge about all this stuff
I do have a 18 AWG copper coil for the primary ready
(4 windings).

P.S I'm powering the exciter with a 40V DC input, using a MJE3055T power transistor/TIP41C.. the circuit is pretty basic..

Best Answer

The conductivity being only two thirds of that of copper wire of the same cross sectional area shouldn't be a problem, especially given a very low current application like a tesla coil secondary.

Enamelled aluminum wire will thus be just fine electrically, but mechanically it is problematic: It won't wet with normal solder, be it lead free or not, unless you actually have copper clad aluminum wire. There are some fancy solder/flux combinations that strip the oxide layer and bond with aluminum, but they aren't exactly common. Even crimp connections of AL with copper/brass fittings are problematic, as such joints tend to corrode, but they should still be your best bet in this case. Another option is to terminate the AL wire with conductive epoxy.