With the global energy transition, can aluminium replace a large portion of the newly increased demand for copper? Currently, many companies and industry experts are exploring ways to better "replace copper with aluminium", and they propose that adjusting the molecular structure of aluminium can enhance its conductivity.
Copper is widely used in various industries due to its excellent conductivity, heat conductivity, and ductility, especially in sectors such as power, construction, household appliances, and transportation. However, as the world shifts towards green energy, such as the development of electric vehicles and renewable energy, the issue of copper supply sources has become increasingly prominent, and the demand for copper in the market is soaring. For example, the amount of copper used in an electric vehicle is approximately four times that of a traditional vehicle, and the electrical components used in renewable energy power plants and the wires connecting them to the power grid require even more copper. 
Analysts from the energy consulting firm Wood Mackenzie estimate that in the next 10 years, offshore wind farms will require 550 million tons of copper, mainly for the large cable systems inside the generators and for transmitting the electricity generated by the turbines to the coast. With the recent surge in copper prices, some analysts predict that the copper shortage will become increasingly severe. Goldman Sachs analysts even call copper "the new oil". As copper is crucial for achieving decarbonization and the use of renewable energy, the market is facing a shortage of copper supply, which could cause copper prices to rise by more than 60% within four years. In contrast, aluminum, as the most abundant metal element in the earth's crust, has reserves about 1,000 times that of copper. Due to its much lighter weight than copper, aluminum mining is also more economical and convenient. In recent years, some companies have adopted technological innovations to replace rare earth metals with aluminum. Manufacturers such as those in the power, air conditioning, and automotive parts industries have adopted "aluminum instead of copper", saving billions of dollars. Saudi Electricity Company has stated that by replacing copper with aluminum in the medium-voltage distribution network, the company has saved 2.4 billion Saudi riyals (approximately 640 million US dollars). Moreover, high-voltage wires can achieve longer distances by using both economically and lightweight aluminum wires. 
However, Jonathan Barnes, the chief copper market analyst at Wood Mackenzie, said that this "aluminum replacing copper" trend has slowed down. In broader electrical applications, the main limiting factor is the conductivity of aluminum, which is only two-thirds that of copper. 
Currently, researchers at the Pacific Northwest National Laboratory (PNNL) in the United States are striving to enhance the conductivity of aluminum, making it more competitive in the market than copper. The researchers believe that by altering the structure of the metal and introducing appropriate additives, the conductivity of the metal can indeed be influenced. If this experimental technology is fully realized, it may produce superconducting aluminum, which will play a role in markets beyond power transmission lines and bring about changes in areas such as automobiles, electronic devices, and power grids. 
"If the conductivity of aluminum could be enhanced to reach 80% or 90% of that of copper, aluminum could replace copper, leading to a significant transformation. Because such aluminum would have better conductivity, be lighter in weight, be cheaper, and have a more abundant reserve." PNNL materials scientist Keerti Kappagantula believes that conductivity is the key. If it has the same conductivity as copper, the lighter aluminum wires could be used to design lighter motors and other electrical components, allowing cars to travel longer distances. "From automotive electronic devices to energy production, and to transmitting energy through the grid to charge car batteries at home, anything that relies on electricity can become more efficient." 
The researchers at PNNL employed a process known as solid-phase manufacturing, which utilizes shear force and friction at lower temperatures to incorporate new carbon materials into the metal. At this temperature, aluminum becomes more elastic, allowing the researchers to control the distribution of the materials. They used computer simulations to model the atomic structure of the new aluminum alloy to verify the distribution of the materials. Kappagantula stated that it is worthwhile to reinvent the aluminum manufacturing process that has a history of two centuries. 
In the future, the aforementioned research team will use the new aluminum alloy to manufacture wires, as well as rods, sheets, etc. They will conduct a series of tests to ensure that it has stronger conductivity, as well as sufficient strength and flexibility for industrial applications. If these tests are passed, the team stated that they will collaborate with manufacturers to produce more aluminum alloys.