6 Methods of Stripping Enameled Aluminum Wire

Enameled aluminum wire is becoming the preferred choice for transformers and motors due to its cost-effectiveness and light weight. However, technicians often face a common challenge: Removing the insulation (stripping) without damaging the conductor.

Unlike copper, aluminum is soft and brittle. If you use excessive force or the wrong method, the wire can easily snap or deform.

Here are the six most effective methods for stripping enameled aluminum wire, ranging from manual DIY techniques to industrial solutions.

1. Chemical Stripping (Best for Protecting the Conductor)

Chemical stripping is often the safest method for aluminum wire because it involves no physical force.

• How it works: Apply a specific paint remover or stripping gel (like Depaint) to the end of the wire. Wait for 1-2 minutes until the enamel softens or blisters, then wipe it off with a cotton cloth.

• Pros: No risk of nicking or breaking the soft aluminum wire.

• Cons: Involves chemicals; requires ventilation.

2. Centrifugal Wire Stripper (Handheld Machine)

For thicker aluminum wires, a handheld electric paint scraper (centrifugal stripper) is highly efficient.

• How it works: The machine has three high-speed rotating blades that close in on the wire. You insert the wire, and the blades scrape the enamel off uniformly.

• Pros: Very fast; clean finish.

• Note for Aluminum: Ensure the blade pressure is adjusted correctly. If too tight, it will cut into the aluminum diameter.

3. High-Speed Fiber Wheel Stripping

This is a common benchtop industrial method.

• How it works: A machine spins two wheels (often made of fiberglass or wire brush) at high speed. You push the wire between the wheels, and the friction removes the insulation.

• Pros: Extremely fast for production lines.

• Note for Aluminum: Fiberglass wheels are preferred over steel wire wheels for aluminum, as they are less abrasive and less likely to damage the soft conductor.

4. Manual Scraping (Knife or Sandpaper)

The classic method for prototypes or on-site repairs.

• How it works: Use a utility knife or fine-grit sandpaper to scrape the coating off.

• Warning: This method requires skill. Because aluminum is soft, it is very easy to accidentally cut through the wire or create a "stress riser" where the wire will break later. Sandpaper is generally safer than a knife for fine aluminum wires.

5. Burning (Flame Method)

A quick method often used in the field, though it requires care.

• How it works: Use an alcohol lamp or lighter to burn the insulation at the tip, then wipe away the residue with a cloth.

• Critical Warning: Aluminum has a melting point of only 660°C (compared to Copper's 1085°C). If you hold the flame too long, the aluminum wire will melt and break. Use this method only for thick wires and be quick.

6. Direct Soldering (The "Non-Stripping" Method)

This is not technically "stripping," but it is the most efficient method if you choose the right material.

• How it works: If you use Polyurethane (UEW) enameled aluminum wire, it is "solderable." You can simply dip the wire end into a solder pot at roughly 360°C-380°C. The heat melts the enamel, and the solder tins the aluminum simultaneously.

• Pros: No stripping labor required; perfect connection.

• Limitation: Only applies to UEW class wire. High-temperature wires (PEW/EIW/AIW) cannot be stripped this way.

Conclusion: Which Method is Best?

Choosing the right method depends on your volume and the wire thickness:

• For Mass Production: Use Chemical Stripping or Fiber Wheels to ensure the aluminum conductor remains intact.

• For UEW Wire: Always use Direct Soldering.

• For Thicker Wires: Centrifugal Strippers are the most consistent.