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Note to replace copper wiring with aluminum, you have to go up at least one gauge size.

Or raise the voltage at the same time you change from Cu to Al.

Yeah, aluminum is a worse conductor so you need thicker cable. It's less dense, though, so I think it usually comes out as being lighter. Thicker cables can be more inconvenient. I think aluminum also tends to have more problems with oxidation causing too much resistance at electrical contacts.

I think for motors generally you just end up with a larger motor for the same amount of power.

All points you make are very true. In addition, aluminum tends to crack as it ages and you'll find aluminum wiring is usually a culprit in electrical fires. In the world of mobile electronics, it's usually looked down upon as the cheapest alternative when compared to real copper conductor used in higher quality automotive wiring.

It only requires proper engineering of the connection. Aluminum itself doesn’t crack in properly engineered joints. What fails in old houses is shoddy connections.

If people look down upon it, it’s because they’re either lazy or ambivalent. It’s the superior performance solution in some situations.

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