Is it ok to use aluminum for a busbar, or power distribution block?

moparmarks said

Really? They have used aluminum bussing that carries hundreds of amps and thousands of volts in the electrical industry for decades, which I used to install, but can't be trusted to handle a few amps at 12 volts. Believe me that little piece of aluminum will out last all of us.

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Significant difference between a system sized with proper engineering and specifically developed conductors using engineered connectors/bonding versus tossing together some (very well shaped and finished) scrap sheet metal with nuts and bolts. The alloys of aluminum used in electrical industry are also fairly specific to electrical industry and not common in sheet stock. These alloys are developed specifically to avoid fatigue and galvanic corrosion, and even then they tend to be clad with materials that play nice with connectors. Aluminum in electrical utilities is a result of cost and weight consideration only, not because it's easier to deal with or superior in performance.

Cars are also subject to a much more variable environment with exposure to greater temperature swings, poor upkeep, road salt and grime, etc. Fixed electrical operations just don't compare.

Could an aluminum bus bar work in theory? Yes.

But why risk inconvenience or worse when doing it with more durable and commonly accepted materials is just as easy and probably cheaper?