Copper Clad Steel Wire: A Revolutionizing Product in Electrical Industry

Copper clad steel wire combines the advantages of both copper and steel through a patented technology of bonding copper to the steel wire. This innovative product has created immense interest in the electrical industry since its introduction.

What is Copper Clad Steel Wire?

Copper clad steel wire consists of a copper layer bonded to a steel core using a patented bonding technique. This involves electrodepositing thin layers of copper on drawn steel wire under controlled conditions. The end result is a composite wire that combines high conductivity of copper with the strength and cost benefits of steel.

The copper layer typically ranges between 2-5% of the total cross-sectional area. This thin layer provides a superior electrical conductivity while the steel core lends it mechanical strength and abrasion resistance. Due to its unique dual material composition, copper clad steel wire offers unmatched benefits for electrical applications.

Advantages of Copper Clad Steel Wire

Cost Effectiveness
The use of a steel core to Copper Clad Steel Wire significantly reduces the material cost compared to pure copper wire. Steel is almost ten times cheaper than copper. This makes copper clad steel wire extremely cost effective for applications requiring high conductivity.

High Electrical Conductivity
Despite a thin copper layer, the electrical conductivity is only marginally lower than pure copper wire. The copper layer provides conductivity levels more than twice that of steel. This enhances the current carrying capability.

Superior Mechanical Strength
The steel core imparts exceptional tensile strength to withstand stresses during manufacturing and installation. It also offers resistance to abrasion, impact, and vibrations. This significantly improves the service life of the wire.

Ease of Processing
Unlike copper, steel can be easily drawn into finer gauges. This allows copper clad steel wire to be produced in a wider range of diameters and with intricate shapes for specialized applications.

Uniform Bonding of Copper
The proprietary bonding technique assures a consistent, defect-free bonding between copper and steel. This provides stability to the conductivity over extended usage periods.

Applications of Copper Clad Steel Wire

Power Distribution Cables
Copper clad steel finds extensive application in low and medium voltage power cables for both indoor and outdoor usage. Its high strength and conductivity make it an ideal substitute for copper in voltage ranges up to 1kV.

Motor Windings
Many motors employ copper clad steel wire for armature and field windings. Its superior conductivity helps boost the efficiency while the mechanical strength withstands winding stresses. This has led to its increasing use in industrial motors.

Transformer Windings
Power and distribution transformers are increasingly adopting copper clad steel wire for primary and secondary windings. Its high strength accommodates tighter winding configurations. This has enabled miniaturization of transformer designs.

Building Wiring
With conductivity matching most copper grades, copper clad steel wire is viable for domestic and commercial building wiring. The flexibility to use thinner gauges has benefits for conduit installations.

Future Adoption in Other Sectors

E-mobility
As the electric vehicle scales up globally, copper clad steel wire presents opportunities in motor, traction, and wiring applications to optimize cost and performance. Trials are on to test its viability in e-mobility segments.

Renewable Energy
The quest to reduce LCOE (Levelized Cost of Energy) in solar and wind energy makes copper clad steel wire an attractive proposition. R&D is ongoing to validate its suitability in generators, cabling, and grid interconnection equipment.

3D Printing
Advances in 3D printing of electromagnetic components point to potential use of copper clad steel fillers. This could make complex 3D printed products more cost competitive through material savings.