U.S. Copper Clad Steel Wire. Leads the Global Production

Tue, 24 Sep 2024 09:38:58 +0000

Copper clad steel wire, also known as CCS wire, is a specialty electrical cable that consists of a thin layer of copper metallurgically bonded to a steel wire core. The copper layer provides high conductivity for power transmission while the steel core offers high tensile strength and flexibility. This unique composite structure makes copper clad steel wire suitable for a variety of electrical applications.Raw Material Sourcing and Manufacturing Process Steel is the primary raw material used to manufacture U.S. Copper Clad Steel Wire. Most steel cores use low carbon steel grades optimized for flexibility and strength. Copper is electroplated or rolled over the drawn steel wire to form a metallurgical bond. The manufacturing process starts with drawing steel wire from steel billets or rods to the desired diameter. Next, the drawn steel wire passes through a plating bath containing an acid copper solution. An electric current is applied to deposit a thin layer of copper onto the steel surface. Multiple passes through the plating bath build up the required copper coating thickness, typically around 20% of the total diameter.After copper plating, the copper clad steel wire undergoes an annealing process to relieve internal stresses and improve ductility. Strict quality controls ensure a uniform copper thickness and integrity of the bonding interface. The finished CCS wire spools are then ready to supply global demand.Applications in Power Cables and TransformersCopper clad steel wire finds widespread use in power cables and transformers due to its unique electrical and mechanical characteristics. As electrical load demands increase with industrialization, CCS wire helps expand transmission capacity of aging power infrastructure.In power cables, the high conductivity copper skin efficiently transports electricity while the flexible steel core holds the cables together and withstands tensile loads. Copper clad steel is the conductor of choice for underground feeder cables, submarine power cables and overhead transmission lines. It facilitates power distribution over long distances and challenging terrains.Within distribution transformers, CCS wire forms the coil windings that control magnetic fields for voltage conversion. Its continuous filament structure prevents eddy currents and reduces power losses compared to stranded copper conductors. This improves efficiency and lifespan of distribution transformers.The U.S. Copper Clad Steel Wire Dominates Global Production