The copper clad aluminium wire produced by Henan Chalco is different from the traditional hydrostatic extrusion, rolling and splicing, cladding welding and sleeve rolling. The original "horizontal continuous casting and high efficiency forming-rolling" technology is adopted to achieve a certain metallurgical bonding between the copper clad aluminium wire and the aluminium clad wire and to strengthen the two metals. The interface shear strength ensures the mechanical and electrical properties of the product, and improves the stability of the product.
Copper-clad aluminum (CCA) is composed of aluminum core wire and outer copper layer which is tightly clad. It has the advantages of good conductivity of copper and light weight of aluminum. It is the preferred material for inner conductor of coaxial cable and cable in electrical equipment. The same process cable can be used for pure copper wire.
Production standard:
1.SJ/T112233-2000 "copper clad aluminum wire", American ASTMB566-93 "copper clad aluminum wire".
2. Copper clad aluminium wire can be divided into soft (A) and hard (H) according to mechanical properties, and it can be divided into 10% and 15% according to the volume ratio of copper layer.
A. Copper clad aluminum flat wire
1.Reference table for allowable deviation of straight line dimension
| Diagonal dimension/mm | Permissible deviation | |
| Advanced level | General level | |
| 0.5~1.0 | 0.01 | 0.02 |
| ＞1.0~3.0 | 0.015 | 0.03 |
| ＞3.0~6.0 | 0.02 | 0.03 |
| ＞6.0~10.0 | 0.03 | 0.05 |
| ＞10.0~15.0 | 0.07 | 0.1 |
2.Reference table for physical properties of flat wire at room temperature
| Volume ratio of cladding layer/% | Subtense distance/mm | Temper | Density（g/cm3） | Tensile strength/MPa | Elongation/% |
Maximum dc resistivity （Ω·mm2/m） |
Volume conductivity is not less than （%IACS） |
| 20 | 0.5~15 | Hard | 3.94 | ≥160 | ≥1.0 | 0.02596 | 66.4 |
| 0.5~15 | Soft | ≥110 | ≥12 | 0.0255 | 67.6 | ||
| 25 | 0.5~15 | Hard | 4.25 | ≥170 | ≥1.5 | 0.02548 | 67.7 |
| 0.5~15 | Soft | ≥115 | ≥13 | 0.02498 | 69 | ||
| 30 | 0.5~15 | Hard | 4.56 | ≥180 | ≥2 | 0.02477 | 69.6 |
| 0.5~15 | Soft | ≥120 | ≥14 | 0.02424 | 71.1 |
| Width of flat wire/mm | Coil weight of flat wire /kg | |
| Standard coil | Lighter coil | |
| 0.5~1.0 | 10±1 | 8±1 |
| ＞1.0~3.0 | 22±2 | 20±2 |
| ＞3.0~5.0 | 25±3、40±4 | 22±3、30±3 |
| ＞5.0 | 70±5 | 50±5 |
B. Copper clad aluminum round wire
Reference table for allowable deviation of CCA round wire
| Diameter/mm |
Optimize diameter size /mm |
Acceptable tolerance |
| ＞1.0~8.25 | 2、3、4、5、6、7、8 | ±1%d |
1.Reference sheet for tensile strength and elongation at break of CCA round wire
| Standard diameter/mm | Tensile strength/MPa | Elongation/% | ||
| Hard Y | Soft R | Hard Y | Soft R | |
| min | max | min | max | |
| 1.00~2.05 | 207 | 138 | 1 | 15 |
| 2.06~2.30 | 200 | 138 | 1 | 15 |
| 2.31~2.59 | 193 | 138 | 1 | 15 |
| 2.60~2.91 | 186 | 138 | 1 | 15 |
| 2.92~3.26 | 179 | 138 | 1 | 15 |
| 3.27~3.67 | 172 | 138 | 1.5 | 15 |
| 3.68~4.12 | 166 | 138 | 1.5 | 15 |
| 4.13~4.62 | 159 | 138 | 1.5 | 15 |
| 4.63~5.19 | 152 | 138 | 1.5 | 15 |
| 5.20~5.83 | 138 | 138 | 1.5 | 15 |
| 5.84~6.54 | 124 | 138 | 1.5 | 15 |
| 6.55~8.25 | 110 | 138 | 1.5 | 15 |
2.Reference table for maximum DC resistivity and volume conductivity of CCA round wire
|
Cladding volume ratio /% |
Temper | Density（g/cm3） | Maximum DC resistivity（Ω·mm2/m） | Volume conductivity is not less than（%IACS） |
| 20 | Hard | 3.94 | 0.02596 | 66.4 |
| Soft | 0.0255 | 67.6 | ||
| 25 | Hard | 4.25 | 0.02548 | 67.7 |
| Soft | 0.02498 | 69 | ||
| 30 | Hard | 4.56 | 0.02477 | 69.6 |
| Soft | 0.02424 | 71.1 |
Product performance:
1. Unique composite properties, Copper-aluminum interface for metallurgical bonding, high performance products, with copper conductivity and aluminum density characteristics of small;
2. High interfacial bonding strength, excellent electrical conductivity and excellent mechanical properties.
3. The thickness of copper layer is large and adjustable, which is suitable for transmitting large current.
4. Lightweight, easy to transport and install.
5. Obvious economic benefits: saving copper resources and reducing production costs.
The density of copper clad aluminum wire is only 37-40% of that of pure copper wire, and its length is 2.45-2.65 times of that of pure copper wire with the same mass and diameter, and its tensile strength is 1.6-2 times higher than that of pure copper wire. Therefore, using wire length or strength to produce wire and cable will greatly reduce the production cost.
Application of copper clad aluminum wire:
1. Electrical equipment manufacturing: mainly including low-voltage, medium-voltage, high-voltage distribution, bus system, rectifier, motor winding, etc.
2. Bimetal connectors in crane track supply system, vacuum switchgear, generator set, substation, aluminum foil winding transformer, etc.
3. wind power, solar photovoltaic field: mainly including reactors, inverters and so on;
4. railways, aerospace, high-speed ferry and so on.
5. high frequency signal transmission
6. preferred conductor material for cable TV coaxial cable
7.50 RF cable, flexible RF coaxial cable inner conductor material
8. leakage conductor inner conductor material
9. computer power and other data cable inner conductor materials
10. internal conductor material for micro coaxial cable
11. power transmission
12. stranded wire
13. conductor materials for power cables
14. control cable inner conductor
15. special conductors for automobiles and locomotives
16. building materials without wires and conductors
17. conductor material such as busbar.
18. fuse
19. RF shielding network.