What Are Copper Clad Aluminum Wires?

Everyone knows that copper is the most used metal in making wires. Its excellent electrical conductivity enhances its usability. However, copper metal is premium and expensive, and its wire price has increased. That's where copper cladding, particularly with aluminum, comes into play. But what are copper clad aluminum wires, and why are they used??

Cladding is a handy procedure for making lightweight wires. However, people don't understand this. The truth is that such clad wires are not used aggressively. Why? Because they are weak. However, in some conditions, this cladding comes in handy. In this article, I will explore everything about these copper-clad wires.

Overview of Cladding

Before I explain copper-clad wires, let's discuss the cladding. Remember, the copper-clad aluminum wires are made through this process.

Cladding is the technique of applying a coating of one material to another. Simply put, it is a process that applies an additional layer to a wire made of another material. It enhances and combines the properties of two materials. It is a cost-effective way of achieving the desired properties in wires.

Let me explain this in more detail. Suppose you have a relatively weak wire. You can take another strong material and apply a coat to that weak wire. What will it do? The robust material's layer will give strength to the weak one. Simply put, it would protect and improve the properties of weak material (wire) in the long run.

What is Copper Clad Aluminum Wire?

Copper-clad aluminum wires are made through cladding. These wires have aluminum cores. The copper layer surrounds the aluminum core, giving it high electrical conductivity. The aluminum core is lightweight, so the clad wire becomes lightweight with better electrical conductivity.

Copper is a premium material with high conductivity. Wires made with this material are used professionally, i.e., in transmission lines. However, there is an issue as this material is costly. Using it in wires makes wires very expensive. On the flip side, aluminum material is lightweight. However, its electrical conductivity is not as good as copper.

Remember, aluminum is less costly than copper. So, manufacturers use a combination of copper and aluminum to make lightweight wires. Are you confused and considering the usage of two materials more expensive? But that's not true. Manufacturers make the core of wires with inexpensive aluminum material.

They apply a thin coating of copper around this core. This coating of copper is very thin, so very little copper material is used. The usage of small copper increases the electrical conductivity overall. The key benefit is that this combination makes the wires very affordable. Copper remains outside, surrounding the aluminum-made core.

How Copper Clad Aluminum Wire is Made?

Making copper-clad aluminum wire is not straightforward. There are multiple steps involved in the cladding process. Let's explain each step to learn how to make CCAW.

1- Creation of Aluminum Core

First, the core wire is made of aluminum. This core is thin and lightweight. In this step, the aluminum wire is stretched and thinned with machines. This core wire has a silvery white color as it consists of aluminum. Its thickness varies depending on the manufacturer's needs.

2- Adding the Copper Layer

As said earlier, cladding is a prominent technique that makes these wires. In this step, a thin layer of copper is put on the core aluminum wires. There are different ways to apply this thin layer or coat. The two most prominent methods are as follows:

• Electroplating

• Pressing of copper on the core aluminum

Electroplating happens in the presence of an electrical current. The atoms of copper attach to the aluminum through electricity. On the flip side, some manufacturers combine copper with aluminum and press them together. This pressing is done by using dedicated machines. This additional layer of copper improves the conductivity of the core aluminum wire.

3- Heating Process

Remember, pressing will never make a strong bond. After some time, the copper layer can detach if only attached by pressing. Therefore, manufacturers heat the copper layer present on the aluminum core. Why? This heating helps strengthen the bond between the copper layer and the aluminum core. In this way, the copper layer remains firmly attached to the aluminum wire.

4- Stretching or Drawing

Drawing is the process of stretching wire to make it thin. Copper-clad aluminum wire undergoes this process to make long, thin wires. When manufacturers add a layer of copper to the core, the wire becomes somewhat thick. However, the drawing process makes this layer thin enough to meet the needs of your project.

This drawing not only makes the wire-thin but also strong as well. The copper layer present on the surface becomes part of the cores. In simple terms, this stretching process increases the smoothness of the copper layer. You won't feel that the copper layer is added separately. Instead, copper layer and aluminum cores combine to make one wire.

Why are Copper Clad Aluminum Wires important?

CCAW (Copper-Clad Aluminum Wires) offers many benefits. Their usability is increasing in electrical devices that handle small voltages. In the section below, I will mention some of their benefits. Understanding them will help you comprehend their significance.

1- Cost Effectiveness

Copper metal is premium, and wires are expensive, too. However, these wires have exceptional electrical conductivity. On the other hand, aluminum wires are inexpensive but have compromised electrical conductivity. So, manufacturers apply a copper layer on the aluminum core. 

This increases the electrical conductivity of the aluminum core. However, the layer of copper is very inexpensive. In this way, manufacturers get affordable aluminum wires with better electrical conductivity. So you won't have to buy those high-priced copper wires. The CCAW is an affordable alternative.

2- Lightweight

Aluminum is a lightweight material. Right? So wires made of this material are also lightweight. This sounds good, but this material does not have the ideal conductivity to electricity. That's an issue that manufacturers face. 

In this case, copper cladding helps in increasing electrical conductivity. How? Manufacturers apply a layer of copper to the aluminum wire. This thin coat improves electrical conductivity. So, the users get lightweight wires with excellent electrical conductivity.

3- Electrical Conductivity

Do I need to explain this feature? I bet not! I've already explained this concept in the above. Let's overview it briefly without going into details. Using aluminum wires alone offers reduced electrical conductivity. They don't provide the kind of performance one may need. 

However, they are lightweight, which is in demand in some projects. This is where cladding comes into the scene. The thin layer of copper increases the electrical conductivity of core aluminum. In the end, manufacturers get lightweight wires with excellent electrical conductivity. 

4- Corrosion Resistance & Strength

Have you heard of the copper oxide layer? This oxide coat results from contact between copper and oxygen, right? So, this coating protects the wires from further corrosion. In CCAW, the layer of copper is present at the outer surface. So, this layer shields the inner core of aluminum wires. Remember, aluminum wires are somewhat prone to corrosion. But this layer of corrosion enhances their durability by protecting them from corrosion. 

How Can I Tell If a Wire is Copper Clad Aluminum?

There are a few ways to identify the Clad aluminum wires. I will explain them in the section below.

• Cut the Edge: Take a wire and cut it from one edge. If you see a silvery white color in the mid or core section, it is CCA wires. A reddish copper layer would surround this silvery core. If you see the whole wire as reddish, it is pure copper. Similarly, if the hole wires look white or silvery, they are aluminum.

• Scratch the Surface: The second way is to scratch the wire with a knife or blade. If you see a reddish layer covering silvery-thin wire, it is CCAW. Remember, the copper-cladded wires will have two colors. The upper side would look reddish due to the copper coating. The core would look white due to the aluminum material.

• Weight the Wires: If you have two wires, you can weigh them. The pure copper wires will have more weight. On the flip side, the copper-clad aluminum wires will have to lower weight. This method is only suitable when you have two unknown wires. However, cutting the edge or scratching the surface is the best way. 

What is Copper Clad Aluminum Wire Used For?

Copper-clad aluminum wires are popular because of those two features. First, they are very lightweight, and their usability is common in small products or electronics. Secondly, they are very inexpensive. Using them in any project doesn't break the bank. Here are some of the applications of CCAW:

Have you noted that these wires are used for mild-level applications? They are not suitable for long-distance electricity transmission lines. The reason is that copper-clad aluminum wires have some drawbacks. For example, they face overheating issues. Moreover, their voltage drops if you use them on long-distance electricity transfer.

Moreover, their electrical conductivity is not as good as that of copper. This means their effectiveness in high-end devices is not ideal. Therefore, they are only used in small products that don't need high voltage or current. However, these wires offer inexpensive solutions where copper wires are too expensive. 

Conclusion

Copper-clad aluminum wires are not famous—that's a fact. But they are suitable for specific applications. Sometimes, manufacturers aim to reduce the cost of a product. In such cases, these worries come in handy. One of these wires' most prominent features is their lightweight. Therefore, manufacturers use them to make electronic products.

Moreover, their low price also enhances their value in the market. But they are not suitable where high voltage or current is needed. Therefore, you won't see these copper-clad wires used in transmission lines. The reason is that they drop the voltages and offer high resistance. Moreover, they have overheating issues in them as well.