Copper Conductors VS Copper Clad Steel Conductors

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An Electrical Conductor is a material which allows electricity to flow through it. Conductors can generally be classified by the metals they are made from, which depends on what purpose a conductor is used for. In this blog, we will discuss two of the widely used conductors, i.e., Copper-clad steel conductors and Copper Conductors. However, there are various conductors available in the market, including:

1. 1. Copper-Clad Steel
   2. Copper
   3. High Strength Alloys
   4. Stainless Steel
   5. Bare Copper
   6. Tinned Copper
   7. Silver Coated Copper
   8. Nickel-Coated Copper

A) Copper-Clad Steel Conductors

Copper-clad steel conductors, also known as copper-covered steel conductors are essentially composite material conductors, consisting of a uniform low, medium or high carbon steel core surrounded by a thick layer of copper. The inner carbon steel core gives the conductor its high tensile strength, and the outer copper cladding provides its electrical conductivity.

Manufacturing of Copper-Clad Steel Conductors

Manufacturing of Copper-clad steel conductors is done by a unique cold rolling process, where a copper tube or cladding is formed around the carbon steel core. The outer copper cladding is uniformly and chemically bonded to the inner carbon steel conductor. Both the outer copper tube and the inner carbon steel conductor together are extruded (Squeezed)  or drawn to reduce the conductor cross-section of the Copper-clad steel conductors, thus forming by about 30%. It is then annealed (heated and slowly cooled) and thereafter further extruded to reduce the conductor cross-section by about 10%. The percentage values mentioned are typical.

Applications Copper-Clad Steel Conductors

Copper-clad steel conductors are widely used in grounding, i.e. connection of earthing rods to metallic structures, plates, and grid meshes, in power installations, substations, and for lightning arresters. Copper-clad steel conductors are also used for power transmission and radio frequency (RF) transmission lines.

Advantages of Copper-Clad Steel Conductors

• During the process of bonding copper and steel, the coating is created on the Copper-clad steel conductors to protect the wire from breakage and corrosion. This also gives them about 43% higher break-load capacity than Copper Conductors.
• Due to its corrosion resistance, the wire has lasting durability and longevity, reducing maintenance costs.
• Copper-clad steel conductors are about 10% lighter than Copper ones therefore their transportation costs are less and they are easier to handle during their installation and maintenance.
• In Copper-clad steel conductors, the outer copper layer has a lower impedance than that of the inner steel core. So when these conductors are used in Radio Frequency transmission lines, the ‘skin effect’ at high frequency encounters low impedance in the copper cladding, which is equivalent to that of a solid copper conductor.
• The tensile strength of Copper-clad steel conductors is greater than that of Copper Conductors. Therefore with Copper-clad steel conductors, the span lengths can be greater as compared to the span lengths achieved with pure copper ones.
• Copper-clad steel conductors can be used in coaxial cables thereby allowing higher impedance and smaller cable diameter than by using  Copper Conductors of similar strength.
• In Copper-clad steel conductors, the amount of the more expensive copper is lesser than the amount of steel, and the two metals (i.e. copper and steel) cannot be separated easily. Therefore, this has little scrap value and discourages theft. Copper-clad steel conductors exhibit lower impedance to the ground as compared to copper conductors, thus providing better protection to lines and equipment.

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B) Copper Conductors

These conductors are manufactured from copper having 99.95% purity. Their manufacturing is done by extruding or forcing pure copper ingots using an extrusion machine. The extrusion machine extrudes the copper through several dies in succession to get the desired conductor cross-section.

Where are Copper Conductors Used?

These Conductors are used in power generation, power transmission, power distribution, telecommunications, electronics circuitry, and several types of electrical equipment. They are found to be ideal in permanent applications where the conductors, cables or wires are unlikely to be replaced or changed (e.g. concealed wiring inside walls). Also, Copper Conductors in the form of cables find ideal use in signal transmission over long distances since minimal current is required to drive the signals on account of the high conductivity of copper (conductors). They excel in transmitting high levels of data over these distances – and minimal current is necessary to push signals all the way through.

 Advantages of Copper Conductors

• They possess very high conductivity, much higher than any of the other conventional conductors.
• Copper exhibits durability and flexibility, which are the two big benefits of using them. The conductors can be easily bent back and forth, and are easy to form and shape. Solid copper as a conductor is usually preferred for longer cables.
• These conductors have better bend radius and can retain better signal strengths over long distances.
• They are most suited for permanent applications, such as concealed cabling inside walls, and other applications where the cables are not likely to be changed.
• The expected lifespan of copper is 100 + years.

Conclusion

When it comes to factors like strength, cost-effectiveness, economic feasibility and ease of handling, Copper-clad conductors appear to be a natural choice, being largely preferred across industries and utilities.

We hope you now have a clear idea about all the 2 conductors. At Axis, we have a team of 40+ engineers who are here to help you in designing, installing and testing your Grounding and lightning Protection Systems. Our products have been used in substations, data centres, factories and even in everyday residential and commercial buildings.

Thank you for reading the blog, Axis is a leading manufacturer and supplier of AB Cable Accessories and other Electrical Components to over 80+ Countries. To get a quote or to talk to our industry expert visit our contact us section. You can also watch our videos by our experts – click here.

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Nov. 07, 2023

In the realm of metallurgy, Copper Clad Steel (CCS) emerges as a formidable composite material, boasting a blend of both copper and steel, each imparting distinctive characteristics. This fusion results in a product that inherits the advantageous properties of both metals, offering a versatile solution across various industries.

The Composition and Properties of Copper Clad Steel

Copper Clad Steel, as the name suggests, comprises a core of steel encased or layered with a coating of copper. The steel core serves as the structural base, providing strength and durability, while the outer layer of copper offers superior conductivity and corrosion resistance. This amalgamation yields a material with a unique set of attributes beneficial in numerous applications.

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What Is the Use of Copper Clad Steel? 

1. Electrical and Telecommunication Industries

One of the primary uses of Copper Clad Steel lies within the electrical and telecommunication sectors. The exceptional conductivity of copper makes it an ideal choice for transmitting electrical signals with minimal loss. However, pure copper cables can be costly, prompting the development of Copper Clad Steel cables that balance performance and cost-effectiveness. According to a study by the Copper Development Association Inc., CCS cables have witnessed a substantial rise in adoption, accounting for over 30% of the global market share in telecommunications infrastructure.

 2. Grounding Systems

The blend of steel's strength and copper's conductivity makes Copper Clad Steel an excellent material for grounding systems. Its corrosion-resistant properties ensure longevity, offering reliable grounding solutions in various environments, including industrial and residential settings. This is crucial, as effective grounding is pivotal in preventing electrical hazards and ensuring safety.

 3. Automotive Industry

Copper Clad Steel finds application in the automotive sector as well. The material's balance of conductivity and strength makes it suitable for manufacturing automotive parts such as connectors, terminals, and electrical components. This integration aids in enhancing electrical performance while maintaining structural integrity in vehicles.

 4. Antennas and Radio Frequency (RF) Devices

In the realm of antennas and RF devices, Copper Clad Steel's properties prove advantageous. Its combination of conductivity and durability enables the production of antennas with efficient signal transmission capabilities. This is particularly significant in applications requiring reliable wireless communication, such as satellite systems and mobile networks.

Types of Copper Clad Steel and Their Advantages:

1. Solid Copper Clad Steel:

   Solid CCS comprises a solid core of steel enveloped by a layer of copper. It finds applications in electrical engineering, transmission lines, and grounding systems, among others.

   - Advantages:

     - Enhanced Conductivity: The outer copper layer facilitates excellent electrical conductivity while maintaining the structural strength of the steel core.

     - Corrosion Resistance: The copper layer shields the underlying steel, offering robust resistance against corrosion, ensuring longevity in various environments.

2. Copper-Clad Steel Wire:

   Copper-clad steel wire involves a process where copper is bonded to a steel core, primarily used in electrical wiring and communication applications.

   - Advantages:

     - Optimal Electrical Conductivity: The copper layer facilitates high electrical conductivity, making it suitable for transmitting signals and power efficiently.

     - Strength and Durability: The steel core contributes to the wire's mechanical strength, enhancing durability and resilience.

3. Copper Clad Steel Sheets and Plates:

   These consist of a copper layer bonded to a steel substrate, employed in applications requiring the combined properties of both materials.

   - Advantages:

     - Versatility: Copper clad steel sheets and plates offer a versatile solution for various industries, combining the benefits of copper and steel.

     - Cost Efficiency: They provide cost-effective alternatives in applications where pure copper may be too expensive, offering similar properties with enhanced strength.

Conclusion

The utilization of Copper Clad Steel spans across diverse industries, owing to its unique amalgamation of properties derived from copper and steel. Its significance in electrical conductivity, corrosion resistance, and structural integrity makes it a sought-after material in fields where these attributes are paramount. As technological advancements continue to evolve, the demand for Copper Clad Steel is anticipated to rise, reinforcing its pivotal role in various sectors.

In conclusion, the versatility and utility of Copper Clad Steel underscore its importance as a material that bridges the gap between conductivity, strength, and corrosion resistance, making it an indispensable component in numerous industrial applications.

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