Copper-Clad Steel: Applications and Benefits
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John Ferreol Monnot, a metallurgist, invented the first successful process for manufacturing copper-clad steel.
Understanding Copper-Clad Steel
Copper-clad steel (CCS), also known as copper-covered steel or the trademarked name Copperweld, is a bi-metallic product. It is primarily used in the wire industry. CCS combines the high mechanical strength of steel with the conductivity and corrosion resistance of copper.
Main Uses of Copper-Clad Steel
CCS is mainly used for grounding purposes and line tracing to locate underground utilities. Other applications include drop wire of telephone cables, inner conductor of coaxial cables, and certain antennas for RF conducting wires. It is also employed in some household and industrial power installations.
Historical Background
The first recorded attempt to make copper-clad steel wire took place in the early 1860s. Though various methods to unite copper and steel were suggested over the years, it wasn't until Farmer and Milliken wrapped a strip of copper around a steel wire that a feasible method was found. Subsequent attempts in the 1880s and 1890s, including electroplating copper on steel, were less successful.
John Ferreol Monnot's work between 1900 and 1905 laid the foundation for modern CCS production. After extensive experimentation, Monnot organized the Duplex Metals Company, creating a reliable process for producing copper-clad steel.
Uses of Copper-Clad Steel
Copper-clad steel wire is used in various applications such as grounding, connecting ground rods to metallic structures, ground grid meshes, substations, power installations, and lightning arresters. It is also used occasionally for power transmission.
Additionally, copper-coated welding wire has become popular due to the increased use of wire welding equipment.
In the field of radio antennas, CCS is utilized for its nearly identical HF conductivity compared to a solid copper conductor of the same diameter. It provides extra strength to withstand high tension, which could otherwise break or excessively stretch solid copper or aluminum wire.
Key Properties
- Good corrosion resistance of copper
- High tensile strength of steel
- Resistance against material fatigue
Advantages of Copper-Clad Steel
Since the outer conductor layer is low-impedance copper while the center is higher impedance steel, the skin effect allows RF transmission lines with heavy copper-cladding to have low impedance at high frequencies, equivalent to a solid copper wire.
Tensile strength of copper-clad steel conductors is greater than that of ordinary copper conductors, allowing for greater span lengths. Additionally, smaller diameter copper-clad steel conductors can be used in coaxial cables, permitting higher impedance and a smaller cable diameter than similar-strength copper conductors.
The inseparable union of copper and steel and the minimal amount of the costlier material render CCS less attractive for theft. The low scrap value of CCS makes it impractical for copper recovery.
Copper-clad steel conductors are generally accepted as fulfilling the legal specifications for a good electrical ground. Consequently, they are preferred by industrial companies and utilities when cost is a concern.
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