Copper-clad aluminum wire

Newly Developed Copper-Clad Aluminum Wire: Tailored for High Elongation Demands

Product Overview

Introducing our newly developed Copper-Clad Aluminum Wire (CCA Wire)—a customized composite conductor exclusively engineered to address our customers’ critical demand for high elongation performance. Crafted through advanced cladding technology, this innovative product features a tightly bonded structure of high-purity copper layer (purity ≥ 99.95%) and premium aluminum core. Beyond integrating copper’s excellent conductivity, corrosion resistance, and solderability with aluminum’s lightweight and cost-effectiveness, it is specifically optimized to deliver exceptional elongation, filling the gap for applications requiring enhanced ductility. As a customer-centric new offering, it not only serves as a reliable alternative to solid copper wire but also provides tailored performance to meet your most demanding project needs.

Core Features & Advantages

• Customized High Elongation Performance: Developed in direct response to customer requirements, this CCA Wire boasts an elongation rate of ≥ 18% (surpassing the industry average of ≥ 10%), ensuring superior ductility for complex processing like repeated bending, twisting, and forming without cracking or breaking—ideal for applications with strict deformation resistance needs.
• Balanced Conductivity & Lightweight: The high-purity copper cladding guarantees excellent electrical conductivity (≥ 60% IACS) to meet most electrical transmission demands; compared to solid copper wire of the same specification, it reduces weight by approximately 40%, easing equipment load and simplifying installation.
• Superior Corrosion Resistance: The dense copper outer layer acts as a robust barrier against moisture, chemicals, and environmental oxidation, while the aluminum core undergoes specialized anti-corrosion treatment—ensuring long-term stable operation even in harsh environments such as humid areas or industrial settings.
• Excellent Solderability & Processability: The copper surface enables easy and reliable soldering, compatible with standard electrical connection processes; paired with its high elongation, the wire maintains structural integrity during cutting, stamping, and assembly, adapting to diverse manufacturing workflows.
• Cost-Effective Solution: By replacing part of the copper with high-quality aluminum, it cuts raw material costs by 25%-35% compared to solid copper wire—without compromising high elongation, conductivity, or durability—helping customers optimize production costs while achieving performance goals.
• Stable Cladding Bonding: Adopting advanced hot-dip or cold-drawing cladding technology, the copper layer and aluminum core form an ultra-tight bond (bonding strength ≥ 15N/mm²), preventing delamination even under long-term current load, mechanical vibration, or high-elongation processing.
• Eco-Friendly & Sustainable: Manufactured using energy-saving cladding processes to reduce carbon emissions; both copper and aluminum materials are fully recyclable, aligning with global environmental protection and sustainable development standards.

Technical Specifications

Typical Applications

This newly developed, high-elongation CCA Wire is ideally suited for scenarios where ductility and performance coexist:

• Automotive Electronics: Low-voltage wiring harnesses (interior lighting, audio systems, sensor connections) that require frequent assembly adjustments; auxiliary circuit cables for electric vehicles (EVs) needing resistance to vibration-induced deformation.
• Consumer Electronics: Internal connecting wires for foldable devices (smartphones, laptops), wearable tech, and audio equipment (speakers, headphones)—where high elongation prevents wire breakage during product use or assembly.
• Industrial Equipment: Wiring for flexible machinery, robotic arms, and movable control panels that undergo repeated bending or position changes; low-power motor windings requiring enhanced ductility during winding processes.
• Electrical Wiring: Building wires for areas with complex installation paths, household appliance internal wires (washing machines, refrigerators) that may experience minor structural shifts, and portable device charging cables.
• Communication Equipment: Flexible data cables for mobile base stations, coaxial cables for wearable communication devices, and internal wiring for lightweight telecom gear.

Quality Assurance

As a customer-tailored new product, our high-elongation Copper-Clad Aluminum Wire is produced in ISO 9001-certified facilities, with rigorous quality control 贯穿 every stage—from raw material selection (high-purity copper and aluminum) to cladding, drawing, and final inspection. Each batch undergoes specialized testing for elongation performance, along with conductivity, bonding strength, corrosion resistance, and dimensional accuracy checks, ensuring compliance with international standards (ASTM B566, IEC 60228) and our customers’ specific requirements. We offer further customization, including adjustable elongation rates, copper cladding thickness, wire diameter, and surface treatment (tinned, bare copper), to fully align with your project needs. Our professional technical team provides one-on-one pre-sales consultation and after-sales support, helping you integrate this new product seamlessly into your production.

For inquiries about product samples, detailed technical data sheets, custom elongation adjustments, or pricing, please contact our sales team. We are dedicated to delivering this customer-centric new Copper-Clad Aluminum Wire and supporting your business with tailored, high-performance solutions.