From construction and mining to marine environments, copper-clad steel wire rope provides high strength, corrosion resistance, and long-lasting performance.
To produce the steel core, manufacturers draw high-carbon steel wire through a series of dies. This process reduces the wire&#;s diameter and increases its strength. Manufacturers clean the steel core and apply a layer of copper using an electroplating process. The process helps to protect the steel core from rust and other types of environmental damage. It also provides additional benefits such as electrical conductivity and thermal conductivity.
Copper is an excellent conductor of electricity, which makes it ideal for applications where electrical conductivity is important. Copper also has high thermal conductivity, which means it can dissipate heat quickly and efficiently. In addition, copper is highly resistant to corrosion. This property helps to protect the steel core from rust and other types of environmental damage.
Manufacturers can vary the number of strands to achieve different levels of strength. They can also vary the direction of the twist to achieve different levels of flexibility.
Wire ropes with a higher number of strands tend to be more flexible and easier to handle. And with a lower number of strands tend to be stronger and more durable.
After forming the wire, manufacturers subject it to a heat treatment process. This process helps to improve the wire rope&#;s strength and durability, making it more resistant to wear and tear over time. The wire rope is then coated with a layer of lubricant to reduce friction and prevent corrosion. The lubricant also helps to improve the performance of the wire rope by reducing wear and tear on the individual strands.
Manufacturers test the finished copper-clad steel wire rope to ensure that it meets the required specifications for diameter, tensile strength, and weight capacity. Manufacturers package the wire rope after testing and ship it to customers for use in various applications.
Overall, the manufacturing process for copper-clad steel wire involves several complex steps, but the end result is a high-quality product that can provide superior performance and durability in a wide range of applications. Copper-clad steel wire rope offers the strength, flexibility, and corrosion resistance needed for a variety of applications. Whether building a bridge, mining for minerals, or operating a marine vessel, this wire rope can get the job done right.
Copper-clad steel (CCS), also known as copper-covered steel or the trademarked name Copperweld is a bi-metallic product, mainly used in the wire industry that combines the high mechanical strength of steel with the conductivity and corrosion resistance of copper.
It is mainly used for grounding purposes, line tracing to locate underground utilities, drop wire of cables,[1] and inner conductor of coaxial cables, including thin hookup cables like RG-174 and CATV cable. It is also used in some antennas for RF conducting wires.
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The first recorded attempt to make copper clad steel wire took place in the early s.[2] Although for over 100 years people had been suggesting various ways of uniting copper and steel, it was not until the period mentioned that Farmer and Milliken tried wrapping a strip of copper about a steel wire. American engineers in and again in the s made attempts to produce a copper-steel wire, in one instance at least, by electroplating copper on steel.[1]
The Duplex Metals Co. traces its beginning to John Ferreol Monnot between and . He had been very interested in the work of Mr. Martin in Paris.
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Copper-clad steel wire find applications in grounding, connection of ground rods to metallic structures, ground grid meshes, substations, power installations, and lightning arresters. This wire is also sometimes used for power transmission.
Copper coated welding wire has become common since wire welding equipment has become popular.
Copper-clad steel is occasionally used for making durable radio antennas, where its HF conductivity is nearly identical to a same-diameter solid copper conductor. It is most often used in antennas with long spans of unsupported wire, which need extra strength to withstand high tension which would cause solid copper or aluminum wire to break or stretch excessively.
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The main properties of these conductors include:
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Since the outer conductor layer is low-impedance copper, and only the center is higher impedance steel, the skin effect gives RF transmission lines with heavy copper-cladding a low impedance at high frequencies, equivalent to that of a solid copper wire.
Tensile strength of copper-clad steel conductors is greater than that of ordinary copper conductors permitting greater span lengths than with copper.
Another advantage is that smaller diameter copper-clad steel conductors may be used in coaxial cables, permitting higher impedance and smaller cable diameter than with copper conductors of similar strength.
Due to the inseparable union of the two metals and the low amount of the more costly one, it deters theft since copper recovery is impractical and thus has very little scrap value.
Installations with copper-clad steel conductors are generally accepted as fulfilling the legal specifications for a good electrical ground. For this reason its use is preferred by industrial companies and utilities when cost is a concern.
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