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 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.
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.
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.
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.
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.
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