Stranded vs. Solid Wire: Which is Best for You?
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You have likely already heard or read references to stranded or solid cabling. If you need to decide to pick either one, there are multiple factors to consider, including environment, standards, application, and price. Hence, we cover the key distinctions between stranded vs. solid wire to help you determine which is most suitable for you.
1. Solid vs Stranded Cable: The Basics
The terms solid and stranded refer to the construction of the conductors in the cable.
What is a Stranded Wire Cable?
A stranded wire is composed of multiple small gauge wires twisted together (usually but not always in a helix) to form an organized bundle.
There are different types of stranded wire construction.
Stranded Wire Conductors are best for:
You will typically deploy stranded wire conductors to situations where you must route the cable through tight spaces, significant flexing and vibration, and where intricacy is vital. They do not sever or split even when bent or twisted.
Examples of situations where you could use stranded wire conductors include patch cables, appliance cables, headphone cables, speaker wire, circuit boards, robotic arms, and internal wiring of electronic devices.
What is a Solid Wire Cable?
A solid wire consists of single solid metalcore. It is heavier, more rigid, and less flexible than stranded wire.
Solid Wire Conductors are best for:
Backbone cabling – This includes noisy CAT6 runs and straight-pinning for backbone runs. Backbone cabling here consists of transmission media, intermediate as well as main terminations, and cross-connects.
Since they are a single wire, you can easily punch down-solid cable conductors onto patch panels and wall jacks. Other applications of solid wire include home electrical wiring and instances where you do not need to flex the wire constantly.
Solid wire is the best choice for intra-building and inter-building wire connections. It also works well for structured cabling between telecommunications closets, equipment rooms, and entrance facilities.
Rugged-duty or outdoor applications – Solid wire is ideal where the cable is exposed to frequent movement, adverse weather conditions, and corrosive elements.
Breadboard or protoboard wiring – Solid wire is preferred for breadboard or protoboard wiring. It is easier to push through the solid wire into the breadboard and through the holes of a printed circuit board. The wire is more resistant to abrasion and impact. Trying to do the same with a stranded wire can be difficult as the strands will tend to separate when you press them in.
Summary table of the most suitable application for solid and stranded wires.
2. Stranded vs. Solid Wires: The Key Differences
Stranded vs. solid wires have several key differences.
Wire current capacity
Solid cables offer superior and more stable electrical properties over a wider range of frequencies than stranded wire.
Thinner (that is, higher gauge) conductors have more insertion loss than thicker conductors. So stranded cables experience 20-50% more attenuation than similar gauge solid conductors. And since the cross-section of a stranded cable is not all copper, the wire has a higher DC resistance.
Solid wire has a higher current capacity. When electricity flows through a wire, a skin effect occurs. The parts closest to the outer layer of the wire are most vulnerable to electromagnetic fields and therefore more prone to the electricity dissipating into the air.
Due to its thickness, the solid wire has a smaller surface area and therefore experiences less current dissipation. On the other hand, because the stranded wire has multiple strands, air gaps, and a greater surface area, it has a lower carrying capacity for electric current.
Routing
Stranded wire has better bendability and routing. This makes it easier to maneuver around diverse obstacles when compared to solid wires.
Flexibility
Stranded wires are more flexible than solid cables. Thus, they can withstand vibration and flex better. Solid wire conductors would break if bent too many times. You would have to replace solid wires more often than stranded wires in instances where there are significant vibrations and movement.
However, when it comes to cable termination, stranded wires are more fragile. They are prone to growing loose or breaking over time, unlike solid conductors, which hold their shape and seat well in position, whether on jacks, connecting blocks, or patch panels. The termination of solid wires is, therefore, less complex.
Ease of manufacturing
With a single-core, the structure of solid wire is simple, which makes it much easier to manufacture. Stranded wires require fairly complex manufacturing processes to twist the wires together.
Distance
Since solid wire has lower dissipation, it is best suited for longer runs through walls, floors, and ceilings. Its superior signal handling lowers the degree of signal deterioration. Also, the semi-rigid nature of solid wire makes it easier to pull through buildings.
Stranded wire will be most ideal over shorter distances such as from a router to a computer.
3. Stranded vs Solid: Which is Best?
You can use stranded and solid wires in a wide range of applications. Each has pros and cons that determine the circumstances where it will be most suitable. The best cable will depend on what factors are a priority for you. Consider initial cost, long-term cost, environmental factors, motion, durability, loads, and applications.
When it comes to cost, durability, and simplicity, solid wire is king. Like a single strand of thick wire, it is not only easy to manufacture but resistant to damage. The wire’s thickness also inhibits the effect of electromagnetic interference on its surface. On the downside, the wire lacks malleability. When you twist a solid wire, there is a risk that it could split or severe.
Stranded wires are most ideal in applications that require intricate movement, bending, snaking, and reshaping, as in an electronic, vehicle, and robotic circuit boards.
If you are uncertain about which type of wire is best for you, seek advice from an electronic expert or a qualified electrician.
4. Stranded Wire or Solid Wire, what cable to choose?
When evaluating stranded vs. solid wire, pay attention to the following.
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Amperage load
A solid wire carries more current than an equivalent gauge-stranded wire.
Use case
Since they are more delicate, intricate, and flexible, stranded cables are your best alternative where twisting and bending are necessary to connect electrical components. Solid wire is best for outdoor, rugged areas as well as building wiring.
Costs
The production cost of a solid cable is substantially lower than that of stranded wire. In addition, strand count has an impact on the price of different types of stranded wire. Therefore, the more the strands, the greater the cost.
Nevertheless, when comparing stranded vs. solid wires based on cost, ensure you weigh the initial cost against longevity. Whereas a solid wire will cost less at the point of purchase, the stranded wire will last longer in applications that require frequent motion and wiring alterations. Under such circumstances, the stranded cable may have a lower total cost of ownership (TCO) over the long term.
Metal type
Conductor wires may be copper, aluminum, or copper-clad aluminum (CCA).
Copper is the most conductive metal (except silver) and is an international standard for conductivity. Apart from its exceptional conductivity, copper demonstrates excellent thermal expansion, thermal conductivity, and tensile strength. Copper is used for building wire, automotive, electronic cables, power distribution, and power generation applications.
While copper is by far the most popular metal for conductor wires, aluminum has several advantages too. While it has 61 percent copper’s conductivity, aluminum is just 30 percent as heavy as copper. You can find aluminum conductors in aircraft and overhead transmission lines.
Copper-clad aluminum is the best of both worlds. That is the conductivity of copper and the weight advantages of aluminum.
Wire gauge
Two numbers usually denote stranded cable. The first represents the number of strands and the second the gauge. For instance, a 7/32 (or 7X32) means the conductor cable comprises 7 strands of 32 American Wire Gauge (AWG) wire.
Solid wire cables are specified using a single gauge number that shows the size of the conductor, such as 24 AWG.
It may be confusing to see that both solid and stranded wire can have the same gauge. But remember, whether solid or stranded wire, the overall size is the same – a 24 AWG cable is a 24 AWG cable.
That being said, solid wires are mostly available in smaller gauges.
Conclusion
Both solid and stranded wire have pros and cons before making your decision whether to go for stranded wire or solid wire, weigh and consider the intended use.
In case you need assistance with cable assemblies, get in touch with us. When you partner with us, you enjoy the full expertise of our team to ensure your project’s success.
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Conductor stranding refers to stranding several single wires with the same or different diameters together in a certain direction and according to certain rules to form an overall stranded wire core. Large cross-section solid conductors cannot be laid, formed and connected smoothly because they are not easy to bend. Stranded conductors solve this problem. The stranding methods depends on the metal and its properties.
Concentric Stranding
This is the typical way that power cable conductors are twisted. Consists of a center line or a core surrounded by one or more layers of spirals. Each following layer add six more wire cores than the previous layer. Except for conductors that are stranded in one direction, each layer is laid in the opposite direction to the layer below. For the conductors of power cables, the core is a single wire, and the twisted wires are all of the same diameter. As shown in the figure, the first layer outside the wire core is 6 wires; the second layer is 12 wires; the third layer is 18 wires; and so on. The distance that a single wire of a conductor completes a complete spiral within a layer is called the pitch. The pitch requirements are specified in Part 4 of the ASTM standard. The pitch should be between 8 and 16 times the outer diameter of the corresponding lay layer.
In power cables, the stranding standard is Class B. The standard requires that the outermost twisting direction should be left. This means that when viewed along the axis of the cable conductor, the outermost strands are twisted to the left as they leave the observer. Better flexibility is obtained by increasing the number of single wires in the conductor. Class C has one more single wire layer than Class B, and Class D has one more single wire layer than Class C. Level settings all the way up to level M (commonly used for welding cables etc.). Class C and Class D conductors are similar in weight to Class B conductors and have outer diameters within 3 mils greater than Class B conductors. n=1+3N (N+1) can be used to calculate the number of single wires of concentrically stranded conductors. In the formula, n is the total number of single wires in the stranded conductor; N is the number of layers outside the central single wire.
Compact Stranding
This concept describes the tight integration of the stranded layers through slight deformation. The conductor area is not reduced. The diameter of the final compacted conductor can be reduced by no more than 3% compared to the equivalent diameter of ordinary concentrically stranded core conductors. The common reduction is 2.5%.
Reducing the conductor outer pitch can solve this problem, but results in high impedance and requires the consumption of more conductor material.
Compact stranding is the more common stranding method because the pitch set in concentric stranding creates tiny gaps between the layers of conductors. The low-viscosity material "falls" into these gaps after extrusion. This results in surface irregularities, increases the voltage to be withstood, and makes the layer more difficult to peel off.
Profile Line Stranding
This method is similar to compaction stranding, except that the additional forming process allows the conductor diameter to be reduced by 9% compared with the diameter of ordinary concentrically stranded conductors. Resulting in a conductor diameter that is approximately that of a solid conductor. However, the air gap still exists as a migration channel for moisture. The main advantage of profiled stranded conductors is the reduced conductor diameter.
Bunch Stranding
This concept is used to describe the centralized twisting of single wires in a uniform direction without considering the geometric arrangement.
This structure is used for cables with small American wire gauge conductors that require extremely high flexibility, such as portable cables used in vacuum cleaners, lawn mowers, etc.
In Class K and Class M conductors, the single wire diameter is constant. The required conductor cross-sectional area is met by increasing the number of single wires.
Multi stranding
This concept is used for concentric stranded conductors where each single wire is also stranded. That is, a collection of concentric conductors and bundled conductors. The final conductor is constructed from a concentric assembly of bundled or coaxially stranded conductors. Each group is made up of a certain number of single wires, rather than a single wire. The description of a multi-stranded conductor shall give the number of groups of strands and the number of single wires in each group.
Class G and Class H cables are commonly used for mining portable cables. Class I, Class L, and Class M cables use twisted cables to form concentric cables with the same single wire size. The required cross-sectional area size can be achieved by increasing the number of wires. Class I cables use #24AWG (0.020in) single wire, Class L cables use #30AWG (0.010in) single wires, and Class M cables use #34AWG (0.0063in) single wires. Class I cables are typically used on railways, while Class L and Class M cables are used in more portable applications such as welding cables and mobile power cords.
Fan Shaped Conductor
A conductor whose cross-section is approximately fan-shaped is called a fan-shaped conductor. A typical three-conductor cable has three 120° sectors, which form the basic shape of a circular cable. Such cables have a smaller outer diameter than corresponding concentric conductor cables and can exhibit lower AC impedance due to reduced proximity effects.
For paper-insulated cables, the sector conductors are mostly twisted and compacted to obtain the highest possible ratio of conductor cross-sectional area to cable cross-sectional area. The exact shape and dimensions of each manufacturer's products vary slightly.
Picture shown a typical compressed fan-shaped conductor ratings.
To a certain extent, solid rather than stranded sector conductors have been used in low-voltage cables, and there have been attempts to use such conductors in medium-voltage cables, but this has not yet been achieved due to economic considerations at the time.
Milliken Conductor
Milliken conductors are circular and consist of three or more strands twisted together and separated by a thin insulation layer. Each block carries a smaller current than the entire conductor, and the current is transmitted through the inner and outer locations of the entire conductor. The advantage of this structure is that the skin effect is lower, and the smaller skin effect makes the AC impedance lower than the traditional twisting method.
This form of conductor should be considered for use in cables such as 1000kcmil (corresponding to metric 507mm²) and larger cross-sectional areas that carry large currents. The diameter of a quarter conductor is approximately equal to the diameter of a Class B concentrically stranded conductor.
Annular Conductor
Annular conductors are circular stranded conductors in which individual wires are stranded around a central fiber rope, threaded metal pipe, or I-shaped beam. The advantage of this type conductor is that for a conductor with a certain cross-sectional area, the influence of the skin effect at the center can be eliminated, making the overall AC impedance smaller. Subject to space permitting, ring conductors are more economical for cables with a cross-sectional area of 60Hz, 1000kcmil and above, and for cable conductors with a cross-sectional area of 1500kcmil (corresponding to 760mm² in the metric system) and above under low-frequency conditions (such as 25Hz).
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