The basic process of copper clad steel wire forming is mainly 2 steps:
Firstly, coat the copper layer on the surface of the steel
Secondly, draw or roll to the desired finished size.
(The most critical of which is the coating process and quality of the copper layer)
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There are several production methods for copper clad steel wire:
The most commonly used processing techniques in China are electroplating and cladding welding.
The electroplating method applies the principle of electrolytic plating. Use the core wire as the cathode. Use the cladding metal as the anode, and plate the cladding layer on the core wire.
The electroplating tank consists of a pre-treatment tank and an electroplating tank. Through the pre-treatment tank and the electroplating tank, immerse a large length of steel wire in the electroplating tank to complete the electroplating process.
Multi-segment linear continuous copper plating and reciprocating threading continuous copper plating. This can make the wire less subject to bending and ensure sufficient plating time and plating quality.
After electroplating, the wire billet becomes CCS wire with various specifications and properties after stretching and heat treatment.
Only have thin copper layers by electroplating for CCS wires.
Moreover, the electroplating equipment is relatively large and consumes a lot of power, and electroplating is an important disadvantage of environmental pollution.
However, the electroplating process is relatively mature, and the process is relatively simple and easy to master.
The electroplating method is not very productive, but it can also achieve faster production speeds when producing thin wires.
At present, some companies mainly use in the production of copper-clad steel fine wire.
In addition, special composite wires such as tin-plated copper wires, nickel-plated copper wires, and silver-plated copper wires also mainly use this process.
The production of copper-clad steel wire by cladding welding is a relatively advanced processing technology in the world at present. Meanwhile, it is also the craft that our company General Clad currently manufactures.
It is made of high-quality and high-purity copper strip, and coat the copper layer on the steel wire.
Weld the copper-clad steel rod blank by argon arc welding, and draw the copper-clad steel after argon arc welding by special processes for many times, and then heat-treated to form wire rods of various specifications.
So what are the advantages of the cladding welding method?
Firstly, it can produce high-quality copper-clad steel wire.
Secondly, to realize the bonding of gold atoms between the copper layer and the steel core wire.
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Thirdly, the copper layer is evenly distributed, with good concentricity, stable quality and good uniformity.
Then, the metallurgical bond is firm, and its surface is bright and round without any defects.
Next, in the strict twisting test, there will be no detachment, cracking or peeling like electroplated products.
Lastly, the surface is very bright, without any harm to people and the environment.
At the same time, this type of equipment can also produce copper-clad aluminum wire, stainless steel-clad steel wire, nickel-clad copper wire, etc.
However, the equipment investment is large and the process requirements are strict.
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.
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.
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.
The main properties of these conductors include:
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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