When discussing the components in an electrical grounding system, we often hear the terms &#;copper-clad steel&#; and &#;copper-bonded steel&#; used interchangeably.Though it may seem inconsequential, each term represents a different copper plating process, in which the copper is composite on the steel core. In this post, we consider the question, what is the difference between copper-clad and copper-bonded steel?
The reason the two terms are often used interchangeably is because, on a basic level, they appear the same. Both consist of a steel core and copper exterior.
For use in grounding, both products possess the high tensile strength of steel coupled with the corrosion resistance of copper.
Compared to pure copper, the conductivity of these bi-metallic conductors is lower. To match the current carrying capability of copper, the diameter and copper thickness of bi-metallic conductors are increased. Depending on a conductor&#;s specific application and region, conductivity requirements may differ.
The primary difference between these two types of processes is the way the copper is composited on the steel core.
Copper-bonded steel is manufactured through a continuous electro-plating process of copper over steel core, resulting in a permanent molecular bond between the two materials.
The technique, known as electrophoretic deposition (EDP), creates a homogenous layer of copper over the steel core, regardless of whether the product is a wire, solid conductor or ground rod. The copper layer thickness is measured in unit of [mils].
Copper-clad steel is manufactured by installing two copper strips over a steel core using pressure and heat to form a metallurgical bond. The copper lair thickness is adjusted to the percentage conductivity of pure copper. Most common conductors used in the U.S. are 40% conductivity of copper.
Copper-bonded steel is mainly used in manufacturing ground rods, solid wire and solid conductors. Copper-clad steel is generally used in manufacturing of stranded and solid conductors. Both copper-bonded and copper-clad steel are used in theft deterrent applications where the conductor is exposed. Both technologies are good alternatives to copper with similar corrosion resistance and higher tensile strength.
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Copper clad vs. solid copper cables &#; which is better suited for your needs? You may already have some familiarity with these two types of cables, but it&#;s always good to brush up on the basics to help determine which one to use for your next application. After all, not all cables are the same and making the correct choice between the two is crucial for both saving costs and maintaining data integrity. We&#;ve broken things down here to help you with your next cable assembly selection.
Copper clad cables are available in two different varieties: aluminum (CCA, or copper clad aluminum) and steel (CCS, or copper clad steel). This means the conductor is made of either aluminum or steel, and there&#;s a coating of copper wrapped around it.
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Compared to solid conductors, copper clad cables are typically much lighter. That&#;s one of their key benefits. Another key benefit of copper clad cables is cost savings. Because the cable is coated in copper as opposed to being solid copper, they are typically less expensive than their counterpart.
However, due to the copper coating, these cables are generally better for short distances and sending lesser amounts of data. If the distances become longer, there could be issues with signal integrity. This could mean the signal may need to be sent multiple times to reach the end point.
As we noted, copper clad cables come in aluminum and steel varieties. Though their performance is similar over short distances, steel tends to be the more durable option. This is especially useful in outdoor use applications.
Copper clad cables are an ideal, cost-effective means for transmitting signals over short distances. However, the longer the distance, the more likely signal loss will occur.
Durability and flexibility. Those are the two big benefits of using solid copper cables. The cable easily bends back and forth, and it&#;s easy to form and shape. Above all, it performs very well as a conductor.
Solid copper cables are ideal for transmitting signals over long distances. In fact, they excel in transmitting high levels of data over these distances &#; and minimal current is necessary to push signals all the way through. They&#;re ideal for more permanent applications, such as inside wall cavities, and other applications where the cable isn&#;t likely to be changed out.
Solid copper cables are durable, flexible and the ideal solution for transmitting high levels of data over long distances.
There are many factors that you should weigh to determine whether copper clad or solid copper cables is the best fit. These include cost, distance, weight, durability and data load. Here&#;s a closer look at each of these factors as they pertain to selecting cable:
One of the things that&#;s important to remember when it comes to custom cable assemblies is that they&#;re not a one-size-fits-all proposition. In fact, educating our partners is important to ensure they receive the right cable that works best for their application.
Many of our partners don&#;t even realize there are different types of copper cables. This was the case recently when a partner of ours was looking for a 150 foot cable and had their eyes on copper clad due to the cost.
Because of the length of the cable, solid copper was the better choice on paper. However, after discussing with our team about a number of different variables, our partner wound up going with copper clad because very little data was being sent via the cable and it was the best choice based on the application and their budget.
To recap, solid copper is usually preferred for longer cables. It also has a better bend radius and keeps signal strength over distance better.
CCA and CCS tend to be more brittle and not ideal for bends, twists and turns. However, they&#;re inexpensive. It&#;s part of why they&#;re best suited for short lengths.
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