In order for electricity to travel through a wire, it needs a really nice conductor to be able to flow. Conductor: A conductor is a material that doesn't impede the passage of an electric current. Copper and aluminum are among the most used conductors. Both of those substances have their pros and cons, but if only we could merge the best bits of both to form something better. This is where copper clad aluminum or CCA wire comes into the picture!
Copper clad aluminum wires are very cost-effective, which is one of the primary reasons for using these wires. Copper, while more expensive than aluminum, can be refinished when mixed with both types of material, and can be easily expanded into a strong wire of little cost. As a result, CCA wire is widely used in various industries, including, but not limited to, construction, telecommunications, and automotive manufacturing.
Another good point of CCA wire is that it weighs less than pure copper wires. Copper is also heavier than aluminum, so if you can use less copper in your wire, the wire itself is lighter. This is especially useful in applications where weight is an issue, such as automotive, aerospace and other vehicular uses. The lighter wire can improve fuel economy and make transport easier.
Aluminum, by contrast, is lighter and generally less expensive than copper. It does, however, not conduct electricity with the same efficiency, which requires using more aluminum to achieve similar conductivity as with copper. The oxidation and rust at first glance will be more susceptible than copper. This means that when you have aluminum wires, they might not last as long in rugged environments.
There are several sectors that utilize copper clad aluminum wires, such as automotive, aerospace, and telecommunications, among others. CCA wires are commonly used for automotive wiring harnesses and battery cables. They offer the advantage of being light weight and a lower cost for these usages. A wiring harness is a time-consuming and tedious part of a car, a bundle of wires to connect and transport power and signals between various components.
In the aerospace sector, CCA wire is deployed for electronics and wiring, where it is critical to keep the weight low. A lighter plane is a more efficient plane since airplanes have to be as light as they can so CCA wire earns its keep here. In the telecommunications example, CCA wire is frequently found in phone cables and in other applications. This is a very critical place for strength and economy to co-exist, and CCA wire fits perfectly here.
A thicker wire, for instance, may be necessary in applications requiring a higher conductivity, but this can also mean increased weight or cost of the wire. If the wire will be subjected to harsh environments — such as high heat, moisture or chemicals — then it may need a coating or insulation to help prevent corrosion or damage over time. Insulation must be correctly applied to allow the wire to function safely and efficiently.
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