Enameled Copper Clad Aluminum Wire

Copper Clad Aluminum (CCA) is a clad bi-metal utilizing electrical conductor grade aluminum as its core and oxygen free copper for its outer layer. The cladding process creates a permanent continuous weld between the two metals. The composite wire is uniquely suited to electrical applications where weight and conductivity issues are critical. The copper makes up either 10% or 15% of the cross sectional area of the wire and assures excellent solderability. AC conductivity at frequencies greater than 5MHz is equal to solid copper. CCA is manufactured in accordance with the requirements of ASTM B-566. Film Insulations are available on CCA. See the magnet wire insulation guide for enamel options.

Parameters

Uses
The primary applications of this conductor revolve around weight reduction requirements. These applications include high-quality coils, such as the voice coils in headphones or portable loudspeakers; high frequency coaxial applications, such as RF antennas and cable television distribution cables; and power cables.
CCA was also used in electrical wiring for buildings. The copper/aluminium construction was adopted to avoid some of the problems with aluminium wire, yet retain most of the cost advantage.
CCA is also seen in unshielded twisted pair networking cables. These cables are often less expensive than their full-copper counterparts.

Applications of Copper Clad Aluminum
Music
Amplification, Noise elimination, custom guitar cables, loudspeakers, subwoofers and high performance audio

Power
Wireless chargers, custom power supplies

Aerospace, military, commercial
Extreme temperature sensors, noise control, custom magnetics, underwater sensors

Space propulsion systems, sensors
Booms (Retractable tube for inflight tranfer of fuel)

Specialty resistors and capacitors
Wireless power transfer systems using inductive coupling through magnetic field

Electromagnetic radiation and atomic research
Coaxial Cable

Microwave connectors and cables
CATV semi-rigid trunk, distribution cables

Hobby motors and wiring
Residential power conductors

Automotive
Advanced fuel injection systems

Technical equipment
Outdoor control panels, sensors, printers

Hearing Aids
Button Cell Batteries

Properties
The properties of copper-clad aluminium wire include:
Less expensive than a pure copper wire
Lighter than pure copper
Higher electrical conductivity than pure aluminium
Higher strength than aluminium
Electrical connections are typically more reliable than pure aluminium[citation needed]
Typically produced as a 10% or 15% by copper volume product