Copper-Coated Steel Wire

Copper-coated steel wire is a composite metal wire with a layer of pure copper on the surface of the steel wire. It combines the high tensile strength of steel with the excellent conductivity, corrosion resistance, and ductility of copper. Produced using electroplating or cladding processes, it features a uniform copper layer, stable performance, and low cost. It is used in power, telecommunications, construction, and industrial applications. Wanzhi Steel offers specialty products such as 18-gauge and 16-gauge copper coated wire, and can customize diameters, lengths, and coil weights. If you are interested, please contact us.

Specification

Item	copper-coated steel wire
Place of Origin	Hebei, China
Standard	AISI, ASTM, BS, DIN, JIS, GB, EN
Delivery Time	8-14 days
Conductor Material	Copper
Color	Copper color
Thickness	0.25mm – 4.0mm
customized support	OEM/ODM
Sample	Free Available
Payment term	TT 30% Advance + 70% Balance
Price Item	FOB, CIF, EXW, CFR, etc
Packing	Standard export packaging
Certification	ISO 9001, SGS, ABS, BV, AWS, CE
MOQ	5 tons

Core Features

• Performance Advantages: Combines high tensile strength, tensile strength, and electrical properties; the pure copper layer provides excellent conductivity.

• High Cost-Effectiveness: 30-50% lower cost and approximately 40% lighter than pure copper, suitable for large-scale industrial applications.
• Durability: Metallurgical bonding ensures the copper layer does not peel, maintaining stable and reliable performance within a temperature range of -40℃ to 200℃.
• Excellent Weather Resistance: The copper layer effectively isolates air and moisture, enhancing the steel core’s rust resistance, making it suitable for complex outdoor environments.
• Easy to Process and Shape: Can be bent, braided, and stranded to meet the shape requirements of various scenarios.

Main Types

Based on the copper layer forming process and coating structure, the core categories are as follows:

1. Electroplated Copper Coated Steel Wire

Utilizes an electrolytic deposition process, similar to that of electroplated zinc wire. The copper layer thickness is controllable (0.5-5μm), resulting in high surface smoothness, moderate cost, and stable conductivity.

2. Hot-Dipped Copper Coated Steel Wire

Immerses a steel core in molten copper, forming a metallurgical bonding layer through thermal diffusion. The coating thickness can reach 10-50μm, exhibiting extremely strong adhesion and corrosion resistance, and wear resistance far exceeding that of electroplated wires.

3. Clad Copper Coated Steel Wire

Uses mechanical hot pressing or extrusion processes to tightly wrap copper strips around a steel core. The copper layer thickness is uniform and customizable, with excellent bonding strength, balancing the strength of steel with the electrical and thermal conductivity of copper.

4. Alloyed Copper Coated Steel Wire

After copper plating, it undergoes high-temperature heat treatment, which forms a copper-iron alloy transition layer between the copper layer and the steel core, further improving the coating’s anti-peeling and anti-corrosion properties.

 

Technical Characteristics of the 4 Types

Performance Specifications	Electroplated copper steel wire	Hot-dip copper-plated steel wire	Copper-coated steel wire	Alloyed copper-plated steel wire
Copper Layer Thickness	0.5-5μm	10-50μm	10-20% volume content	10-50μm + alloy layer
Conductivity	15-40% IACS	20-40% IACS	21-40% IACS	15-35% IACS
Tensile Strength	290-1500 MPa	300-1200 MPa	350-1000 MPa	400-1300 MPa
Salt Spray Test	720 hours	2000+ hours	1500+hours	2000+ hours
Operating Temperature	-40-200℃	-50-250℃	-40-250℃	-50-300℃
Price	Medium-low temperature	Medium-high temperature	High	Extremely high

Application

• Power and Grounding: Used for manufacturing grounding leads, lightning protection wires, and power cable armor to ensure conductivity and structural strength.
• Telecommunications: Used for shielding communication cables and signal transmission lines, balancing signal conduction and tensile strength.
• Wire Mesh Products: Weaves corrosion-resistant wire mesh and filter screens, suitable for humid and corrosive environments such as marine and chemical plants.
• Hardware Fasteners: Manufactures screws, rivets, etc., meeting the requirements for rust prevention and high-strength fastening.
• Automotive and Aerospace: Serves as a reinforcing core for automotive wiring harnesses and aerospace cables, improving the tensile strength and conductivity of the cables.

Application Scenario Recommendations

• Marine Engineering: Hot-dip copper-plated/alloyed copper-plated steel wire is preferred. Hot-dip galvanized copper wire with ≥30% copper content for offshore grounding; annealed copper-plated wire for floating platforms.
• Power Industry: For substation grounding, choose wires with 21%/30% conductivity; for overhead grounding wires, choose high-strength wires with tensile strength ≥800MPa; for corrosive soils, use copper-clad steel stranded wire with a copper layer ≥0.25mm.
• Telecommunications Industry: For cable inner conductors, choose copper-clad steel wire; for high-frequency applications, choose wires with a copper layer ≥2μm.
• Construction and Infrastructure: Hot-dip copper-plated steel wire is used for lightning protection in high-rise buildings; alloyed copper-plated steel wire is used for prestressed materials in bridges and tunnels.

Weight Calculation Formula

Weight (kg) = Wire length (m) × (Diameter (mm/2)² × 7.8 g/cm³ × 3.14

 

Procurement Decision Recommendations

Cost-effectiveness

For short-term/temporary projects, choose electroplated copper steel wire due to its lower initial cost. For long-term or permanent projects, choose hot-dip copper steel wire.

Supplier selection

Prioritize manufacturers with 10+ years of experience, annual production capacity ≥ 5000 tons, ISO 9001 certification, and the ability to provide technical services and a stable supply chain.

Wanzhi Steel Factory-Cooper Coated Steel Wire Manufacturer

• Mature Technology: Four production lines covering electroplating, hot-dip galvanizing, coating, and alloying ensure precise control over copper layer thickness and conductivity, meeting customized needs.
• Quality Assurance: Full-process quality inspection, combined with ISO 9001 certification, ensures a factory pass rate of over 99.8%. Salt spray, tensile strength, and other performance tests consistently meet standards.
• Sufficient Production Capacity: Annual capacity of 200,000 tons allows for rapid delivery of bulk orders, supports small and urgent orders, and non-standard customization.
• Comprehensive Service: Free selection solutions, after-sales technical guidance, and direct domestic and international logistics lines.

 

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Wanzhi Steel is an ISO 9001-certified steel factory located in Hebei Province, China. For 14 years, Wanzhi Steel has been specializing in the production of Galfan Wire, Aluminium Wire, Galvanized Wire, Oval Wire, CCA Wire, Baling Wire, Copper-coated steel wire, and Zinc Aluminum Alloy Wire with a monthly output of 1800 tons. With high-quality products and good services, its products have been exported to more than 120 countries around the world.

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