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Precision Rolling Lines
Rolling, slitting and dimensional control
Manufactured by Clad & Weld
Copper Clad Aluminum High-Performance Composite
Significant weight reduction at equal geometry; conductivity is confirmed by copper ratio and purchase specification. Clad & Weld process forms a metallurgical bond at the Cu-Al interface.
RAYTRON is a specialized manufacturer of Copper Clad Aluminum (CCA) wire. Specified bare round CCA wire may be supplied against ASTM B566 where the product class, diameter, temper and purchase specification are confirmed. Other CCA forms use project-specific specifications and agreed test methods. CCA bimetallic conductor conductivity depends on the copper cross-sectional area ratio, product form and purchase specification. Significant weight reduction at equal geometry (magnitude depends on the copper volume fraction; equal-ampacity designs may need a larger cross-section). System-level weight reduction depends on conductivity, conductor size, insulation, termination and application design. Engineered with a metallurgical bond; interface quality is inspected per the product control plan. Whether CCA is suitable as a replacement for copper requires application validation.
ISO 9001 ASTM B566 (specified bare round wire) 15,000 tons/year capacity
±0.005mm
Dimensional Tolerance
0.035mm
Min Foil Thickness
150×
Max Width-to-Thickness Ratio
CCA
Copper-Aluminum Composite PV Ribbon Direction
What is Raytron CCA?
Raytron CCA (Copper Clad Aluminum) is a bimetallic conductor available as round wire, flat wire, strip and foil. Conductivity depends on the CCA grade and specification. Confirm the applicable grade and measured values per product and lot in your RFQ. It is intended for applications where weight, cost and conductivity must be balanced, subject to termination, thermal-rise and corrosion validation.
Manufacturing Process
This product is manufactured using Clad & Weld process with metallurgical bonding. It is NOT electroplated.
Metallurgical bonding creates a permanent metallurgical connection, ensuring stable reliability compared to electroplating. This enables excellent weldability, designed to resist peeling during bending, and stable performance under thermal cycling conditions.
CCA vs Pure Copper - Interactive Comparison
Drag the sliders to compare material performance
Performance Chart
Density (g/cm³)
CCA: 3.64 Cu: 8.96
Calculated by rule of mixtures: about 3.326 g/cm³ at 10% copper by volume, about 3.639 g/cm³ at 15% (calculated, not measured).
Conductivity
CCA: by specification Cu: 100% IACS
Conductivity depends on the CCA grade and specification. Confirm the applicable grade and measured values per product and lot in your RFQ.
Relative Weight (equal geometry)
CCA: 41% Cu: 100%
At equal geometry (same cross-section and length), CCA with 10% copper by volume is about 63% lighter than copper, and about 59% at 15%. Equal-ampacity designs may need a larger cross-section, so actual weight savings differ.
CCA can reduce equal-geometry conductor mass compared with pure copper. Electrical and economic results depend on copper ratio, aluminum alloy, conductor area, required resistance, joining method and current copper/aluminum prices.
Lightweight Advantage
At equal geometry CCA is significantly lighter than copper (magnitude depends on the copper volume fraction). System-level savings depend on the application design; equal-ampacity designs may need a larger cross-section.
Cost Effectiveness
Cost depends on copper price, aluminum price, copper volume fraction, conductor geometry and processing fee. Static savings percentages are not used because equivalent-current designs and joining costs may change the result.
Conductivity
Conductivity depends on the CCA grade and specification. Confirm the applicable grade and measured values per product and lot in your RFQ.
Application Scenarios
Browse by application type and validation status: commercially established, available after validation, and controlled engineering inquiry (including aviation, robotics and eVTOL) are labeled separately.
CATV / Ethernet Coaxial & Network
Commercially Established
CATV cable / Cat5e/6/7 Ethernet inner conductor — at HF the current concentrates in the copper surface layer; electrical and cost results depend on copper ratio and copper price
HF Skin Behavior Validation Required
Featured Application
Cable & Harness Manufacturer Evaluation
Application Boundaries
Suitable For / Not Recommended For / Validation Required
CCA is not equivalent to pure copper. Confirm application boundaries and validation path before inquiry.
View CCA validation route →Suitable For
- ● RF / Coaxial Cable
- ● Communication Cable (Cat5e/6/7)
- ● Speaker Wire
- ● Lightweight Wire Harness
- ● Motor Winding / Coil after validation
- ● Composite PV Ribbon validation
Not Recommended For
- ● Unvalidated high-current power cable
- ● Harsh outdoor termination without protection
- ● Safety-critical wiring without certification
- ● Direct building wire replacement
- ● EV high-current systems without evaluation
- ● Medical devices without evaluation
Validation Required
- ● Termination and crimping
- ● Soldering compatibility
- ● Resistance and voltage drop
- ● Thermal rise validation
- ● Bending fatigue
- ● Corrosion and aging
- ● Dissimilar metal contact isolation
Engineering Inquiry Note: Aerospace / eVTOL / Robotics / Medical / Safety-critical wiring applications must be marked as "Engineering Inquiry / Project Validation Required" and must not be presented as ordinary applications.
CCA is not equivalent to pure copper: CCA conductivity depends on grade and purchase specification and is lower than pure copper. Termination, thermal rise and long-term reliability must be validated for the specific application. ASTM B566 applies only to specified bare round wire categories. Final compliance depends on product form, copper ratio, diameter and purchase specification.
⚠️ Electrochemical Compatibility Notice
Copper Clad Aluminum (CCA) may experience galvanic corrosion in humid or salt spray environments when in direct contact with dissimilar metals (such as copper or steel). To ensure product lifespan, please note the following:
- • Avoid direct contact between CCA and pure copper or steel; use insulating spacers or coatings for isolation
- • In outdoor or high-humidity environments, tin-plated or silver-plated post-processing options are recommended
- • For grounding applications, please select Copper Clad Steel (CCS) for better corrosion resistance
CCA Product Series
Various specifications for different applications
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Copper Clad Aluminum Round Wire
Copper Clad Aluminum (Cu/Al)
Conductivity: Confirm by copper ratio and specification
Copper Clad Aluminum Flat Wire
Copper Clad Aluminum (Cu/Al)
Conductivity: Confirm by copper ratio and specification
Copper Clad Aluminum Strip
Copper Clad Aluminum (Cu/Al)
Conductivity: Confirm by copper ratio and specification
Copper Clad Aluminum Foil
Copper Clad Aluminum (Cu/Al)
Conductivity: Confirm by copper ratio and specification
Copper Clad Aluminum Ribbon Wire
Copper Clad Aluminum (Cu/Al)
Conductivity: Confirm by copper ratio and specification
Copper Clad Aluminum Stranded Wire
Copper Clad Aluminum (Cu/Al)
Conductivity: Confirm by copper ratio and specification
Frequently Asked Questions
Learn more about CCA products
What are the advantages of CCA compared to pure copper?
Key characteristics: 1) Significant weight reduction at equal geometry (magnitude depends on the copper volume fraction; equal-ampacity designs may need a larger cross-section); 2) Conductivity depends on the copper cross-sectional area ratio, product form and purchase specification; 3) System-level weight reduction depends on conductivity, conductor size, insulation, termination and application design; 4) Whether CCA is a suitable replacement for copper requires application validation. Cost comparison is indicative, depending on copper price, dimensions and order volume.
What conductivity can CCA achieve?
Conductivity depends on the CCA grade and specification. Confirm the applicable grade and measured values per product and lot in your RFQ. The copper layer ratio can be optimized for different application requirements.
What is the service life of CCA products?
Service life depends on the operating environment, termination method, coating, insulation and application validation. CCA can provide long-term reliability in validated applications, but it should not be treated as a universal direct replacement for copper. Our Clad & Weld process forms a metallurgical bond at the copper-aluminum interface; interface quality is inspected per the product control plan. Actual service life must be validated for the target application.
Can custom specifications be made?
Yes, we can customize various specifications including different wire diameters, copper layer ratios, and insulation requirements. MOQ can be negotiated based on specifications.
Which applications are suitable for CCA?
CCA is most suitable for selected cable, RF, communication, speaker, lightweight harness, motor winding and composite PV ribbon evaluation projects. Visit our CCA Application Guide for detailed suitability, risks and validation requirements.
Last Reviewed: July 2026
Specifications subject to change without notice Get Latest Datasheet