Engineering FAQ Guide
Copper-Clad Aluminum: Conductivity and Connection FAQ
What is Copper Clad Aluminum?
aluminum core with metallurgically bonded copper cladding.
Copper-clad aluminum combines an aluminum core with a bonded copper outer layer. Specify the copper proportion and how it is measured, the finished dimensions and the required resistance. Assess the terminal and cable construction together with the conductor.
Primary Applications
- lightweight cable
- coaxial cable
- selected windings
- automotive conductors
Critical RFQ Specifications
- copper ratio
- diameter
- conductivity
- tensile strength
- elongation
- surface condition
Selection
Can CCA be sized from copper diameter alone?
No. Start with measured or agreed material resistivity and the required length and resistance at the same temperature. Then check available space, termination, thermal conditions and the applicable product specification. Equal diameter does not imply equal resistance.
Specifications
How should the copper fraction be stated?
Identify whether copper content is by mass, volume or cross-sectional area, and specify the measurement or calculation basis. These percentages cannot be exchanged without accounting for the material construction.
Testing
What is needed to evaluate a connection?
Identify the terminal, conductor dimensions, crimp or joining method, current profile, moisture, temperature and flexing. Check the exposed end or cut surface and test the complete connection. If the drawing requires copper, obtain the specification owner’s approval for a change.