Raytron Technical Review RESEARCH ARTICLE cca-automotive

CCA in Automotive Applications: Weight Reduction Strategies

Gao-Lei Xu¹ *

¹RAYTRON Group Technology Research Center, China

^*Corresponding author

Received: 2025-12 Accepted: 2026-02 Published: 03/2026

DOI: 10.1234/raytron.2026.WP-02-07

1. Introduction

1.1 AutomotiveOverview

Automotive Wiring Harness Weight Distribution Diagram

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Figure Fig. 1 Automotive Wiring Harness Weight Distribution

1.2 CCAopportunity

CCAcan reduces Weight40-50%。

2. AutomotiveWeight ReductionDrivers

2.1 efficiency

Weight Reduction on Fuel Efficiency Impact Diagram

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Figure Fig. 2 Weight Reduction Impact on Fuel Efficiency

2.2 EV

3. regulatory requirements

4. Applications section

5. Thermal Considerations

6. EVSpecificApplications

7. Conclusion

CCAas AutomotiveSystemprovides significant opportunity ，especiallyin Electric Vehicleapplications 。

Frequently Asked Questions

How much weight can CCA save in automotive applications?

CCA can reduce wiring harness weight by 40-50% compared to copper. For a typical EV with 50-80 kg of copper wiring, this translates to 25-40 kg weight reduction.

What automotive standards apply to CCA wiring?

ISO 6722 governs low-voltage automotive cables internationally. SAE AS4395 applies to aerospace wire. Manufacturers must ensure CCA cables meet applicable temperature, mechanical, and electrical requirements.

Is CCA suitable for electric vehicles?

CCA is increasingly used in EVs for non-critical circuits, infotainment systems, and auxiliary wiring. High-current applications like battery connections typically require copper or aluminum, but many secondary circuits can use CCA.

What is the fuel efficiency impact of weight reduction?

Every 10 kg reduction typically saves approximately 0.1 L/100km in fuel consumption for ICE vehicles. For EVs, 50 kg weight reduction can extend range by 5-10 km.

Figures

Automotive Wiring Harness Weight Distribution Chart

Fig. 1 Automotive Wiring Harness Weight Distribution

Weight Reduction Impact on Fuel Efficiency Chart

Fig. 2 Weight Reduction Impact on Fuel Efficiency

Tables

Table 1 Automotive Wiring Harness Overview

Vehicle Type	Wire Length	CopperWeight
CompactTypeICE	1-2 km	15-25 kg
in TypeICE	2-3 km	25-40 kg
ICE	3-5 km	40-60 kg
ElectricAutomotive	4-8 km	50-80 kg

Table 2 CCAWeight ReductionPotentialForce

Material	Weight Reduction
CCA-62%	59% vs Cu
CCA-70%	55% vs Cu
CCAA-6101	50% vs Cu + MoreHigh strength

Table 3 Weight Reduction Benefit

Weight Reduction	Fuel Savings	Range Increase
10 kg	~0.1 L/100km	+1-2 km
50 kg	~0.5 L/100km	+5-10 km

Table 4 Automotivestandards

Standard	Scope	Region
ISO 6722	LowPress Cable	International
SAE AS4395	AerospaceWire	USNational
LV 112	NationalAutomotive	Europe

References

ISO ISO 6722: Road vehicles - Low tension cables ISO (2021)
SAE SAE AS4395: Aerospace Wire SAE (2020)

Authoritative References

ASTM International IEC (International Electrotechnical Commission) ISO (International Organization for Standardization) SAE International IEEE

Gaolei Xu

Senior Materials Scientist

Credentials & Honors

• CTO, Raytron Group
• Zhejiang Provincial High-level Talent Special Support Program - Young Talent
• Shaoxing "Technology Vice President"
• Shaoxing Science and Technology Commissioner
• Member of National Technical Committee 243 on Heavy Metals (SAC/TC 243/SC2)

National Standards (Lead Author) View Official

GB/T 27671-2011 - Copper Profiles for Electrical Conductors
YS/T 1043-2015 - Silver-bearing Oxygen-free Copper Strip for Motor Commutators
YS/T 974-2014 - Copper and Copper Alloy Strip for Composite Contact Materials
YS/T 1082-2015 - Copper Strip for Lamp Lead Stents

Patents (Inventor) Search Patents

CN104959396A - Production Process of Copper Strip for Composite Contact Materials
CN106077125A - Production Process of Copper Profile for Magnetic Pole Coils
CN201410710206 - Conductive Material for High-speed Railway Traction Motors and Production Method
CN201310719717 - Method for Controlling Strip Shape of Copper Strip Blank by Continuous Extrusion
CN201310720126 - Device for Controlling Strip Shape of Copper Strip Blank by Continuous Extrusion
CN201310376884 - Five-in-one Copper Strip Edge Treatment Equipment for Transformers
CN201420184755 - Continuous Extrusion Die Flow Promotion Device
CN201320761640 - Continuous Extrusion Waste Cleaning Device

Areas of Expertise

Copper-Clad Aluminum (CCA) Technology Copper-Clad Steel (CCS) Manufacturing Bimetallic Composite Materials PV Ribbon for Solar Cells Battery Tab Materials for EV Applications Continuous Extrusion Technology

Selected Publications

• Research and Application of Rolling Method for Manufacturing Metal Laminated Composites, Aluminum Processing Journal, 2008
• Annealing Process Research of Copper-Aluminum Composite Strip
• Research on Preparation Process of Copper/Aluminum Composite Strip for Cables
• Interface Microstructure Evolution of Rolled Copper/Aluminum Composite Strip During Annealing

Mr. Xu Gaolei is a distinguished expert in non-ferrous metal processing with over 15 years of experience. He is recognized as a Young Talent under the Zhejiang Provincial High-level Talent Special Support Program. He leads R&D initiatives in bimetallic composite technologies and has contributed significantly to the standardization of copper and bimetallic materials in China.

Click standard/patent codes to view official documents