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Raytron Technical Review RESEARCH ARTICLE

Lifecycle Cost Analysis: CCA vs Copper

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-02-15

1. Introduction

1.1 total cost of ownershipcost

TCOincluding from to cost 。

Cost CompositionDecomposition Diagram

MEDIA TODO
Figure Fig. 1 Cost Composition Breakdown Chart

2. Cost

2.1 material cost

CCAmaterial cost as 36%。

3. CostAnalysis

4. Cost

5. Cost

6. TCO

Create TCOvs Curve

MEDIA TODO
Figure Fig. 2 TCO Comparison Curve

7. Case Studies

8. Conclusion

CCAin applications provides significant total cost of ownership,especiallyin cost sensitive and Weightsensitiveapplications 。

Figures

Cost CompositionDecomposition Diagram

Fig. 1 Cost CompositionDecomposition Diagram

Create TCOComparison Curve

Fig. 2 TCOComparison Curve

Tables

Table 1 TCO Framework
PhaseCu Cost FactorCCA Cost Factor
ProcurementMaterial CostLower Material Cost
InstallationWeight、TreatmentEasier Handling
OperationLossHigher Losses
MaintenancestandardsSimilar
Service LifeRecycling ValueLower Recycling Value
Table 2 Material Cost (March 2026)
MaterialPrice ($/ton)Density (g/cm³)Volume Cost ($/m³)
Copper8,8908.9679,700
Aluminum2,4502.706,600
CCA-62%Calculated3.63~29,000
Table 3 Cost Index Comparison
MaterialCost Index (Cu=1.0)
Copper1.00
CCA-62%0.36
CCA-70%0.42
CCA-80%0.55
Table 4 Case Study: 10km Cable
ItemCopperCCA-62%Savings
Material Cost$80,000$29,000$51,000
Installation Cost$15,000$12,000$3,000
20Year Loss$8,000$13,000-$5,000
TotalCost$103,000$54,000$49,000

References

  1. LME London Metal Exchange Historical Prices LME (2026)
  2. IEA Energy Efficiency Indicators IEA (2025)
XU

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

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

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Our technical team is the author of multiple Chinese national standards, with 30 years of industry experience and 34 patents, delivering professional bimetallic composite material solutions. Contact us for technical support and product quotes.

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