Copper Wire

Copper bare
As indicated by the name, bare copper does not have any coating. Bare copper wire has excellent conductive properties, high strength, good ductility, malleability, and creep resistance, making bare copper conductors ideal for applications in electrical transmission, jumpers, grounding electrical systems, electrical hookups, and electrical appliances.

Copper tin plated
This is uninsulated copper wire coated with a thin layer of tin to protect against oxidation. A tin-plated copper wire has exceptional conductivity, weldability, and resistance to corrosive environments and is suitable for water treatment, desalination, power generation, and chemical processing applications.

Copper wire plated with nickel or silver
This copper alloy conductor is often used in aerospace, defense, petrochemical, nuclear, and medical applications.

Oxygen-free copper wire
Can be bare or plated. This is a top-grade type of copper wire that’s been refined in an electrically charged solution of copper sulfate and sulfuric acid, causing the copper to have an exceptionally low oxygen level (0.001%). Oxygen-free copper wire offers high thermal and electrical conductivity, great corrosion resistance and solderability, and higher temperature resistance, recrystallization, and workability making it suitable for applications that demand high durability and accuracy.

Copper clad steel
This type of wire combines the high tensile strength of steel as its core and the conductive properties of copper as its outer layer. Common applications of copper-clad steel wire include temperature measuring instruments, medical products, motors, intelligent pressure, hardware, magnetic assemblies, and power supplies.

Copper clad aluminum
With an aluminum core and an external layer of copper, copper-clad aluminum is a more affordable alternative to pure copper wire. Cca possesses increased strength compared to copper and enhanced conductivity compared to aluminum.

Copper alloy
Conductor made of copper alloy might include different chemical elements, which define the properties of the final product – copper alloy wire. Here are a few examples of copper alloys: Zirconium, beryllium, chromium, cadmium, brass and bronze. Application and requirements for strength, solderability, durability, and insulation define which copper alloy conductor to utilize.

Drawing process
Take ec grade continuous cast copper rod of 8 mm diameter, for drawing on our wire into different gauge wires. In this process of drawing copper wires, we use the best quality diamond dies to get the finest results out of it. The rod and dies are put into a coolant and are proofed with an industrial lubricant. This helps us maintain the temperatures and carry the drawing process in a controlled manner. Here we make sure that the copper coils get the best of treatment to reach the best of its utility in industrial applications.

Annealing process
After the drawing operation is over the coils of the drawn wire are put into an electric furnace in a pot to remove the internal stresses and increase the toughness of it. This process is called annealing. We pass an electrical current through the wire for a second at a temperature of 1000ofv. This is a very precise and controlled operation. Annealing is performed using water and in the process, it is made sure that no oxidation takes place or otherwise it could overheat and burn the coil.

Bunching / stranding process
After the wires are annealed, it is wound on reels and are put for bunching/ stranding on the wire stranding machines to process them into the different size range of twisted wires. These are then passed through nozzling process to get a smoother surface. Here, we strand two different wires following a proprietary formula and the twist length can vary anywhere from two to seven inches. Our bunching process follows the finest of ergonomic techniques and the latest tools to make it achieve optimum quality in time.

Braiding
Taking it to the braided finishing touch is the next task. In this attempt, the tinned copper wire is put into the braiding machine to get different sizes of braided wires as per specifications. In the process it adopts a new appearance forming different patterns being braided into single or multiple-thread layers. Here we apply high quality braiding techniques and practices to get the best results. Built with the copper with high conductive ratio and great durability, it can be used as a flexible conductor in electric appliances and storage batteries.

Process for tinsel wire
Fine gauge copper wire duly wound on reels is put on flattening machine for getting it flattened. After this process the wire is put on lapping machine for getting lapping of nylon thread. After this process is complete, the wire is put on braiding / twisting machine for braiding of wire to required size and then the wire is processed for chemical coating on required machine.

Process of glass wire
Tinned copper wire bunching is done on bunching machine and then the wire is put on lapping machine for lapping of pp. After this process is over the wire is put on braiding machine for braiding of fiber glass coating and hen put on the machine for varnish coating on the wire.

Preparing the oxide cleaner
The best chemical to clean copper wiring would be acetic acid, and the best news is that it is readily available in every household, better known as vinegar. Any type of vinegar is good to do this, from white, or balsamic, or rice vinegar and combined with salt, another common ingredient. When you dip the exposed wire into such a solution, the acid from the vinegar strips the patina from the copper while the salt provides the abrasion necessary to remove the grime.

Along with those products, you will need at least two containers made of plastic, glass, or paper such as paper cups, one container to be put aside for the next chemical solution.

Begin with putting one tablespoon of salt in the first container and fill the rest with the vinegar while stirring the solution together. While stirring, you should then add as much salt to the container as the solution will dissolve.

Preparing the neutralizer
The other solution needed is sodium bicarbonate, another very common household product known as baking soda mixed with water. This second solution besides further cleaning the wires will be used to neutralize the corrosive properties of the vinegar solution and to further clean the wires. Without neutralizing the effects of the vinegar solution, the wires would soon oxidize again.

Put one tablespoon of sodium bicarbonate in the second container then finish filling with water while stirring together. You can then add more baking soda to the mix while stirring as the mixture becomes more cloudy and alkaline as it is needed to cancel the acidic reaction of the vinegar solution.

Cleaning the wire
Dip the end of the wire or wires in the vinegar solution, making sure the stripped exposed copper is completely submerged into the solution while stirring the solution with the wire to speed up the process. Only the portion of the wires under the solution will be cleaned.

The wire will become very shiny after a couple of minutes in the solution as the oxides are removed by the acidic solution and exposing the bare copper. You might need to keep stirring the wire in the solution longer until it becomes uniformly shiny.

Neutralizing the acid
After the wire becomes uniformly shiny inside the container, you can pull it out of that container and submerge the copper completely inside the neutralizing solution. Stir in that solution for 10 or 15 seconds for the neutralizing action of the baking soda to take effect against the acid's corrosive properties and you're done! Your wire is now shiny again and ready for use.