Enameled Copper-Clad Aluminum Wire
Jingda enameled copper-clad aluminum wire is manufactured with a copper-clad aluminum conductor, combining a copper outer layer with a lightweight aluminum core to balance electrical performance, connection compatibility and weight reduction.
Specifications
Stable performance, lower weight and broad design compatibility — a practical route to reducing winding material cost.
| Conductor | Copper-clad aluminum: concentric copper layer metallurgically bonded over an aluminum core |
| Copper volume ratios | 10% (Cu:Al weight 3:7) · 15% (4:6) · 40% (7:3); custom ratios on request |
| Insulation options | Polyester(-imide) overcoated with polyamide-imide · Polyurethane · Customizable on request |
| Thermal classes | 200 °C · 180 °C · 155 °C |
| Minimum order quantity | 600 kg per type and per size |
| Customization | Other round copper-clad aluminum wire products can be customized to actual customer requirements |
Product Options
Two insulation systems are available as standard, covering thermal classes from 155 °C to 200 °C, each matched to specific motor and coil applications.
| Insulation type | Clase térmica | Characteristics | Main applications |
|---|---|---|---|
| Polyester(-imide) overcoated with polyamide-imide | 200 °C | High conductivity; excellent heat resistance; good mechanical strength of the insulation film | General industrial motor coils; special home-appliance motor coils |
| Poliuretano | 180 °C / 155 °C | High conductivity; directly solderable | Small motor coils; magnetic coils |
Beyond the two systems above, other round copper-clad aluminum wire products can be customized to your actual requirements.
Copper vs Aluminum vs CCA
Choosing a winding conductor? Here is how copper-clad aluminum (CCA) sits between solid copper and solid aluminum on conductivity, weight, solderability and cost.
| Propiedad | Copper (Cu) | Aluminum (Al) | Aluminio revestido de cobre (CCA) |
|---|---|---|---|
| Conductor | Solid copper | Solid aluminum | Copper shell metallurgically bonded over an aluminum core |
| Conductivity (% IACS) | 100% (benchmark) | ≈ 61% | ≈ 60–75% (rises with copper ratio; ≈ copper at high frequency via skin effect) |
| Density (g/cm³) | ≈ 8.9 | ≈ 2.7 | ≈ 3.6–6.5 (by copper volume ratio) |
| Weight vs copper, same size | Baseline (heaviest) | ≈ 30% of copper | ≈ 40–46% lighter than copper (10–15% Cu) |
| Soldabilidad | Excellent — directly solderable | Poor — oxide layer needs special flux / ultrasonic | Excellent — copper surface, directly solderable |
| Tensile strength (MPa) | ≈ 200–250 | ≈ 70–110 | ≈ 150–220 |
| Thermal class (heat resistance) | Set by the enamel, not the conductor — 155 / 180 / 200 / 220 °C available for all three | ||
| Relative material cost | Highest | Más bajo | Middle — typically 25–40% less than copper |
| Best suited to | High-efficiency, high-current motors where maximum conductivity is critical | Cost-driven large / low-frequency windings and large transformers | Weight- and cost-sensitive coils and high-frequency windings — voice coils, speakers, transformers, induction & deflection coils — that still need easy soldering |
Typical values; actual figures vary with alloy, temper and copper volume ratio. For DC applications, size CCA and aluminum by the required current rather than by copper-equivalent diameter. Contact Jingda engineers for exact data on your specification.
Structure & Copper Volume Ratios
The thickness of the copper cladding can be customized with different volume ratios: 10% (copper-to-aluminum weight ratio 3:7), 15% (4:6) and 40% (7:3). The 15% copper volume ratio is the most widely selected by customers, balancing cost reduction with current-carrying performance well above that of pure aluminum wire.
The appropriate ratio depends on the winding design and should be confirmed with our technical team for your application.
Manufacturing Process
From aluminum core to finished enameled wire, the conductor is built up in six controlled stages.
Aluminum Core
High-purity aluminum rod drawn to the required core dimension.
Copper Cladding
Copper layer metallurgically bonded concentrically over the aluminum core.
Copper-clad Aluminum Rods
Bonded bimetallic rod inspected for concentricity and copper-layer ratio before drawing.
Wire Drawing
The rod is drawn down through successive dies to the target conductor diameter.
Enamel Insulation
Enamel applied and cured in multiple passes to build the insulation film.
Surface Lubricant
Lubricant applied to support winding performance before spooling.
Campo de aplicación
Supplied as winding wire for motor and coil manufacturing. Typical applications and wire diameters:
Quality & Compliance
Frequently Asked Questions
Enameled copper clad aluminum (ECCA) wire is magnet wire whose conductor is an aluminum core clad with a metallurgically bonded copper layer, then coated with enamel insulation. The copper outer layer provides the connection compatibility and surface behavior of copper, while the aluminum core keeps the conductor lightweight.
Standard copper volume ratios are 10%, 15% and 40% by volume, corresponding to copper-to-aluminum weight ratios of 3:7, 4:6 and 7:3. The 15% ratio is the most widely selected by customers; other ratios can be customized on request.
The copper cladding gives ECCA wire better current-carrying performance than pure aluminum wire of the same dimension, while keeping the weight advantage of an aluminum core. The correct ratio for a given winding should be confirmed with the technical team.
For volume production of standard products, the minimum order quantity is 600 kg per type and per size. For special products, samples or trial orders, availability and commercial terms are confirmed case by case.
Yes. Beyond the two standard insulation systems, other round copper-clad aluminum wire products can be customized to actual customer requirements. Contact the engineering team to discuss your winding specification.
Request a Quote or Sample
Tell us your specification — a Jingda sales engineer will respond within 1 business day with a quotation or technical feedback.
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