Custom Nickel Clad Copper Wire | High-Temperature & Corrosion-Resistant Conductor for Industrial & Aerospace Applications

Custom Nickel Clad Copper Wire

Einführung

1. Nickel Clad Copper Wire is a high-performance bimetallic conductor featuring a thick, continuous nickel layer metallurgically bonded to a high-purity copper core. Unlike standard nickel-plated wire, the “clad” process creates a much heavier and more uniform nickel barrier that remains stable even under extreme mechanical stress and thermal cycling. This material combines the superior electrical and thermal conductivity of copper with the exceptional oxidation and corrosion resistance of nickel, making it the premier choice for applications in aerospace, military electronics, and harsh industrial environments where temperatures reach up to 600°C.

2. We offer fully customizable Nickel Clad Copper Wire tailored to your specific technical requirements, including a variety of cladding ratios (commonly 10%, 20%, and 27% by weight) and wire diameters. Our wire is engineered for excellent solderability, weldability, and mechanical durability, ensuring stable electrical performance in heating elements, high-temperature cables, lead wires for sensors, and oil-and-gas exploration equipment. All products are manufactured to meet rigorous industry standards (such as ASTM B355), providing consistent resistance and long-term reliability for your most demanding engineering projects.

   Spezifikationen

   Typ	Nickel-Clad Copper (NCC) Wire / High-Temperature Conductor / Bimetallic Wire
   Structure	High-purity copper core with a thick, metallurgically bonded nickel cladding (not electrolytic plating)
   Material Grade	Core: Oxygen-Free High Conductivity (OFHC) Copper (C10100/C10200) or ETP Copper (C11000) Clad: Nickel 200/201 (99.0% minimum purity)
   Cladding Ratio	Customizable by weight: Standard ratios include 10%, 20%, and 27% (The 27% ratio is most common for extreme high-temp use)
   Electrical Conductivity	High conductivity typically ranging from 70% to 90% IACS (International Annealed Copper Standard), depending on the cladding thickness
   High Temperature Limit	Suitable for continuous operation at 450°C to 600°C (842°F to 1112°F); maintains structural integrity during thermal cycling
   Formular	Round wire, flat wire (ribbon), stranded wire, or braided shield wire
   Diameter Range	Standard: 0.05 mm to 5.0 mm (AWG 44 to AWG 4); custom fine wire and heavy gauge sizes available
   Temper	Annealed (Soft), Half-Hard, or Full-Hard depending on the mechanical requirements of the application
   Bonding Quality	Continuous, non-porous metallurgical bond; will not flake, peel, or delaminate during drawing, bending, or high-speed stranding
   Surface Finish	Bright, smooth, and clean; silver-like appearance with excellent oxidation resistance in atmospheric conditions
   Corrosion Resistance	Superior resistance to salt spray, humidity, oxidation, and various chemical agents compared to silver-plated or tin-plated copper
   Weldability & Joining	Excellent for ultrasonic welding, laser welding, and crimping; can be soldered using specialized high-temperature flux
   Mechanical Properties	Combines the ductility of copper with the surface hardness and toughness of nickel; resistant to mechanical wear and abrasion
   Dimensional Tolerances	Tight diameter control (typically within ±0.001mm to ±0.01mm) for precision electronic and aerospace components
   Standards & Reference	Manufactured in accordance with ASTM B355 (Standard Specification for Nickel-Coated Soft or Annealed Copper Wire) and relevant military/aerospace specs
   Application Range	Aerospace & Defense wiring, Lead wires for high-temp sensors/thermocouples, Heating elements, Lead-in wires for lamps/vacuum tubes, Oil & Gas downhole cables, and Industrial ovens
   Processing Capability	Supports high-speed wire drawing, stranding, cabling, braiding, and over-insulating (with PTFE, PFA, or Ceramic fibers)
   Customization	Tailored cladding thickness (2%–30%), specific core materials, custom diameters, and stranded configurations (e.g., 7-strand, 19-strand)
   Packaging	Supplied on precision spools (DIN, PT, or customized), coils, or pails; vacuum-sealed or moisture-proof packaging available

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