fushi copperweld/dynext bimetallic conductors, cca and ccs...

Place of Business Corso Sempione, 169 20025 Legnano- Milano-Italy July 2013 1/ 9

Fushi Copperweld/Dynext bimetallic

conductors, CCA and CCS, alternative to Copper.

The companies

Fushi Copperweld Inc. (FCW) is the leading manufacturer and innovator of copper-clad bimetallic

engineered conductor products with facilities in USA, China, UK and Belgium.

Dynext S.r.l. based in Italy (Milan) is the sales and innovation center partner of FCW, a new venture,

arm of FCW for the European and North African market development.

Reference people at Dynext

Commercial Director, Antonio Pezzoni, e-mail [email protected]

Technical Director, Franco Peruzzotti, e-mail [email protected]

The products

Copper Clad Steel, CCS, 21%, 30%, 40% Copper conductivity (IACS=100 for Copper)

Copper Clad Aluminum, CCA, 10%, 15% of cross-section area is Copper,

(10% = IACS 63 ; 63% weight vs CU - 15% = IACS 65; 59% weight vs CU)

Copper Clad Aluminum/Magnesium, CCAM, 10% of cross-section area is Copper.

The products are available in rods, single wire and stranded conductors.

The process technology

A high tech and environmentally friendly process is used for manufacturing where a Copper flat

sheet is pressured over Al or Steel rod in Oxygen free conditions. The result is a high quality

permanent metallurgic bonding at the interface Al/Cu or Steel/Cu. This unique process allows

obtaining superior quality products compared to any galvanized/dipping process.


Copperlite™ CCA Process

Fushi Copperweld holds exclusive rights to this equipment design

Drawing CCA/CCS

due to the permanent metallurgic bonding, after drawing, the cross-section ratio between the

two metals will remain constant provided that this process will be carried out in the proper

conditions, adopting specific die design and a progressive reduction of the wire diameter to avoid

troubles at the interface of the two metals.

The service

Dynext is providing Technical and Commercial assistance to support new product solutions,

industrial development and qualification in addition to Die Design for drawing CCA.

Moreover Dynext can support customer to add value to his industrial scraps. Dynext will recover

the bimetallic scraps at customer’s plant and dealing with treatment from grinding, possible

separation from plastics/other non metallic materials, re-use in Aluminum/Copper alloy for special

applications.

Copperlite™, Copper Clad Aluminum, CCA

Key performance

Mechanical

– CCA shows higher flexibility and light weight vs Copper;

Skin effect

– High-Frequency (HF-AC) current density is greater near the outside surface of the wire

than at its center, the product is widely used for HF TLC cable;

Anti-theft

– The conductor cannot be easily recovered in the common metal reprocessing industry

generating less value for thieves;

Environmentally friendly


– compared to electrochemical process, metallurgic bonding is an environmentally

friendly process with low energy consumption, so that the products allow Carbon Foot

Print improvement;

Pricing

– lower in cost compared to solid copper.

Copperlite™ vs Copper, main advantage

MATERIAL DIAMETER AREA WEIGHT RESISTANCE WEIGHT SAVINGS vs Copper

mm mm 2 kg/km Ω/km %

Copper 1,129 1,00 8.94 17,149 0 CCA 10% 1,428 1,60 5.31 17,149 40

Copper wire replacement with CCA10% same Resistance requires:

60% higher cross-section

26% higher diameter

40% weight savings

Main current applications

CATV / Coax , Data cable, High Frequency

Telecom

– Telecommunication and CATV drop wire, coaxial cable, – To avoid theft trouble, a new Twisted pair aerial TLC cable in CCA has been

already introduced and is being currently used by Telecom Italia according to its

Spec. CT 948, Sept 2011


(see link http://www.telecomitalia.com/tit/it/archivio/media/note-stampa/market/2012/02-

28a.html and paper presented at IWCS 2012 Providence-USA “Anti-Theft” aerial TLC cable, using

Copperlite™ CCA conductor as an alternative to copper: Telecom Italia’s experience in its

infrastructure network”);

Utility, Low Voltage multi-polar cable, concentric neutral conductor in CCA alternative

to Copper, ENEL Spec. DC 4126, Aug 2010

ARG7(E4*)OCR-0,6/1 kV – AUG7(E4*)OCR-0,6/1 kV

3 central core conductors in Aluminum and CCA10% concentric neutral conductor

Screen Wire in Medium Voltage power cables

winding electrical engine, electrostatic valves,

Electronics

– fine wire down to 30-50 micron diameter,

Automotive, Flexible class 5 conductors


– Harness wire, signal wire, booster cables,

– Jumper/booster/starter cables,

Tracer wire

– for buried non-metallic such as fiber optics and plastic piping.

Enamelled magnet wire

Copperweld®, Copper Clad Steel, CCS

Key performance

Mechanical

– CCS shows higher strength and fatigue resistance, anti-corrosion vs Copper, the

product is widely used for grounding applications;

Skin effect

– High-Frequency AC current density is greater near the outside surface of the wire than

at its center, the product is widely used for grounding;

Anti-theft

– The conductor has intrinsic less value for thieves.

Main current applications

Utility and renewable energy

Grounding / lightning (earthing), transmission, distribution,

naked and insulated CCS stranded conductors, composite conductors, CCS and Copper.

(pls see some examples at bottom page)


Reference Utility using CCS.

REE- Madrid (RED ELECTRICA)

CAMO, new solution for grounding was developed to reduce Theft effect:

– Any single wire of the stranded conductor is covered by special coating and to show

different aspect than Copper of standard Copperweld® CCS.


Railway

– signal wire, pole and track ground, cables,

– catenary component for High Speed train, it was development of new products for drop

wire, CCS based, mechanical testing at Polytechnical University Milan and Fatigue

testing according to EN 50119 performed in independent laboratory showed exceeding

performance against Copper Magnesium 0.4% alloy conventional solution.


Copper

reference

CCS - equal

cross section

CCS - meets

fusing current CCS - matching resistance

50mm

2 50mm

2 7 Nr. 7 19 Nr. 9

Wire in the strand Nr. 7 7 7 19

Copper wire Nr. 7 - - -

CCS wire Nr. - 7 7 19

Single end Diameter mm 3 3 3.67 2.91

Conductor Diameter mm 9 9 11 14.5

Area Cu mm2 50 - - -

Area CCS mm2 - 50 74 126

Total Area mm2 50 50 74 126

Copper Weight kg/km 444.28 - - -

CCS Weight kg/km - 411.54 614.29 1037.6

Total Weight kg/km 444.28 411.54 614.29 1037.6

Copper Resistance Ohms/km 0.3519 - -

CCS Resistance Ohms/km - 0.8972 0.6013 0.3490

Total Resistance Ohms/km 0.3519 0.8972 0.6013 0.3490

I2t - Copper kA2.

sec 194.14 - -

I2t - CCS kA2.

sec - 87.23 194.34 565.82

Current duration Seconds 0.5 0.5 0.5 0.5

Short time current (Fusing) kA 19.7 13.21 19.7 33.64

Minimum Break Load Kgf 1033 1215 1814 3192

(calculation based on CCS 40% Low Carbon)

fushi copperweld/dynext bimetallic conductors, cca and ccs...

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