What are the Raw Materials Used in Manufacturing Wire and Cable?

Monday / 23 October 2023

Electric wires and cables are utilized for delivering electricity and energy to various destinations. An electric wire is comprised of two components: the conductor and the insulation. An electric cable is made from multiple wires housed within a protective cover. Now the pivotal question arises: what metals are used in manufacturing electric wires? Certain metals are utilized as conductors. Copper and aluminum are used for the conductor, and PVC is typically used for the wire insulation. The quality of these raw materials is paramount

Now the pivotal question arises: what metals are used in manufacturing electric wires? Certain metals are utilized as conductors. Copper and aluminum are used for the conductor, and PVC is typically used for the wire insulation. The quality of these raw materials is paramount
What are the Raw Materials Used in Manufacturing Electric Wires and Cables? 

What is an electric wire composed of? An electric wire is comprised of two components: the conductor and the insulation. The conductor is responsible for conducting electric currents and therefore is made of metal. The insulation is responsible for the containment of electrical flow and is crafted from polymer. Electric wire conductors are crafted from select metals, specifically, copper and aluminum.

What Metals Are Utilized in Manufacturing Electric Wires?
What metal is an electric wire composed of? Wire conductors are typically composed of copper and aluminum. Among these, copper sees the most utilization and is used with exceptional purity.
Copper is the primary raw material in electric wire and cable production. It is often used with a purity, surpassing 99.5%. The high purity mitigates the chemical reactions of impurities. Copper is resistant to atmospheric elements and is malleable which makes it easy to turn to the desired shapes.

Copper has a specific weight of 8.9 grams per cubic centimeter. These properties make Copper a preferred metal in electric wire and cable manufacturing.
Aluminum as a Conductor Material
Apart from copper, aluminum is also utilized in electric wire production. Aluminum is lighter and has a lower cost. Copper weighs three times more than aluminum, however, it boasts several advantages over aluminum. Aluminum is susceptible to humidity and weather changes; it tends to oxidize when in contact with humidity. This hinders the electrical conduction as aluminum oxide is an electric insulator.

Aluminum has a specific weight of 2.7 grams per cubic centimeter. Aluminum is not as flexible compared to copper. Aluminum is utilized in aviation due to its lightweight and cost-effectiveness.
Both copper and aluminum offer distinct advantages as electrical wire conductors. Aluminum is more lightweight and cost-effective. Copper is resistant to atmospheric changes and is highly flexibility which makes it easy to shape. In recent years, to address the existing concerns, aluminum wires are covered with a copper coating. This prevents oxidation, high wire costs, and high weights in wires. These wires are known as aluminum wires with a copper coating.

Advantages of Copper and Aluminum as Electrical Conductor Materials
In summary, we've discussed the metals utilized in electric wire production: copper and aluminum. Copper is recognized as the second-best electrical conductor after silver, and is used in electric wire and cable production due to the high cost of silver. Its characteristics make it ideal for use in electric wire conductors.

Properties like malleability, flexibility, and resistance to humidity and atmospheric elements make it ideal for electric wire production. Aluminum is an electrical conductor as well. It's lighter and more cost-effective compared to copper, however, it is susceptible to oxidation and has a lower flexibility. To address these issues, aluminum wires are covered with a copper coating, preventing aluminum oxidation.

Raw Materials for Insulating Coatings in Electrical Wires
The insulating coating of electric wires is crafted from Polyvinyl Chloride (PVC). It prevents electric current leakage in electric wires. PVC granules are packed in 25 kg bags and have an average specific weight of 1.5 grams per cubic centimeter.

Advantages of PVC for Electrical Wire Coating
PVC is an excellent electrical insulator. It is more efficient and cost-effective compared to traditional oil-based insulators and therefore has replaced them in the market. PVC is highly flexible, which makes it ideal for manufacturing electrical wires and cables.

PVC has a long lifespan and a lightweight composition, therefore, PVC-coated electrical wires are particularly suitable for the construction sector. They are widely settings such as indoor environments, industrial facilities, power plants, underwater, underground, etc., where there is no potential danger for damaging the wires.

Other Raw Materials Used in Electric Wire and Cable Production
As mentioned before, we know that electric wires are comprised of insulation and a conductor. In addition to metal for the conductor and PVC for the insulation, various other raw materials are utilized in electric wires and cables. These materials include Crossed Polyethylene (XLPE), galvanized wire, Polypropylene (PP) tape, wooden and iron spools, waterproof tape, and pigments for coloration.

In Conclusion
The raw materials used in electric wire and cable manufacturing fall into two categories: conductors and coatings. In addition to copper and aluminum for electric wire conductors and PVC for wire insulation, other materials are needed for the production as well. Aluminum wire with copper coatings is ideal for transferring electric currents due to its low weight, resistance to humidity, and cost-effectiveness. It is vital to procure raw materials for electric wire manufacturing from reputable sources and ensure their quality.