Coated Copper Wire is a high-conductivity copper conductor covered with a protective or functional coating to enhance electrical insulation, corrosion resistance, thermal endurance, chemical stability, and mechanical durability.
Unlike bare copper wire, coated copper wire is engineered for safe, long-term operation in demanding electrical, thermal, and environmental conditions.
Common Coating Types
PVC
XLPE
PE / HDPE
PTFE (Teflon)
Polyurethane (PU)
Polyester / Polyesterimide
Enamel (magnet wire)
Tin, Nickel, or Silver plating (metallic coatings)
Typical Chemical Composition (Copper Core)
| Element | Typical % |
|---|---|
| Copper (Cu) | 99.90 – 99.99 |
| Oxygen | ≤ 0.04 (ETP) / Nil (OFC) |
| Phosphorus | Trace (if DHP) |
| Other elements | < 0.01 |
Physical Properties (Copper Conductor)
| Property | Typical Value |
|---|---|
| Density | 8.9 g/cm³ |
| Melting Point | 1085 °C |
| Electrical Conductivity | 97 – 101% IACS |
| Thermal Conductivity | ~390 W/m·K |
| Coefficient of Expansion | 16.5 × 10⁻⁶ /°C |
| Magnetic Behavior | Non-magnetic |
Mechanical Properties (Depending on Temper)
| Property | Typical Range |
|---|---|
| Tensile Strength | 200 – 460 MPa |
| Yield Strength | 70 – 400 MPa |
| Elongation | 10 – 45% |
| Hardness | 40 – 120 HV |
| Flex Fatigue Resistance | Excellent (annealed grades) |
Mechanical behavior depends on copper temper (annealed vs hard-drawn), type and thickness of coating, and operating temperature.
Strengthening & Metallurgical Behavior
Copper Core:
FCC crystal structure
Strength increased through cold working (wire drawing)
No precipitation hardening
Annealing restores ductility
Coating Behavior:
Polymer coatings provide insulation,
mechanical protection,
and thermal stability.
Metallic coatings (tin, nickel, silver) enhance
solderability, oxidation resistance,
and high-temperature performance.
Refining & Processing
Electrolytic refining produces high-purity copper cathodes, followed by continuous rod casting (CCR). Copper rods are drawn through multi-stage wire drawing, annealed if required, and coated using extrusion, enameling, or electroplating processes.
✔ Excellent drawability
✔ Uniform coating adhesion
✔ High production consistency
✔ Spark testing and quality inspections
Available Forms
Single-core coated copper wire
Multi-strand coated copper wire
Flexible cords
Magnet wire (enameled copper)
Tinned copper wire
Shielded and braided copper wire
Flat coated copper wire
Sizes: 0.05 mm to 50+ mm²
Supplied in spools, coils, or drums
Key Characteristics
✔ High electrical conductivity
✔ Excellent insulation reliability
✔ Corrosion and oxidation resistance
✔ Thermal endurance (up to 260 °C for PTFE)
✔ Excellent flexibility and bend life
✔ Chemical and moisture resistance
✔ Flame-retardant options available
Applications
Electrical & Power
Power cables, control panels,
switchgear wiring, transformers
Electronics
PCB connections,
magnet wire for motors,
data and signal cables
Automotive & EV
Wiring harnesses,
battery cables,
sensor wiring
Industrial & Renewable Energy
Solar cables,
wind turbine wiring,
robotics and automation
Specialized Uses
Aerospace wiring,
medical devices,
marine and offshore systems
Advantages
✔ Superior conductivity compared to aluminum
✔ Long service life
✔ Reduced electrical losses
✔ Enhanced safety and insulation
✔ Excellent solderability (plated wires)
✔ Wide operating temperature range
Why Choose Coated Copper Wire?
Coated copper wire is selected when reliable electrical performance, high current-carrying capacity, environmental and thermal protection, and long-term durability are required.
Engineering Insight:
Coated copper wire offers the best balance
of electrical efficiency, safety,
and durability for critical electrical systems.
Comparison: Coated vs Bare Copper Wire
| Property | Coated Copper | Bare Copper |
|---|---|---|
| Electrical Safety | ⭐⭐⭐⭐⭐ | ⭐⭐ |
| Corrosion Resistance | ⭐⭐⭐⭐⭐ | ⭐⭐ |
| Environmental Protection | ⭐⭐⭐⭐⭐ | ⭐ |
| Flexibility | ⭐⭐⭐⭐ | ⭐⭐⭐⭐ |
| Installation Safety | ⭐⭐⭐⭐⭐ | ⭐⭐ |