Nickel-Plated Copper Wire consists of a high-conductivity copper core uniformly coated with a thin, continuous layer of nickel. The nickel layer protects the surface, while the copper core provides excellent electrical and thermal conductivity.
This wire is specifically engineered for high-temperature, corrosive, and oxidative environments where bare copper would degrade rapidly.
Typical Structural Composition
| Component | Typical % |
|---|---|
| Copper core (ETP / OFC) | 98 – 99.5 |
| Nickel coating | 0.5 – 2.0 (by weight equivalent) |
Physical Properties
| Property | Typical Value |
|---|---|
| Density | ~8.9 g/cm³ |
| Melting Point | Copper 1085 °C / Nickel 1455 °C |
| Electrical Conductivity | 90 – 98% IACS |
| Electrical Resistivity | ~1.7 – 1.9 μΩ·cm |
| Thermal Conductivity | ~350 – 390 W/m·K |
| Coefficient of Expansion | ~16.5 × 10⁻⁶ /°C |
| Magnetic Behavior | Slightly magnetic (Ni layer) |
| Oxidation Resistance | Excellent |
Conductivity reduction is minimal compared to bare copper.
Mechanical Properties
| Property | Typical Range |
|---|---|
| Tensile Strength | 200 – 450 MPa |
| Yield Strength | 70 – 400 MPa |
| Elongation | 10 – 40% |
| Hardness | 60 – 150 HV |
| Fatigue Resistance | Very good |
| Wear Resistance | Excellent (Ni surface) |
Strengthening & Metallurgical Behavior
Copper core and nickel coating both exhibit FCC crystal structures. A strong metallurgical bond is achieved via electroplating or chemical deposition.
Strengthening occurs through cold working during wire drawing. The nickel layer adds surface hardness, wear resistance, and oxidation stability.
❌ No precipitation or age hardening involved.
Key Characteristics
✔ High electrical conductivity
✔ Outstanding oxidation and corrosion resistance
✔ Excellent high-temperature performance
✔ Superior long-term solderability
✔ Improved wear and abrasion resistance
✔ Compatible with aggressive environments
✔ Long shelf life without surface degradation
Refining & Processing
Electrolytically refined copper is drawn to wire, annealed if required, and nickel electroplated to controlled thickness. Final drawing and inspection ensure adhesion and uniformity.
✔ Uniform coating thickness
✔ Strong nickel-copper adhesion
✔ Coating remains intact during bending
✔ Stable high-volume production
Available Forms
Solid round wire
Stranded wire
Fine and ultra-fine wire
Nickel-plated magnet wire
Braided conductors
Flat and shaped wire (limited)
Sizes range from 0.02 mm to 10+ mm, supplied in spools, coils, or drums.
Applications
High-Temperature Electrical Systems
Furnace wiring, heating elements, thermal sensors
Aerospace & Defense
Aircraft wiring, avionics systems,
space-grade conductors
Oil, Gas & Chemical
Downhole instrumentation,
corrosive atmosphere wiring,
refineries
Automotive & EV
Engine compartment wiring,
exhaust sensors,
high-temperature harnesses
Electronics & Power
Transformer leads,
high-reliability connectors,
switchgear wiring
Advantages
✔ Operates up to 260 – 450 °C (insulation dependent)
✔ Prevents copper oxidation and sulfide formation
✔ Maintains solderability over long periods
✔ Higher wear resistance than tin-plated copper
✔ Stable performance in harsh conditions
Why Choose Nickel-Plated Copper Wire?
Nickel-plated copper wire is selected when applications demand high-temperature reliability, oxidation resistance, long-term solderability, and corrosion protection without sacrificing conductivity.
Engineering Recommendation:
When tin-plated copper fails at high temperatures
and bare copper oxidizes,
nickel-plated copper is the preferred solution.
Comparison with Other Copper Wires
| Property | Ni-Plated Cu | Tin-Plated Cu | Bare Cu |
|---|---|---|---|
| High-Temp Resistance | ⭐⭐⭐⭐⭐ | ⭐⭐⭐ | ⭐⭐ |
| Oxidation Resistance | ⭐⭐⭐⭐⭐ | ⭐⭐⭐⭐ | ⭐⭐ |
| Conductivity | ⭐⭐⭐⭐ | ⭐⭐⭐⭐ | ⭐⭐⭐⭐⭐ |
| Wear Resistance | ⭐⭐⭐⭐⭐ | ⭐⭐⭐ | ⭐⭐ |
| Cost | ⭐⭐⭐ | ⭐⭐⭐⭐ | ⭐⭐⭐⭐⭐ |
Sustainability & Lifecycle
Copper core is fully recyclable
Nickel layer does not impair recycling
Extended service life reduces material waste
Lower maintenance frequency