Solid Copper Wire is a single-conductor wire made from high-purity copper (≥ 99.9%), produced through continuous casting, rolling, and drawing. Unlike stranded wire, solid copper wire consists of one solid metallic core, providing lower electrical resistance, better dimensional stability, and long-term reliability in fixed installations.
It is commonly manufactured from ETP Copper (C11000), Oxygen-Free Copper (C10100 / C10200), or Electrolytic Tough Pitch copper.
Typical Chemical Composition
| Element | Typical % |
|---|---|
| Copper (Cu) | ≥ 99.9 |
| Oxygen (ETP Grade) | ≤ 0.04 |
| Phosphorus (DHP, if used) | 0.015 – 0.04 |
| Other Impurities | Trace |
Metallurgical Note:
Electrical conductivity is highly sensitive to impurities,
which is why strict control during refining is essential.
Key Physical Properties
| Property | Typical Value |
|---|---|
| Density | 8.96 g/cm³ |
| Melting Point | 1085°C |
| Electrical Conductivity | 97 – 101% IACS |
| Thermal Conductivity | ~390 – 400 W/m·K |
| Coefficient of Expansion | 16.5 × 10⁻⁶ /°C |
| Color | Reddish-brown |
| Magnetic | Non-magnetic |
| Corrosion Resistance | Excellent |
Key Mechanical Properties
| Property | Typical Range |
|---|---|
| Tensile Strength | 200 – 450 MPa |
| Yield Strength | 70 – 350 MPa |
| Elongation | 5 – 45% |
| Hardness | 40 – 120 HB |
| Modulus of Elasticity | ~110 GPa |
| Fatigue Resistance | Moderate |
Condition Matters:
Annealed wire offers maximum flexibility,
while hard-drawn wire provides higher strength and stiffness.
Strengthening & Metallurgical Behavior
✔ Single-phase FCC copper microstructure
✔ Uniform grain structure after annealing
✔ Strengthening by cold working (wire drawing)
✔ No precipitation or heat-hardening capability
Heat Treatment:
Annealing restores ductility and reduces electrical resistance;
recrystallization begins at approximately 200–300°C.
Refining & Processing Properties
✔ Copper cathodes produced via electrolytic refining
✔ Oxygen content controlled based on application (ETP vs OFC)
✔ Continuous casting → hot rolling → multi-stage cold drawing
✔ Excellent drawability, solderability, and brazability
✔ Poor machinability (not relevant for wire)
✔ Fully recyclable without property loss
Available Forms
Bare solid copper wire
Insulated solid copper wire (PVC, XLPE, PTFE)
Enamelled (magnet) wire
Tinned copper wire
Rectangular and square copper wire
Diameter range: 0.1 mm to 10+ mm
Key Characteristics
✔ Very low electrical resistance
✔ Stable conductor geometry
✔ Excellent heat dissipation
✔ High corrosion resistance
✔ Strong bonding with insulation
✔ Long service life
✔ Fire-safe performance (no creep like aluminum)
Applications of Solid Copper Wire
Electrical & Power
Residential and commercial wiring
Earthing and grounding systems
Distribution panels
Bus connections
Electronics
PCB tracks and jumpers
Transformer and inductor windings
Signal transmission
Industrial & Infrastructure
Control wiring
Instrumentation lines
Rail and power substations
Renewable Energy
Solar PV systems
Wind turbine electrical systems
Advantages of Solid Copper Wire
✔ Higher conductivity than aluminum
✔ Lower voltage drop
✔ Better thermal stability
✔ Stronger mechanical integrity
✔ Easier termination and clamping
✔ Reduced risk of loosening over time
✔ Long-term cost efficiency
Why Choose Solid Copper Wire?
Choose Solid Copper Wire when you require maximum electrical efficiency, reliable fixed installations, minimal maintenance, excellent heat dissipation, compliance with international electrical codes, and long service life.
Industry Rule:
For fixed wiring systems, solid copper wire offers the best balance
of safety, performance, and durability.
Solid vs Stranded Copper Wire
| Feature | Solid Copper | Stranded Copper |
|---|---|---|
| Conductivity | Slightly higher | Slightly lower |
| Flexibility | Low | High |
| Installation | Fixed | Dynamic / flexible |
| Cost | Lower | Higher |
| Durability | Very high | High |