Titanium-Clad Copper (Ti-Cu) wire is a bimetallic conductor consisting of a high-conductivity copper core metallurgically bonded to an outer layer of titanium. This design combines copper’s electrical and thermal performance with titanium’s exceptional corrosion resistance, chemical inertness, and strength-to-weight ratio.
Ti-clad copper is engineered for extreme environments where pure copper would corrode, but where full titanium conductors would be too resistive or costly.
Structural Composition
| Component | Typical % (by volume) |
|---|---|
| Copper Core (ETP or OFC) | 85 – 95% |
| Titanium Cladding (Grade 1 or 2) | 5 – 15% |
Note:
Titanium-clad copper wire is defined by its layered structure, not alloying.
Key Physical Properties
| Property | Typical Value |
|---|---|
| Density | ~8.0 – 8.5 g/cm³ |
| Melting Point | Cu: 1085°C / Ti: 1668°C |
| Electrical Conductivity | 80 – 95% IACS |
| Thermal Conductivity | ~300 – 380 W/m·K |
| Coefficient of Expansion | ~15 × 10⁻⁶ /°C |
| Magnetic Behavior | Non-magnetic |
| Corrosion Resistance | Exceptional |
Electrical current flows primarily through the copper core, keeping conductivity close to that of pure copper.
Key Mechanical Properties
| Property | Typical Range |
|---|---|
| Tensile Strength | 350 – 600 MPa |
| Yield Strength | 250 – 450 MPa |
| Elongation | 10 – 25% |
| Hardness | 120 – 220 HV |
| Fatigue Resistance | Very Good |
| Creep Resistance | Excellent |
Mechanical performance benefits from titanium’s surface strength combined with copper’s ductility.
Strengthening & Metallurgical Behavior
✔ Copper core with FCC crystal structure
✔ Titanium cladding with HCP crystal structure
✔ No Cu–Ti alloying
✔ Bond achieved via solid-state diffusion or explosion bonding
✔ No precipitation or age hardening
Key Advantage:
Titanium naturally forms a self-healing TiO₂ oxide film,
providing long-term corrosion protection.
Key Characteristics of Titanium-Clad Copper Wire
✔ Near-copper electrical conductivity
✔ Outstanding resistance to acids, seawater, and chlorides
✔ Excellent galvanic corrosion resistance
✔ High-temperature and oxidation resistance
✔ Non-magnetic and non-sparking
✔ Extremely long service life in harsh environments
Limitations:
Higher cost than CCA or CCS
More complex termination methods
Limited global supplier base
Refining & Processing Properties
✔ High-purity copper rod preparation
✔ Titanium tube or strip cladding
✔ Bonding by explosion bonding, hot roll bonding, or diffusion bonding
✔ Wire drawing and controlled stress-relief annealing
✔ Extremely strong Cu–Ti interface
✔ No delamination under thermal cycling
Available Forms
Round wire
Stranded titanium-clad copper wire
Bus wire
Electrochemical anode wire
Custom profiles
Size range: 0.5 mm to 12+ mm (coils, spools, or drums)
Applications of Titanium-Clad Copper Wire
Chemical & Electrochemical
Electrolysis electrodes
Cathodic protection systems
Chlor-alkali plants
Marine & Offshore
Seawater grounding systems
Offshore platform wiring
Subsea corrosion-resistant conductors
Power & Infrastructure
Corrosion-resistant earthing
Coastal and high-salinity installations
Aerospace & Defense
Harsh-environment electrical systems
Lightweight corrosion-proof conductors
Renewable Energy
Offshore wind grounding
Tidal and wave energy systems
Advantages of Titanium-Clad Copper Wire
✔ Copper conductivity with titanium durability
✔ No coating degradation or peeling
✔ Reduced maintenance and downtime
✔ Long-term electrical stability
✔ Excellent lifecycle economics in harsh environments
Why Choose Titanium-Clad Copper Wire?
Choose Ti-clad copper wire when you need copper-level conductivity in corrosive environments, long-term reliability in seawater or chemicals, and superior lifecycle performance compared to plated conductors.
Engineering Recommendation:
When pure copper corrodes and stainless steel lacks conductivity,
titanium-clad copper is the optimal engineering solution.
Comparison with Other Clad Conductors
| Property | Ti-Clad Cu | CCS | CCA | Pure Cu |
|---|---|---|---|---|
| Conductivity | ★★★★ | ★★ | ★★★ | ★★★★★ |
| Corrosion Resistance | ★★★★★ | ★★★★ | ★★★ | ★★★ |
| Mechanical Strength | ★★★★ | ★★★★★ | ★★ | ★★★ |
| Weight | ★★★ | ★★★ | ★★★★ | ★★ |
| Lifecycle Cost | ★★★★★ | ★★★★ | ★★★ | ★★★ |
Sustainability & Lifecycle
✔ Extremely long service life reduces replacement
✔ Lower copper consumption than solid copper
✔ Recyclable with material separation
✔ Ideal for low-maintenance installations