Any advantages to cheap copper coated steel/alloy wire?

Any advantages to cheap copper coated steel/alloy wire?

Exploring the advantages and disadvantages of cheap copper-coated steel or alloy wire, focusing on magnetic distortion effects and practical applications in various industries.

Overview of Magnetic Distortion

Distortion 9: Magnetic Distortion typically occurs when a signal at amplifier output level passes through a ferromagnetic conductor. Such materials exhibit a nonlinear relationship between the current flowing through them and the magnetic flux they generate, which induces voltages that distort the signal. This phenomenon is most commonly seen in output relays, where signals pass through the soft-iron frame, a part of the magnetic circuit. Detailed exploration of this can be found in Chapter 17 of the Audio Power Amplifier Design Handbook by Douglas Self.

The issue has also been identified in loudspeaker terminals. A case in point involved a set of gold-plated terminals, which worked well during the prototype phase, but during mass production, they exhibited unforeseen third-harmonic distortion. Investigations revealed that the terminals, initially made from gold-plated brass, were substituted with gold-plated steel—a significantly cheaper material. With steel, the nonlinear magnetic effects caused output distortion to nearly double, from 0.00120% to 0.00227% at 100W into 8R at 1kHz.

This rise in distortion could be overlooked in amplifiers with intrinsically higher distortion levels, as the nonlinearity would blend into the background noise. The presence of steel instead of brass can be easily identified with a small magnet, ensuring quality control in manufacturing.

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Enameled Copper Clad Steel Winding Magnetic Wire: Uses and Specifications

The use of enameled copper-clad aluminum wire is expanding across various industries due to its unique properties. These wires are commonly applied in motors, high-frequency transformers, inductors, voice coils, and other electromagnetic coils. Some specific applications include:

• Small transformers, linear motors, relays, solenoids, small motors, clock coils, and speakers
• Automotive sensors and ignition coils
• Generators, both dry-type and oil-immersed
• Military and space technologies

Advantages of Enameled Copper Clad Aluminum Wire

Enameled CCA wire boasts numerous benefits, such as excellent thermal stability, high resistance to abrasion, strong chemical resistance to solvents and coolants, and better sliding capabilities during coil insertion. The lightweight aluminum core combined with a copper layer not only ensures good conductivity but also reduces the material's tendency to oxidize, thereby extending its life and reducing costs.

Manufacturing Process and Quality Control

Our company utilizes over 100 high-speed drawing machines, vacuum tube annealing stoves, and enameled machines to produce enameled CCA wire. We also employ advanced testing equipment, including solderability test instruments, automatic spring-back angle test instruments, and dielectric loss test devices to maintain high-quality standards throughout the manufacturing process.

Product Models and Certificates

We offer a variety of models, such as 130°C PEWAL, 155°C UEWAL, and 180°C/200°C EIWAL, all adhering to global quality standards and possessing UL certification.

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Comprehensive Quality Assurance in Manufacturing

Our factory has implemented rigorous quality control measures, with a dedicated QC department staffed by five inspection personnel. These experts oversee the entire process, from raw material inspection to finished product evaluation. We maintain a strict quality control protocol, including full inspections for each wire reel.

Your satisfaction is our priority. We offer short, timely delivery, professional after-sales service, and the ability to customize products as per your requirements. Being a factory, we provide competitive pricing without compromising on quality.

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