Electric Cable

The materials used for cable conductors are selected based on their electrical conductivity, durability, and suitability for specific applications. This is often the first step in cable manufacturing, after cable design. Here are the most common materials:

Copper
The most widely used material for electrical cable conductors, copper is highly conductive, ductile and durable, making it ideal for both power and communication cables. It is also resistant to corrosion, ensuring a long lifespan for the cables.

Aluminium
Lighter and less expensive than copper, aluminium is also commonly used as a conductor – especially in power transmission lines and overhead cables. Although it has lower conductivity than copper, aluminium’s reduced weight makes it easier to handle and install, especially in larger gauges.

Silver
Silver has the highest electrical conductivity of all metals, but its high cost limits its use to specialised applications, such as in high-frequency equipment, satellites, and military technology. Silver-plated copper conductors are often used in these settings to reduce costs while improving conductivity.

Gold
Although not commonly used for bulk conductors, gold is used in connectors and specialised components due to its excellent conductivity and resistance to oxidation, which helps maintain long-term performance in high-reliability applications.

Tinned Copper
Copper conductors are sometimes coated with a thin layer of tin to increase corrosion resistance, particularly in wet or humid environments. Tinned copper is commonly used in marine cables and outdoor cables.

Nickel-plated Copper
For high-temperature applications, nickel-plated copper is used as it withstands higher temperatures and provides good oxidation resistance. It is typically found in heating elements and high-heat industrial applications.

Alloys
Some specialised cables use copper or aluminium alloys that offer a balance of mechanical strength and conductivity. These alloys can improve flexibility, corrosion resistance, or other properties specific to the application.