{"id":5225,"date":"2023-04-18T09:34:51","date_gmt":"2023-04-18T09:34:51","guid":{"rendered":"https:\/\/wiretroop.com\/?p=5225"},"modified":"2023-04-19T14:04:06","modified_gmt":"2023-04-19T14:04:06","slug":"wire-conductors","status":"publish","type":"post","link":"https:\/\/wiretroop.com\/wire-conductors\/","title":{"rendered":"\u00a0Wire Conductors: An ultimate guide on their plating"},"content":{"rendered":"\n<p><strong>Wire conductors <\/strong>are essential <a href=\"https:\/\/www.wiringo.com\/automobile-wire-harness.html\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">wire harness<\/a> components, often requiring coatings to improve their solderability and electrical properties at high frequencies.<\/p>\n\n\n\n<p> This article covers everything about coating wire conductors. <\/p>\n\n\n\n<p>Let&#8217;s get started!<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Types of wire conductors<\/h2>\n\n\n\n<p>Here are the different types of wire conductors;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Silver<\/h3>\n\n\n\n<p>Silver has the best conductivity but is expensive. So we often use it as a coating for copper to improve skin conductivity and offer some protection against corrosion.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Copper<\/h3>\n\n\n\n<p><a href=\"https:\/\/en.wikipedia.org\/wiki\/Copper_conductor\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Copper\u2019s conductivity<\/a> is second only to silver, and it is more economical, plentiful, and ideal for pressure crimping (termination, etc.) with breakthrough surface oxidation.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"664\" src=\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/1-20.jpg\" alt=\"Soldering tin wire\" class=\"wp-image-5228\" srcset=\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/1-20.jpg 1000w, https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/1-20-300x199.jpg 300w, https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/1-20-768x510.jpg 768w\" sizes=\"(max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n\n\n\n<p>Copper wire<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Aluminum<\/h3>\n\n\n\n<p>Aluminum has poor conductivity, making it difficult to sell or plate it while improving its solderability.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Copper-covered steel<\/h3>\n\n\n\n<p>This type of wire conductor combines the following;<\/p>\n\n\n\n<ul>\n<li>Strength of steel with the corrosion resistance<\/li>\n\n\n\n<li>Conductivity of copper<\/li>\n<\/ul>\n\n\n\n<p>Copper-covered steel can be either of the following;<\/p>\n\n\n\n<ul>\n<li><strong>Type 1<\/strong>: Molten welding permanently bonds copper and steel<\/li>\n\n\n\n<li><strong>Type 2:<\/strong> A copper layer electroplated over a steel rod<\/li>\n\n\n\n<li><strong>Type 3:<\/strong> The steel rod and copper metallurgically bonded<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">High-strength copper alloy<\/h3>\n\n\n\n<p>The most common high-strength copper alloys are;<\/p>\n\n\n\n<ul>\n<li>Chromium copper<\/li>\n\n\n\n<li>Cadmium copper<\/li>\n\n\n\n<li>Zirconium Copper<\/li>\n\n\n\n<li>Cadmium-chromium copper<\/li>\n<\/ul>\n\n\n\n<p>Their ideal application areas include;<\/p>\n\n\n\n<ul>\n<li>Aerospace wires and cables applications<\/li>\n\n\n\n<li>Computer wires and cables applications<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Stainless steel<\/h3>\n\n\n\n<p>These wire conductors have worse conductivity than copper. <\/p>\n\n\n\n<p>However, gold-plating ones may improve their conductivity and make them ideal application areas, including medical lead cables and wires.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Tinned copper\/ tin-coated copper wire conductors<\/h3>\n\n\n\n<p>Tin protects a copper conductor from corrosion without affecting its conductivity. <\/p>\n\n\n\n<p>Also, It is eminently solderable. <\/p>\n\n\n\n<p>A \u201ctinned\u201d conductor usually means one coated with a lead-tin alloy \u2014 a solder.<\/p>\n\n\n\n<p>Tinned copper wire conductors are ideal for the following applications;<\/p>\n\n\n\n<ul>\n<li>Solder-dipping of stripped lead<\/li>\n\n\n\n<li>Manual twisting of the stripped lead<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"999\" height=\"667\" src=\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/2-19.jpg\" alt=\"Soldering tin wire\" class=\"wp-image-5227\" srcset=\"https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/2-19.jpg 999w, https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/2-19-300x200.jpg 300w, https:\/\/wiretroop.com\/wp-content\/uploads\/2023\/04\/2-19-768x513.jpg 768w\" sizes=\"(max-width: 999px) 100vw, 999px\" \/><\/figure>\n\n\n\n<p class=\"has-text-align-center\">Soldering tin wire<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Silver-coated copper\/silver-plated copper electrical wire conductors<\/h3>\n\n\n\n<p>These wire conductors are ideal for;<\/p>\n\n\n\n<ul>\n<li>High-frequency applications where higher conductivity is desirable<\/li>\n\n\n\n<li>Wires operating between 150 degrees Celsius to 200 degrees Celsius<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Nickel-coated copper\/nickel-plated wire conductors<\/h3>\n\n\n\n<p>\u201cNickel coated\u201d refers to a much thicker plating, and you can use them where silver plating is objectionable due to possible solder wicking.<\/p>\n\n\n\n<p>The table below compares different conducting materials.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table><tbody><tr><td colspan=\"2\"><\/td><td colspan=\"3\">For 30 AWG Wire<\/td><td colspan=\"2\"><\/td><td colspan=\"2\">Temperature Coefficient<sup>2<\/sup><\/td><\/tr><tr><td><\/td><td>Relative Resistance<\/td><td>Lbs per 100 ft.<\/td><td>Ohms per 1000 ft.<\/td><td>\u201cOhm-Lbs<sup>-1 <\/sup>per 1000 ft.<\/td><td>Specific Gravity<\/td><td>Melting Point (degree Celsius)<\/td><td>Change in temperature % per degree Celsius<\/td><td>Change in resistance per degree Celsius<\/td><\/tr><tr><td>Copper<\/td><td>1<\/td><td>0.304<\/td><td>103<\/td><td>31.4<\/td><td>8.89<\/td><td>1083<\/td><td>61.1<\/td><td>0.0039<\/td><\/tr><tr><td>Aluminum<\/td><td>1.64<\/td><td>0.092<\/td><td>169<\/td><td>15.6<\/td><td>2.7<\/td><td>660<\/td><td>28.7<\/td><td>0.0039<\/td><\/tr><tr><td>Silver<\/td><td>0.94<\/td><td>0.359<\/td><td>97<\/td><td>34.9<\/td><td>10.5<\/td><td>961<\/td><td>18.8<\/td><td>0.0038<\/td><\/tr><tr><td>Gold<\/td><td>1.42<\/td><td>0.661<\/td><td>146<\/td><td>96.6<\/td><td>19.32<\/td><td>1063<\/td><td>14.3<\/td><td>0.0034<\/td><\/tr><tr><td>Tin<\/td><td>0.67<\/td><td>0.25<\/td><td>691<\/td><td>172.7<\/td><td>7.3<\/td><td>232<\/td><td>26.9<\/td><td>0.0042<\/td><\/tr><tr><td colspan=\"9\">Relative to copper<\/td><\/tr><tr><td>Copper<\/td><td>100%<\/td><td>100%<\/td><td>100%<\/td><td>100%<\/td><td>100%<\/td><td>100%<\/td><td>100%<\/td><td>100%<\/td><\/tr><tr><td>Aluminium<\/td><td>164%<\/td><td>30%<\/td><td>164%<\/td><td>50%<\/td><td>30%<\/td><td>61%<\/td><td>178%<\/td><td>99%<\/td><\/tr><tr><td>Silver<\/td><td>94%<\/td><td>118%<\/td><td>94%<\/td><td>111%<\/td><td>118%<\/td><td>89%<\/td><td>117%<\/td><td>97%<\/td><\/tr><tr><td>Gold<\/td><td>142%<\/td><td>217%<\/td><td>142%<\/td><td>308%<\/td><td>217%<\/td><td>98%<\/td><td>89%<\/td><td>87%<\/td><\/tr><tr><td>Tin<\/td><td>670%<\/td><td>82%<\/td><td>670%<\/td><td>550%<\/td><td>82%<\/td><td>21%<\/td><td>167%<\/td><td>10%<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Why does copper wire need plating?<\/h2>\n\n\n\n<p>Plating maximizes and customizes the properties of a wire conductor. <\/p>\n\n\n\n<p>Here are the reasons why copper wire needs plating;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Enhance copper wire\u2019s weldability and oxidation resistance.<\/h3>\n\n\n\n<p>Oxidation of copper when exposed to air does the following;<\/p>\n\n\n\n<ul>\n<li>Increases resistance<\/li>\n\n\n\n<li>Reduces conductivity<\/li>\n<\/ul>\n\n\n\n<p>The plated copper wire prevents redox reactions, which;<\/p>\n\n\n\n<ul>\n<li>Improves the wire\u2019s weldability<\/li>\n\n\n\n<li>Improves the wire\u2019s electrical conductivity<\/li>\n\n\n\n<li>increases heat dissipation.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Increases the obstacle avoidance between the wire and the insulation layer<\/h3>\n\n\n\n<p>You can use tinned copper wire as;<\/p>\n\n\n\n<ul>\n<li>Outer shield braids<\/li>\n\n\n\n<li>Conductive cores<\/li>\n<\/ul>\n\n\n\n<p>Therefore, copper wires need plating because it;<\/p>\n\n\n\n<ul>\n<li>Improves weldability of copper wires;<\/li>\n\n\n\n<li>Prevents the conductive core of the rubber-insulated cable from sticking.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Increase the solderability of metal objects.<\/h3>\n\n\n\n<p><a href=\"https:\/\/wiretroop.com\/copper-vs-tinned-copper\/#more-4953\" target=\"_blank\" rel=\"noreferrer noopener\">Coating copper wires<\/a> increases the metal\u2019s solderability, which makes soldering to another surface easier.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Wire plating options: Tin vs. nickel vs. silver vs. gold<\/h2>\n\n\n\n<p>Here is a comparison of various wire plating options;<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table><tbody><tr><td><strong>Wire plating option<\/strong><\/td><td><strong>Description<\/strong><\/td><\/tr><tr><td><strong>Tin<\/strong><\/td><td>Silver has high conductivity, making it ideal for high-frequency applications. It also; Reduces the resistance of plated wiresImproves chemical resistanceIncreases high-temperature performanceHas excellent solderability.<\/td><\/tr><tr><td><strong>Silver<\/strong><\/td><td>Gold is a common plating choice for the following; ARINC coax contactsBrass connector pinsParts of some other connectors<br>Gold has excellent corrosion resistance properties and high conductivity. Also, you can easily solder it. However, it is an expensive wire plating option.<\/td><\/tr><tr><td><strong>Nickel<\/strong><\/td><td>The properties of nickel include; High resistance to corrosion and high temperatures, relatively low conductivity.<br>Therefore, plating the wire will increase its resistance.<\/td><\/tr><tr><td><strong>Gold<\/strong><\/td><td>Gold is a common plating choice for the following;ARINC coax contactsBrass connector pinsParts of some other connectors<br>Gold has excellent corrosion resistance properties and high conductivity. Also, you can easily solder it. However, it is an expensive wire plating option.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">How does the plating process work?<\/h2>\n\n\n\n<p>Manufacturers create tin-plated objects using the following metal finishing methods;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Hot-dip tinning method<\/h3>\n\n\n\n<p>Hot-dip tinning involves heating and melting solid tin.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\">Measures<\/h4>\n\n\n\n<p>Immerse copper in molten (heated) tin solution<\/p>\n\n\n\n<h4 class=\"wp-block-heading\">Advantages and disadvantages<\/h4>\n\n\n\n<p>The hot-dip tinning method has the following advantages;<\/p>\n\n\n\n<ul>\n<li>Controllable, low cost, low scrap rate<\/li>\n\n\n\n<li>Little environmental pollution<\/li>\n\n\n\n<li>Excellent reflectivity and appears more beautiful<\/li>\n\n\n\n<li>Excellent welding performance<\/li>\n\n\n\n<li>The process is simple, with a short delivery time<\/li>\n<\/ul>\n\n\n\n<p>Its disadvantages include;<\/p>\n\n\n\n<ul>\n<li>Limited storage time<\/li>\n\n\n\n<li>Poorer adhesion and continuity<\/li>\n\n\n\n<li>The tin layer is difficult to control<\/li>\n<\/ul>\n\n\n\n<h4 class=\"wp-block-heading\">Application consideration<\/h4>\n\n\n\n<p>Hot-dip plating is an ideal application method if;<\/p>\n\n\n\n<ul>\n<li>The wire gauge is relatively small (0.15 to 0.32 mm)<\/li>\n\n\n\n<li>You require a thicker coating<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Plating tinning method<\/h3>\n\n\n\n<p>This method uses the <a href=\"https:\/\/en.wikipedia.org\/wiki\/Electrolysis\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">electrolysis<\/a> principle.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\">Measures<\/h4>\n\n\n\n<p>You should use negative and positive electrodes as power media.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\">Advantages and disadvantages<\/h4>\n\n\n\n<p>Wire plating tinning method has the following advantages;<\/p>\n\n\n\n<ul>\n<li>The surface is clean and smooth, with no tin powder<\/li>\n\n\n\n<li>High roundness and consistent wire diameter<\/li>\n\n\n\n<li>Long storage time<\/li>\n\n\n\n<li>Stable in layer<\/li>\n\n\n\n<li>Controllable tin layer\u2019s thickness<\/li>\n\n\n\n<li>Excellent electrical and welding performance<\/li>\n\n\n\n<li>The coating is uniform, with exceptional concentricity and eccentricity<\/li>\n<\/ul>\n\n\n\n<p>Its disadvantages include;<\/p>\n\n\n\n<ul>\n<li>Environmental pollution<\/li>\n\n\n\n<li>Complicated electroplating operation and process<\/li>\n\n\n\n<li>Require high chemical technology<\/li>\n\n\n\n<li>High upfront investment costs<\/li>\n<\/ul>\n\n\n\n<h4 class=\"wp-block-heading\">Application consideration<\/h4>\n\n\n\n<p>Electroplating is recommended for electroplating multiple thin copper wires.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Consideration for choosing a wire tinning machine<\/h2>\n\n\n\n<p>Factors to consider while choosing a wire tinning machine include;<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Production speed<\/h3>\n\n\n\n<p>The production speed of a wire tinning machine depends on the following;<\/p>\n\n\n\n<ul>\n<li>The size of the tinning wire<\/li>\n\n\n\n<li>The type of the tinning wire<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Safety<\/h3>\n\n\n\n<p>Your wire tinning machine should have the following safety features;<\/p>\n\n\n\n<ul>\n<li>Safety guards<\/li>\n\n\n\n<li>Emergency buttons<\/li>\n<\/ul>\n\n\n\n<p>These features prevent possible accidents and damage to the wires.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Repair and maintenance of the wire tinning machine<\/h3>\n\n\n\n<p>The best wire tinning machine should be;<\/p>\n\n\n\n<ul>\n<li>Easy to repair<\/li>\n\n\n\n<li>Easy to maintain<\/li>\n<\/ul>\n\n\n\n<p>By considering this factor, you will choose a machine;<\/p>\n\n\n\n<ul>\n<li>With an extended lifespan<\/li>\n\n\n\n<li>That ensures consistent output<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">Type of metal used for tinning<\/h3>\n\n\n\n<p>The common types of metals used for tinning are;<\/p>\n\n\n\n<ul>\n<li>Silver<\/li>\n\n\n\n<li>Copper<\/li>\n\n\n\n<li>Tin, etc.<\/li>\n<\/ul>\n\n\n\n<p>Therefore, your machine should be adjustable according to the metal used.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Type of tinning process<\/h3>\n\n\n\n<p>Wire tinning machines are designed for unique wire tinning methods. <\/p>\n\n\n\n<p>For instance,<\/p>\n\n\n\n<ul>\n<li>Electroplating tinning machines generate consistent and even coating layers.<\/li>\n\n\n\n<li>Hot-dip tinning machines are slower and can damage the wires<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Conclusion<\/h2>\n\n\n\n<p>Coating wire conductors are essential in wiring projects for high-quality transition. <\/p>\n\n\n\n<p>At Cloom Tech, we provide a wide range of wire harness solutions. <\/p>\n\n\n\n<p><a href=\"https:\/\/www.wiringo.com\/contact\" target=\"_blank\" rel=\"noreferrer noopener nofollow\">Contact us<\/a> today to request a quote.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Wire conductors are essential wire harness components, often requiring coatings to improve their solderability and electrical properties at high frequencies. This article covers everything about coating wire conductors. Let&#8217;s get started! Types of wire conductors Here are the different types of wire conductors; Silver Silver has the best conductivity but is expensive. So we often &#8230; <\/p>\n<p class=\"read-more-container\"><a title=\"\u00a0Wire Conductors: An ultimate guide on their plating\" class=\"read-more button\" href=\"https:\/\/wiretroop.com\/wire-conductors\/#more-5225\" aria-label=\"More on \u00a0Wire Conductors: An ultimate guide on their plating\">Read more<\/a><\/p>\n","protected":false},"author":7,"featured_media":5226,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[10],"tags":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.3 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Wire Conductors: An ultimate guide on their plating<\/title>\n<meta name=\"description\" content=\"Wire conductors are essential wire harness components, often requiring coatings to improve their solderability and electrical properties at high frequencies.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, 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