Many buyers ask the same question when they compare conductor materials: can we reduce weight and material cost and still keep a copper surface? Copper-clad aluminum (CCA) flat wire, strip and foil answer that question for many projects. A copper outer layer is bonded to an aluminum core, so the conductor keeps the surface of copper at a much lower weight.
This guide is written for importers, distributors, OEM buyers and procurement teams. It explains how copper clad aluminum flat wire is made, how it compares with pure copper, which sizes and materials are available, and what to check before you send an inquiry. The product data comes from the CCA flat wire, strip and foil page of Junrun, a manufacturer based in Zhangjiagang City, Jiangsu Province, China.
What Is Copper Clad Aluminum (CCA) Flat Wire, Strip and Foil?
Copper-clad aluminum (CCA) is a composite conductor. It has an aluminum core inside a copper outer layer. The two metals are joined by a metallurgical process, not by a thin coating, so the layers work as one conductor.
Junrun's flat products have a uniform cross-section and regular rounded corners. The copper layer thickness is controllable, and the surface is smooth, without peeling or bubbles. Buyers can order three flat formats:
- CCA flat wire: a narrow, flat conductor for windings, wiring and connection parts.
- CCA strip: a flat conductor for busbar-type parts and ribbon substrates.
- CCA foil: a thin flat conductor for coils and lapped windings.
Width, thickness and copper layer ratio can all be customized. Engineers can match the profile to a drawing instead of changing the design to fit a standard size.
How Copper Clad Aluminum Flat Wire Is Made: Metallurgical Bonding Process
The quality of copper clad aluminum flat wire depends on the bond between the two metals. Junrun builds its composite conductors around bonding, welding, drawing, annealing and surface treatment processes. For flat products, buyers can think of production in three practical stages.
Stage 1: Metallurgical bonding
The copper layer and the aluminum core are joined at the metal level. A good bond keeps the layers together when the conductor is bent, heated or soldered. This is the most important point to discuss with any supplier.
Stage 2: Sizing the profile
The composite is processed to the target thickness and width. Junrun lists thickness from 0.03 to 2 mm and width from 0.3 to 12 mm. The copper layer ratio is set to your request.
Stage 3: Surface treatment and inspection
Surface treatment and outgoing inspection come next. Junrun names batch stability, surface appearance and outgoing inspection control as part of its production. Ask for the inspection records that apply to your order.
Copper Clad Aluminum Flat Wire vs Pure Copper Flat Wire: Key Differences
Both materials suit flat conductor applications, but they solve different problems. These are the main differences buyers should weigh:
- Weight: CCA flat wire is more than 40% lighter than pure copper flat wire.
- Cost: CCA uses less copper, so raw material cost is lower. Junrun lists CCA at 50-60% lower cost than copper wire.
- Conductivity: CCA reaches 58-80% IACS across the series. Pure copper conducts better for the same cross-section.
- Surface: CCA has a copper outer layer, and tin coating is available when you need it.
Choose CCA when weight and material cost matter more than maximum conductivity. Choose pure copper when you need the highest conductivity in the smallest space. Junrun supplies both. Its Bare Copper Series includes pure copper flat wire, strip and foil for comparison.
Key Advantages of CCA Flat Wire, Strip and Foil
- Good heat dissipation: the flat structure spreads heat well and supports high current carrying capacity.
- Space saving: flat profiles fit compact enclosures, coils and busbar layouts.
- Light weight: lower weight reduces handling effort, freight load and installation work.
- Firm bonding: the composite layer is firmly bonded and resists high temperatures.
- Cost advantage: CCA is a cost-effective alternative to pure copper flat wire.
- Custom design: width, thickness and copper ratio follow your requirements.
For buyers who supply large volumes, these advantages add up quickly. A lighter conductor costs less to ship, and a lower material cost improves your quotation position.
How Much Lighter and Cheaper Is CCA Than Pure Copper?
Junrun states that its CCA flat wire is more than 40% lighter than pure copper flat wire. Its product data also lists CCA at 50-60% lower cost than copper wire. The density of the CCA series ranges from 3.19 to 5.3 g/cm³, while solid copper is about 8.9 g/cm³.
Use these figures for first screening. Your final saving depends on three factors:
- Copper ratio: more copper means higher conductivity, higher weight and higher cost.
- Metal market prices: copper and aluminum prices change, so quotations change too.
- Profile size: thickness, width and order quantity all affect unit price.
The most reliable way to see real savings is to send your drawing and ask for a quotation.
Technical Specifications: Thickness, Width, Conductivity and Copper Ratio
The table below summarizes the data published for Junrun's CCA flat wire, strip and foil. Items marked "series range" apply to the wider CCA series. Please confirm them for your exact profile before you order.
| Parameter | Specification | Buyer Note |
| Structure | Copper outer layer, aluminum inner core, metallurgically bonded | Uniform cross-section, rounded corners |
| Thickness | 0.03 - 2 mm (±0.003 mm) | Foil to thicker strip |
| Width | 0.3 - 12 mm (±0.03 mm) | Custom widths available |
| Copper layer ratio | Controllable and customizable | Series range: 8-42% by volume, 22-70% by weight |
| Conductivity | 58 - 80% IACS (series range) | Depends on copper ratio |
| Resistivity | 0.022 - 0.027 Ω·mm²/m (series range) | Check against your resistance target |
| Density | 3.19 - 5.3 g/cm³ (series range) | Solid copper is about 8.9 g/cm³ |
| Copper layer materials | TU0, TU1, T1, T2, brass, Ag-Cu alloy, Cu-P alloy; OFE C101, C102, C110 | Grade matched to application |
| Aluminum core grades | 1060, 1070, 1080, 1350, 5154, 6061, 8030 | Choose by conductivity and strength need |
| Surface options | Tin coated, enameled and stranded options listed | Confirm for your profile |
| Weight vs pure copper flat wire | More than 40% lighter | Lower freight and handling load |
| Cost vs copper wire | Listed as 50 - 60% lower | Varies with metal prices and copper ratio |
Available Copper Layer and Aluminum Core Materials
Material choice affects conductivity, strength and cost. Junrun lists these options:
- Copper layer: TU0, TU1, T1, T2, brass, Ag-Cu alloy and Cu-P alloy, plus oxygen-free grades C101, C102 and C110.
- Aluminum core: 1060, 1070, 1080, 1350, 5154, 6061 and 8030.
Pure aluminum grades such as 1060, 1070, 1080 and 1350 are common choices when conductivity is the priority. Alloy grades such as 5154 and 6061 are options when a project needs different mechanical behavior. Share your current, forming and strength requirements with Junrun's team, and they can help you match the grade.
Custom Sizes: Thickness, Width and Copper Layer Ratio Options
Custom supply is the core of this product. Most buyers need a profile that matches an existing tool, winding machine or busbar design. These are the parameters you can set:
- Thickness: 0.03 to 2 mm, with a tolerance of ±0.003 mm.
- Width: 0.3 to 12 mm, with a tolerance of ±0.03 mm.
- Copper layer ratio: adjustable to balance conductivity, weight and cost.
- Surface and structure: tin coated, enameled and stranded options are listed.
To get a fast and accurate quotation, send the target thickness, width, copper ratio, quantity and application. If you also need round conductors or other CCA formats, browse the full Copper-Clad Aluminum Series.
CCA Flat Wire for Photovoltaic Welding Ribbon and Busbar Applications
Solar module makers and busbar suppliers need conductors that are flat, consistent and easy to process. CCA flat wire works as a photovoltaic welding ribbon substrate and in busbar trunking. The flat shape gives a large contact area, and the lighter weight helps with spool handling and shipping.
Junrun also supplies finished tinned products for solar projects, including black and reflective busbar ribbon and SMBB interconnect ribbon. You can see these in the Pv/solar Smbb Tinned CCA Ribbon category.
When you inquire for PV applications, confirm the ribbon width, thickness, tin coating requirement and spool packing.
CCA Strip and Foil for Transformer Windings and Electrical Coils
Transformer windings and electrical lapped coils use flat conductors in large volumes. Here the weight advantage is easy to see: a lighter winding material reduces coil weight and lowers material cost. Good heat dissipation also helps in compact coil designs.
Keep one design point in mind. CCA has lower conductivity than pure copper, so a winding may need a slightly larger cross-section to reach the same resistance. Your engineers should check resistance, temperature rise and insulation requirements against the supplier's data. Junrun lists enameled options for projects that need insulated conductors.
CCA Flat Wire for Energy Storage Connections and EV Charging Equipment
New energy equipment needs conductors that carry current, save weight and fit tight spaces. CCA flat wire is used for energy storage equipment connection bars, internal conductors of new energy charging piles and electrical control equipment wiring.
Flat conductors fit compact enclosures well, and the lower weight eases assembly. Plan terminations carefully, because aluminum and copper behave differently at joints. Ask the supplier about tin coating or other surface treatment for contact areas, and test samples in your actual connection method.
Surface Quality and Bonding Strength: Heat Resistance, No Peeling or Oxidation
Surface and bond quality decide whether a flat conductor performs in the field. Junrun describes its flat products with these features:
- A smooth surface without peeling or bubbles.
- Regular rounded corners and a uniform cross-section.
- A firmly bonded composite layer that resists high temperatures.
- A structure that does not peel or oxidize.
Do not rely on descriptions alone. Request samples and run your own bend, soldering or heat tests. Ask which dimensional, surface and bonding checks the supplier records for each batch.
How to Choose the Right CCA Flat Wire, Strip or Foil for Your Project
Follow these steps to narrow your specification before you contact a supplier:
- Define the electrical target. Note the current, allowed resistance and conductivity requirement.
- Set the profile size. Choose thickness and width within the available range.
- Choose the copper ratio. Balance conductivity against weight and cost.
- Select materials. Pick the copper layer and aluminum core grade.
- Decide on surface treatment. Choose bare, tin coated or enameled.
- Test samples. Check soldering, winding, bending or connection in your process.
- Confirm supply terms. Agree on quantity, packing and delivery with the supplier.
Why Choose Junrun as Your CCA Flat Wire, Strip and Foil Manufacturer
Junrun focuses on copper clad aluminum, copper clad steel and advanced composite conductors. Its factory is in Zhangjiagang City, Jiangsu Province. For international buyers, these points matter most:
- Process knowledge: production is built around bonding, welding, drawing, annealing and surface treatment.
- Wide product range: CCA, CCA alloy, tinned, enameled and PV solar ribbon products come from one supplier.
- Customization: size, copper ratio and surface follow project requirements.
- Quality control: batch stability, surface appearance and outgoing inspection are part of the workflow.
- Buyer support: the team supports specification matching, sample preparation and quotation.
Junrun does not list certificates or test reports in this article. If your market requires specific documents, request them directly during your inquiry.
Frequently Asked Questions About Copper Clad Aluminum Flat Wire
1. What is CCA flat wire used for?
It is used for photovoltaic welding ribbon substrates, busbar trunking, transformer windings, energy storage connection bars, charging pile internal conductors, electrical control wiring and electrical lapped coils.
2. Is CCA flat wire as conductive as pure copper?
No. CCA conductivity ranges from 58% to 80% IACS, depending on the copper ratio. Pure copper is higher. Many designs offset this with a suitable cross-section and gain weight and cost savings.
3. Can I order custom sizes?
Yes. Thickness from 0.03 to 2 mm, width from 0.3 to 12 mm and the copper layer ratio can be customized.
4. Does the copper layer peel or oxidize?
Junrun describes the composite layer as firmly bonded, heat resistant and free from peeling or oxidation. Test samples in your own process to confirm performance for your application.
5. Is tin coating available?
Yes. Tin coated, enameled and stranded options are listed. Junrun also supplies tinned CCA PV solar ribbon in a separate product category.
6. What should I send to get a quotation?
Send the product type, thickness, width, copper ratio, material grade, surface requirement, quantity, packing needs and application. A drawing helps the team match your specification faster.
Conclusion
Copper-clad aluminum (CCA) flat wire, strip and foil give buyers a lighter and more economical route to flat conductors. The copper outer layer, the firm bond and the custom sizing options make them practical for solar, transformer, coil, energy storage and charging equipment projects. Weigh the lower conductivity against the savings, and test samples before you commit to volume.
If you are planning a project, share your drawing or target parameters with Junrun for product details, samples, customization advice or a quotation. Contact Us to start the conversation.