Copper clad steel wire is gaining more popularity in the electrical industry due to its excellent conductivity and cost effectiveness. This revolutionary material combines the advantages of both copper and steel.

Manufacturing of Copper Clad Steel Wire
Copper clad steel wire is manufactured through an advanced process called continuous rolling and drawing. In this process, a copper sheet is wrapped around a steel wire through high pressure rollers. Then the combined copper-steel cylinder is drawn through successive dies to reduce its diameter and elongate the structure. This process helps in bonding the copper and steel layers metallurgically. Finally, the finished wire achieves an ideal balance of conductivity and strength.

Property Analysis
The unique combination of copper and steel results in superior properties compared to normal copper or steel wires.
- Electrical Conductivity: Due to the thin copper layer surrounding the steel core, copper clad steel wire has an electrical conductivity level close to pure copper. It can conduct electricity efficiently while using less copper material.
- Tensile Strength: Steel core provides high tensile strength which allows the wire to withstand heavy mechanical loads without breakage.
- Flexibility: Even with steel core, the wire remains flexible due to thin copper layer which imparts ductility.
- Corrosion Resistance: Copper coating acts as a barrier and protects the steel core from corrosion in harsh environmental conditions.
- Cost Effectiveness: Use of steel largely instead of copper results in significant cost savings.

Applications
Some major applications of Copper Clad Steel Wire are:
- Power Cables: Used as conductor in power cables for transmission and distribution of electricity both outdoor and indoor.
- Appliance Wiring: Found in the internal circuitry of household appliances like ACs, refrigerators, washing machines etc.
- Transformers: Act as windings in small domestic transformers as well as large power transformers.
- Motors: Serve as armature and field windings in small and large electric motors.
- Electronics: Used in coil winding applications in electronics devices.

Future Scope and Challenges
With the continuous growth in power infrastructure and electronics industry, the demand for copper clad steel wire is expected to rise substantially in coming years. Manufacturers are focusing on further improving the process to enhance conductivity levels. However, maintaining consistency in bonding of copper and steel layers poses a major challenge. Developing automated quality testing methods can help address this issue. Overall, copper clad steel wire has great potential to replace conventional copper wires in near future.

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