Manufacturing of Copper Wire Cables

The production of copper wires has some stages which vary according to the purpose of production. Copper wire manufacturers follow the procedure of processing the copper rod extracted from the ores to make it the finished product. Tin coated copper wire is used for making cables. It has to be taken through three processes of manufacturing for making the finished product. The first process involves drawing the wires in a specific size using C.C. rod or electrolyte copper. The second process is annealing of the wires which have been successfully extracted. The third process is the plating process of the copper wires to finally get tin coated copper wires.

These two processes are called electroplating and hot dip. Copper wire cables are used in all equipments that are used in electrical and electronic works. You can hardly think of an area in these fields of work where copper wires do not find a use. Cables are made by getting a coating on the copper wires. The wires that are fashioned out of copper can withstand the strains of expansion and vibration. Only then can they be used as connectors. Client’s needs dictate the specifications of the dimensions and also the material which has to be used.

A variety of copper wire cables is the stranded copper wire rope. The rope-like structure of these copper wires is made like that to ensure strength, flexibility and ease in handling. Some types of copper wire cables are PVC insulated cables, HR PVC winding wires, flat lead cables with 3 core, insulated fixed or flexible cords and wires, PVC insulated and armored cables. These cables are used in instruments like electric heater, electric motor and other such high temperature instruments.

The two important steps in the manufacturing of tin coated copper wires which go on to become copper wire cables are electroplating and hot dip process.

The Electroplating Process: - A wire is made to pass a chemical tray after which DC current is passed through it. DC current is made from converting it with a rectifier.

This process makes wires for House Wiring, Control Panel Cable and similar other jobs which need Copper wires or cables.

The Hot Dip Process: - In this process, tin is made to melt in an electric pot through which the electrolytic copper wire is passed. This results in tin coated copper wires.

Risks Associated with Copper Wire

Although copper wire is the most extensively used material in electrical industries, the negative effects and health risks it possesses are also very higher. Copper is a naturally occurring mineral which is very extensive in use today due to its electrical and mechanical properties. With its exceptional features like conduction properties, cheap prices, ductility etc. Copper wire use is on the rise, along with its possible health risks.

Exposure to environment: Copper is constantly being mined due to the rising demand of copper wire from electrical industries. It results in a significant increase of copper in environmental areas. Rivers and bodies of water are prime areas where copper can end up. Wastewater containing copper must be disposed of during the process of turning natural copper into usable copper; therefore, much of this waste ends up in naturally-occurring bodies of water.
Creating usable copper also requires the combustion of fossil fuels, which results in copper being released into the atmosphere. The copper returns to earth after it rains and once again ends up in the ground.

Soil

Copper is dangerous in soil due to its tendency to attach to minerals and organic matter. Its lack of ability to breakdown means that over time it can become prevalent in plants and animals. Far fewer plants can grow in copper-rich soil, creating a change in eco-diversity. Copper has been shown to influence microorganisms found within soil, which results in a much slower decomposition of organic matter.

Farmland suffers significantly due to the copper that is present in fertilizers. Animals that absorb the added concentrations of copper suffer health damage. The negative effects on humans are, as of yet, merely projected, but significant research has not been completed.

Short-Term Exposure

The absorption of copper in extremely small amounts is perfectly normal and humans are even shown to be able to handle larger-sized quantities; however, overexposure to large amounts of copper is shown to result in side effects. Very few people receive overexposure to copper; however, metal fever, a sickness with flu-like symptoms, is caused by copper overexposure.

Long-Term Exposure

Solid studies about long-term copper exposure are rare in number. However, what is known is that continuous copper exposure can result in many conditions. These include constant irritation to the eyes, stomach, nose, and mouth---much like allergies. Exposure to copper-fumes has been shown to alter nasal mucous membranes. Copper poisoning can turn into Wilson's disease, which causes a number of problems, including brain damage, cornea problems, renal disease, and cirrhosis. Copper has been linked to changes in the brain as well. It has been suggested that overexposure to copper can result in lower intelligence in developing youth.

Copper Wires – An Important Product for Industrial Revolution

We hardly ever pause to wonder the significance of the dull colored wire that we get in our homes. Copper wire must be the most important wire for industrial revolution mostly because of its use in electrical and electronic works. You get many variations of copper wires or cables made out of them like PVC wires, armoured cables, tinsel copper wire, flat copper wire, copper strip, copper wire gauge, jumper wire and braided copper wires which are manufactured differently for being put to different use.

Copper wire’s main use is electrical for which electrolyte copper wire has special significance because it is the purest variety of copper wire. This wire becomes the raw material for the cable industries. The features of copper wires that make it such a preferable over other metals are its electricity conduction and the ability of being made flexible through tin coating. Tin coated copper wire is used in manufacturing of many types of cables, industrial machines, heaters, high temperature instruments or similar uses. The two processes involved in tin coating of the copper wires is the electrolytic process followed by the hot dip process. These two processes are carried out after annealing of the wires.

Copper strip is used for reduce wastage, resist corrosion and thereby improve production of the automatic machines. These are especially useful in places where the soil content does not comprise of a great proportion of salt. Another very important variety of copper wire which is a boon to the telecommunication industry is the Tinsel copper wire. It is specially designed to be durable. It is manufactured by many strands of thin copper foil on a textile core.

We can understand the serious impact copper wires are having on our lives after being put to different uses. It use in wires of electrical like electrical wiring in homes or in any electronic appliance like the receiver of the phone or your television or radio render it a paramount significance when compared with relatively other metals. The copper wire manufacturers are doing a thankless task of turning out these wires for us. Their up to date machinery and professionals deserve special thanks from all of us who don’t even think twice when enjoying the benefits of electricity and electronic products. The copper wire manufacturers or copper wire exporters on the other hand should ensure that all the industry standards for their products are satisfactorily met.