Copper clad aluminium enameled wire consists of an aluminium core and a layer of copper material covering its surface. The core is usually made of high-purity aluminium, while the copper cover is electroplated, soldered or mechanically clad onto the core.

Compared to pure copper conductors, copper-clad aluminium enameled wire has slightly lower electrical conductivity. Since the conductivity of aluminium is about 61% of that of copper, the resistance of copper-clad aluminium enameled wire will be slightly higher for the same size of wire. Therefore, when designing a coil, it is necessary to take into account the resistance loss of the wire as well as factors that affect the performance of the system.

Copper-clad aluminium enamelled wires are usually covered with an insulating varnish on the surface of the aluminium core. This insulating varnish helps to isolate the current, provides insulation protection and also helps to hold the copper covering in place.


Copper clad aluminium enameled wire has a lower weight compared to pure copper wire. Due to the lower density of aluminium, the aluminium core allows CCA enamelled wires to have a lower weight for the same size. This is an advantage for weight-sensitive applications such as automotive, aerospace and electronics.

Copper clad aluminium enameled wire has a lower manufacturing cost compared to pure copper conductors. Aluminium is a relatively inexpensive metal, and the use of aluminium as the core material in copper clad aluminium enameled wires reduces the cost of the wire to a certain extent.

Copper clad aluminium enameled wire is widely used in a variety of coils and electromagnetic devices, including electric motors, transformers, inductors, solenoid valves, electromagnetic relays and so on. In particular, copper clad aluminium enameled wire is often chosen for applications where weight is critical and cost is sensitive.

The selection of copper-clad aluminium enamelled wire should be based on the requirements of the specific application and design considerations. Although copper-clad aluminium enamelled wire has some advantages, pure copper conductors may be more suitable for applications with high currents, high frequencies or where high conductivity is required.

Copper-clad aluminium enameled wire is a cost-effective wire option for many coil applications, offering lower cost and lightweight advantages. However, a thorough evaluation and selection of the appropriate conductor material for a specific application is still required based on specific needs.