Coating structure

The copper layer accounts for 68% ± 4%, the zinc layer 32% ± 4%. After diffusion, an uniform brass alloy layer is formed with a thickness of 0.2 - 0.4 μm. The coating needs to control the residual oxygen content, temperature (below 1020℃ or 1150℃) and Mn content (0.17wt%) to avoid the formation of Fe-Si-O phase, which can lead to darkening defects.

The material type and characteristics of the copper-coated steel wire base.

The selection of the base material for copper-coated steel wire is of vital importance to the performance of the product. Currently, the commonly used base materials in the industry are mainly low-carbon steel, with the carbon content controlled within the range of 0.10% - 0.30%. This low-carbon steel has good flexibility and processing performance, which can meet the requirements of the subsequent copper plating process and ensure that the finished product is not prone to breaking in applications such as bending and stretching. For example, the copper-coated round steel used for lightning protection grounding adopts this type of base material. After special processing, it can achieve the characteristic of not cracking after 90° bending.

Performance Characteristics

‌Mechanical Properties‌: Tensile strength ranges from 1750 to 2750 MPa, suitable for reinforcing high-pressure rubber hoses and manufacturing springs.

‌Adhesion‌: Strong adhesion to rubber, especially suitable for steel cord production.

‌Corrosion Resistance‌: The zinc-copper alloy layer can prevent rust in outdoor environments for a long time. The thickness of the hot-dip galvanized coating is 45-300 micrometers. Application fields

Rubber industry: Steel cord, framework material for high-pressure rubber hoses.

Communication cables: Substitute for pure copper wires, with excellent high-frequency performance. Hardware products: zippers, multi-layer locks, etc. - daily-use hardware items

Material adjustment in special scenarios

For some high-end application scenarios (such as steel cord for steel belt, and copper-plated steel wire for high-pressure hose reinforcement), high-carbon steel is used as the base material, with a carbon content of up to 0.70%-0.90%. This type of base material is strengthened through cold drawing processes and is suitable for fields with strict requirements for tensile strength. However, it requires a more precise copper plating process to ensure the uniformity of the coating. Additionally, surface treatment of the base material (such as rust removal and phosphating) is also an important factor affecting the final product quality, and it needs to be coordinated and optimized with the copper plating process.