{"id":33583,"date":"2025-04-25T17:17:39","date_gmt":"2025-04-25T09:17:39","guid":{"rendered":"https:\/\/www.ray-tron.com\/?p=33583"},"modified":"2025-04-25T17:17:46","modified_gmt":"2025-04-25T09:17:46","slug":"20254252-2","status":"publish","type":"post","link":"https:\/\/www.ray-tron.com\/en\/20254252-2\/","title":{"rendered":"Systematic process flow of small size copper clad aluminum flat wire"},"content":{"rendered":"<p>The production of small-sized copper-clad aluminum flat wire is a highly sophisticated process, involving multiple links such as copper-aluminum composite, precision rolling, surface treatment, annealing, tinning, etc. Each step has strict requirements on size, bonding strength and electrical properties. The following is a systematic process introduction:<\/p><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\">Production process of small size copper clad aluminum strip flat wire<\/h3><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>1. Raw material preparation<\/strong><\/h3><ul class=\"wp-block-list\"><li><strong>Aluminum core wire selection<\/strong>: High-purity aluminum (such as 1350 or 3003) requires a smooth surface, no oxide scale, and no impurities.<\/li>\n\n<li><strong>Copper layer raw material<\/strong>: High-purity oxygen-free copper or phosphorus deoxidized copper, requiring good ductility, rollability and no cracks.<\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>2. Copper-aluminum composite (cladding)<\/strong><\/h3><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p>Small-size products generally use &quot;cladding composite&quot; or &quot;metallurgical bonding&quot; technology to ensure that the copper layer fits tightly against the aluminum core.<\/p><\/blockquote><ul class=\"wp-block-list\"><li><strong>Coating method<\/strong>:<ul class=\"wp-block-list\"><li>The copper strip is wrapped into a tube, which fits tightly to the aluminum core;<\/li>\n\n<li>The initial forming is completed through continuous compounding equipment;<\/li><\/ul><\/li>\n\n<li><strong>Heat treatment fusion<\/strong>:<ul class=\"wp-block-list\"><li>Some manufacturers use hot rolling or diffusion welding technology to achieve metallurgical bonding and improve peel strength;<\/li><\/ul><\/li>\n\n<li><strong>Detection of copper layer bonding strength<\/strong>:<ul class=\"wp-block-list\"><li>The peel strength test is \u226512N\/cm, ensuring that there will be no peeling or bulging during subsequent processing.<\/li><\/ul><\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>3. Multi-pass precision cold rolling<\/strong><\/h3><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p>The core of the process is to gradually roll the coated copper-clad aluminum round wire into flat wire of target specifications.<\/p><\/blockquote><ul class=\"wp-block-list\"><li><strong>Multi-roll precision rolling mill<\/strong>:<ul class=\"wp-block-list\"><li>Rolled into small-sized strips with thickness of 0.05mm to 0.30mm and width of 1mm to 10mm;<\/li>\n\n<li>Control the width-to-thickness ratio and the integrity of edges and corners to ensure smoothness and brightness;<\/li><\/ul><\/li>\n\n<li><strong>More rolling passes<\/strong>, usually needs 5 to 10 rolling passes;<\/li>\n\n<li><strong>Key control parameters<\/strong>:<ul class=\"wp-block-list\"><li>Thickness tolerance: \u2264\u00b10.005mm;<\/li>\n\n<li>Width tolerance: \u2264\u00b10.03mm;<\/li>\n\n<li>Curvature and edge straightness: must be achieved<a href=\"https:\/\/www.ray-tron.com\/en\/pvribbon\/\" data-internallinksmanager029f6b8e52c=\"43\" title=\"Photovoltaic welding ribbon\">Photovoltaic welding ribbon<\/a>Industry standard.<\/li><\/ul><\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>4. Intermediate annealing<\/strong><\/h3><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p>To improve ductility, eliminate internal stress, and prevent cracking or peeling.<\/p><\/blockquote><ul class=\"wp-block-list\"><li>Control annealing temperature and time to avoid copper and aluminum delamination;<\/li>\n\n<li>Ensure that the material has good weldability and softness;<\/li>\n\n<li>Improve the stability of the next tinning process.<\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>5. Surface treatment and cleaning<\/strong><\/h3><ul class=\"wp-block-list\"><li><strong>Purpose<\/strong>: Remove rolling oil and oxides and improve surface activity;<\/li>\n\n<li>Use alkaline or neutral detergent, ultrasonic + hot water rinse;<\/li>\n\n<li>The surface must meet the standards of being free of particles, scratches, oil and oxide scale.<\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>6. Tin plating (if necessary)<\/strong><\/h3><blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\"><p>Photovoltaic welding ribbons are mostly tin-plated to enhance welding performance.<\/p><\/blockquote><ul class=\"wp-block-list\"><li>Plating type: pure tin or tin containing silver;<\/li>\n\n<li>The tin plating thickness is generally 3~10\u03bcm and can be customized;<\/li>\n\n<li>Tin plating uniformity control \u2264\u00b11\u03bcm;<\/li>\n\n<li>Subsequent drying treatment ensures a bright surface without tin nodules or tin slag.<\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>7. Inspection and cutting<\/strong><\/h3><ul class=\"wp-block-list\"><li><strong>Conductivity test<\/strong>: Ensure that the resistivity meets the welding strip standards;<\/li>\n\n<li><strong>Bond strength test<\/strong>: The copper layer cannot be peeled off or delaminated;<\/li>\n\n<li><strong>Dimensional inspection<\/strong>: width, thickness, edges and corners, surface quality;<\/li>\n\n<li>Slit into rolls of specifications required by customers (e.g. 500m, 1000m rolls).<\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\"><strong>8. Finished product packaging and shipment<\/strong><\/h3><ul class=\"wp-block-list\"><li>Use moisture-proof film + vacuum seal packaging;<\/li>\n\n<li>Add cushioning material to prevent the tape from deforming during transportation;<\/li>\n\n<li>Affixed with technical labels such as size, batch, conductivity, etc.<\/li>\n\n<li>High temperature, low temperature and salt spray test reports are included with delivery.<\/li><\/ul><hr class=\"wp-block-separator has-alpha-channel-opacity\"\/><h3 class=\"wp-block-heading\">Advantages of Ruichuang&#039;s small-size copper-clad aluminum flat wire<\/h3><ol class=\"wp-block-list\"><li>\ud83d\udccf <strong>High dimensional control accuracy<\/strong>:<a href=\"https:\/\/www.ray-tron.com\/en\/\" data-internallinksmanager029f6b8e52c=\"19\" title=\"Ruichuang 2\">Raytron<\/a>Adopting precision rolling mill imported from Germany, it can produce 2<del>10mm, thickness 0.05<\/del>0.3mm high-precision flat wire;<\/li>\n\n<li>\u26a1 <strong>Strong bonding without delamination<\/strong>\uff1aMetallurgical bonding + multiple intermediate annealing to solve the problem of traditional copper-clad aluminum peeling;<\/li>\n\n<li>\ud83e\uddea <strong>Excellent electrical conductivity<\/strong>: The copper layer thickness is uniform, the welding efficiency is high, and it meets the photovoltaic welding ribbon replacement standards;<\/li>\n\n<li>\ud83c\udfed <strong>Large-volume and stable supply capability<\/strong>: Automated continuous production line to ensure stable delivery time.<\/li><\/ol>","protected":false},"excerpt":{"rendered":"<p>The production of small-sized copper-clad aluminum flat wire is a highly sophisticated process involving the composite of copper and aluminum materials, precision rolling, surface treatment, annealing, tinning, etc. 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