Copper wire and copper cable are most often used in electronics and electrical wiring. Wires are used to connect parts and conduct electric current between them, creating a circuit. Copper wiring is used in everything from toaster ovens to overhead lighting.

Copper wire comes in many varieties, like bare, nickel coated, flat, square, and round wire. Bulk copper wire is often available in rolls or specific lengths. When buying electrical copper wire, always check to make sure that the current AMPS are sufficient and that the wire contains the correct number of strands for your job. In addition, always consider the following:

1. Installing copper wiring generally requires a permit from local authorities, and in some cases a license.

2. Regulations often require new or repaired wiring to be inspected by a qualified electrician or government official in charge of electrical inspection.

3. The type of copper wire you can use for specific purposes, like grounding, is generally limited by national standards and local regulations.

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Use bare copper wire for electrical installations

Bare copper wire is often used for overhead distribution lines, grounding in substations and other electrical equipment. Bare copper wires is also used to ground kitchen appliances and other household or industrial items. Copper wiring is often sold on spools, and is available with varying numbers of strands.

I recommend: Buy copper wire from Custom Cable, or purchase spools of bare copper wire from the American Wire Group.

Purchase special copper and copper-alloy wire for specific properties from wire vendors

Other metals can be added to copper wire to make the wire stronger, heat or moisture resistant, or harder. With so many alloys available, the wire properties possible are nearly endless. Adding silver can help make wire more conductive, while coating copper wire in nickel can help protect the wire itself. Special types of copper can be used in addition to alloys, such as oxygen-free copper, phosphorous deoxidized copper and cadmium copper.

I recommend: Buy copper-alloy wire from Wheeler Industrial or check out special types of copper wire from Fisk Alloy Conductor.

Commission custom-designed copper wire for special situations

If you're having trouble finding an industrial copper wire with the right properties and the correct amount of AMPS or strands, try asking copper wire distributors to design the perfect wire for you. Although custom copper wire prices are generally higher, you're guaranteed a product that fits your needs. Just give them your specifications and let them help you choose the coating, strand number, AMPS and other important specs of your custom wire.

I recommend: Get a design from Jersey Strand & Cable, or ask the Standard Wire & Cable Co. about its custom cable design service.

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• •  For larger operations, its often easier to buy copper wire in bulk. This allows plenty of extra wire to correct mistakes or miscalculations, and bulk wire supplies are often discounted. Buying in bulk works best for purchasing the most common types of copper wire, as the wire providers often only offer their best selling wire in bulk.

Copper wire is used primarily in building construction. It conducts electricity better than any other natural material except for silver and is much cheaper. Industrial copper wire of 99.98% purity can be made relatively cheaply and industrial copper wire of purity of 99.99999% can be achieved in commercial quantities.

Copper cable also is used in electronic devices, industrial machinery, transportation equipment and general consumer products. It is the standard in electrical conductivity and the replacement of non-copper electrical conductors with copper electrical cable usually earns a profit for building owners within two years.

Problems with power quality often can be prevented with copper-intensive solutions. Neutral conductors that use copper cable are better able to handle harmonic loads and copper grounding systems dissipate transient power more easily.

Electrical copper wire is replacing aluminum in computer chips, allowing conductor widths to be significantly reduced. This produces a faster operating speed.

Consider these points when using copper wire:

1. Buying copper wire in bulk quantities can save costs for your business.
2. Square copper wire is more costly, but more efficient to use than round copper wire.
3. Match the strength of the of copper wire you buy to the type of the project you're undertaking.
   

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Determine whether you need bulk copper wire or wiring harnesses

Bulk copper is used by manufacturers that are able to integrate copper wire into their manufacturing whereas harnesses are already made and ready to install.

I recommend: Get a quote on copper wire pricing at MWS Wire. If you need wiring harnesses that are already made, EZ Wiring specializes in pre-wired fuse block kits.

Choose between round and square copper wire

Round wire is cheaper, but square wire can save valuable space in applications where the wire needs to be routed around a corner. Square wire also has a tighter configuration when coiled.

I recommend: Compare copper wire prices between round and square wire at Hagstoz. If you need copper wire in other shapes, Radcliff Wire specializes in shaped wire.

Determine the size and source of your copper wire

The size of copper wire is usually determined by its electrical requirements with more current requiring thicker wire. Buy copper wire from manufacturers specializing in a particular application.

I recommend: Use the chart at Powerstream to determine your wiring requirements based on electrical capacity. Ducker Worldwide manufactures copper wire primarily for electrical systems in vehicles.

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• •  Copper wire prices are consistently higher than those for aluminum, and copper is much heavier than aluminum. In addition to superior electrical conductivity, however, the advantages of copper include a fatigue strength and electrochemical decomposition rate.
• •  Know that magnet wire is normally coated with a lubricant to allow the wire to be wound and unwound more easily. This is typically a dilute solution of mineral oil or paraffin wax. Copper wire for sensitive applications may need to be specifically ordered without lubricant if out-gassing is a critical factor.

Working with copper wire requires tools to cut, strip and crimp copper wire installations. These tools come in variety of different types, sizes and prices, depending on the tool quality and complexity. Some have special features, like slip-resistant handles or insulation. The vast majority of these tools come in basic models for the economically minded, and deluxe models for those who need all the bells and whistles.

When looking for tools to handle copper wiring, its best to select several different types and sizes of items like screwdrivers, pliers, crimpers and wire strippers. Some industrial copper wire requires larger tools than simple electrical copper wire, and may be more difficult to cut. Depending on how thick the wire is, you may need to purchase a heavy-duty cutter and pliers. Just remember, thicker wire and cable results in higher tool and copper wire prices.

1. Insulated tools will help prevent you from getting a shock should you accidentally touch a live copper wire with tools.

2. If you plan to work with copper cable and wire often, get ergonomic tools, which are designed to be more comfortable when working for long periods of time.

3. Some tools can do multiple jobs, depending on the model and job. Wire cutters, for instance, are often combined with crimpers to save space in the tool box or belt.

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Buy pliers for installing and adjusting copper wire and cable

Pliers are available in many different types, from long-nose pliers to side and diagonal cutting pliers. Each type of plier is best suited for a certain type of job. Long-nose pliers, for instance, are usually used to adjust, wrap and twist wire during installation. Other types of pliers may be essential depending on what type of job you'll be doing, so its best to have a large selection available.

I recommend: Pick from a wide range of pliers at My Toolstore's website or grab a pair from Goodmart.

Purchase wire cutters for severing copper wire and cable

The strength of the wire cutter you'll need to cut bare copper wire or cable depends on the wire's thickness and the number of strands. The difficulty you'll have cutting it can also be affected by any other metals present in the copper wiring. Copper alloy wires can be more difficult to cut, depending on what metal the copper is mixed with. For most jobs, a hand-held wire cutter will do the job, but some larger jobs may need a foot or electrically operated wire cutter.

I recommend: Choose from a wide variety of hand-held wire cutters available from Cable Organizer, or check out an automated electric model for cutting large amounts, such as bulk copper wire, like the one from Cutter Industries.

Use wire strippers to remove casing from copper wire

You'll need cable and wire strippers to install copper electrical cable and wire. These are sometimes built-in on pliers, or come as their own tool. They are used to pull casing off wire, allowing it to be connected or split. You may need larger or stronger wire strippers to strip thick cable or wire.

I recommend: Buy wire strippers from Lowes, or check out the wire cutter and stripper combo available from Action-Electronics.

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• •  Sometimes other supplies for copper wire, like tape measures, crimpers, levels and other tools are needed to complete a job. Often, tool sets are available in varying sizes specialized for various jobs, like electrical work. These tool sets have everything you'll need to do a wide variety of jobs.

Copper wire is used in a variety of products, as it's an excellent conductor of electricity that's often found in electrical cable and electronic instruments. The conductivity levels of copper wire are based on a number of factors that include the wire gauge, insulation and the shape of the wire. An important factor when choosing copper wire is the price, which varies based on the amount sold and whether the copper wire is clad with aluminum, which is a cost-saving option.

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Gauge

The gauge of a wire is the measurement of the diameter. Gauges are numbered with the largest gauge number representing the smallest diameter.

I recommend: Examine the American Wire Gauge chart at Interface Bus to see the different gauges of copper wire available. American Wire Gauge, or AWG, is the standard measurement for this type of wire.

Circuit

A circuit is an electrical connection between a power source and an electrical device. Copper wire is often used as the connection between the two sides of the circuit.

I recommend: The Tech provides a diagram and explanation of how a simple circuit works.

Bare copper wire

Bare copper wire is a type of wire that's not covered by any type of insulation material. Bare copper wire products come in stranded and solid versions.

I recommend: MWS Wire Industries provides a chart for the resistance values of bare copper wire, which are based on the gauge of the wire.

Flat copper wire

Flat copper wire is a type of wire that does not have a circular shape and cannot be measured in diameters.

I recommend: ASTM International has created the standards for flat copper wire for use in most general applications.

Alloy

An alloy is a combination of two or more metals where the atoms of one metal combine in the spaces between the other metal. An example of an alloy is brass, which is a mix of copper and zinc.

I recommend: Fisk Alloy provides specifications for many types of copper wire alloys used in electrical products.

Corrosion

Corrosion is the process of a material's essential elements breaking down due to chemical reactions in the environment. Copper materials corrode when exposed to water.

I recommend: The Copper Development Association has resources for corrosion protection and resistance for all types of copper materials, including copper alloys.