The Use of Copper Wire in the Aerospace Industry
Manufacturers throughout the aerospace industry seek out copper wire for high-quality conductors. Copper and copper alloys conductors deliver reliability and precision that comply with rigorous industrial standards, while fine and ultra-fine copper wires can support critical operations where failure and disrepair are not an option. Learn more about how aerospace applications can use copper wiring solutions for aircraft avionics, communication systems, instrumentation, and more.
Important Considerations for Conductors in Aerospace Applications
Designing wiring systems for aircraft and spacecraft involves more than just selecting a conductor-it requires evaluating performance under extreme conditions. Here are the most important parameters to assess when specifying copper wire for aerospace use:
- Conductor diameter. Measured across the outermost strands; it affects flexibility and fit.
- Conductor weight. Typically expressed in lbs/1000 ft, it impacts overall system weight—a critical factor in aerospace.
- Conductivity. The ability of a material to conduct electricity. It is typically presented relative to ETP (Electrolytic Tough Pitch) copper using the term % IACS, where ETP copper has a value of 100.
- Flex life. A copper conductor’s flexure endurance is its ability to maintain integrity despite repeated bending and flexing. Manufacturers need conductors with a high flex life for wiring assemblies that undergo a lot of bending and vibration.
- Resistivity. How much a material opposes the flow of electrical current is its resistivity. Conductor materials have a resistivity measured in ohms-cmil/ft, and completed conductor products have a resistivity measured in ohms/1000 ft.
- Tensile strength. The measure of a material’s resistance to breaking under tension. It is typically measured in PSI. An alternate way of measuring the strength of a conductor is its break load, which is the force required to physically break the conductor. It is normally measured in pounds.
- Thermal stability. The ability of a material to maintain properties at elevated temperatures for extended periods of time. Precipitated copper alloys such as Tensile-Flex or 36EF have the ability to maintain tensile strength at temperature for extended periods of time, while other materials such as ETP copper or copper magnesium will weaken very quickly.
Aerospace Wire Compliance Standards
In addition to the above considerations, wiring materials also need to comply with applicable safety and industrial standards. Aerospace wire standards mandate the minimum performance, safety, quality, and reliability measures that conductors must meet in various applications. These standards include:
- ASTM D3032
- NEMA-WC27500
- SAE AS22759
- SAE AS4373
- SAE AS50881
Product designers and manufacturing support teams need to account for all of these variables when selecting copper wire options for different applications.
Why Copper and Copper Alloy Wire Is Ideal for Aerospace
Copper and copper alloy conductors offer the right material characteristics—such as strength, conductivity, and compliance with industrial standards—making them a popular choice for aerospace wiring assemblies. Some of the critical characteristics that make these metals such a good fit are:
- High Conductivity. Copper has very little resistance, allowing for an efficient conduction of electrical current.
- Elasticity & Flexibility. Copper stretches under strain and returns to form, ideal for dynamic environments.
- Malleability. Supports the creation of ultra-fine, complex, and custom-shaped wires without cracking.
- Strength. Copper conductor offers excellent mechanical endurance with easy formability and resilience against fatigue.
Applications of Copper and Copper Alloy Wire in Aerospace
Aerospace companies use copper wires in an extensive range of subassemblies, products, and applications.
- Communication cables. Copper and copper alloy wires can quickly transmit high-speed and high-frequency signals throughout aerospace vehicles.
- Instrumentation cables. Manufacturers use copper wiring for connecting gauges, sensors, and more to control panels.
- Power Distribution cables. Copper wiring can efficiently carry power throughout the aircraft.
- Specialty Aerospace cables. Manufacturers can also produce specialty copper wires for grounding, bonding, shielding, current return paths, and more.
Reliable Copper Wire Solutions for Aerospace From International Wire
At International Wire Group, Inc., we engineer and manufacture precision copper wire products that meet and exceed aerospace performance standards. Whether you’re developing custom avionics harnesses or scaling up production for large assemblies, our team delivers:
- Custom-engineered solutions
- Aerospace-grade copper and copper alloy conductors
- Scalable production capabilities
- Full compliance with global standards
Ready to get started? Contact us today to learn more, or request a quote to start your order.
