Preventing copper wire from corroding

The sole purpose of wire and cable is to conduct electrical current from one place to another, but if the cable begins to corrode, it will quickly break down and cause performance degradation. Any copper in the wire is susceptible to corrosion. While bare copper is fairly resistant to corrosion, tinned copper (copper coated with a layer of tin) is able to resist accelerated corrosion from moisture and polluted environments.

Tinned copper is primarily used to prevent oxidation and corrosion. When copper is exposed to water for long periods of time in climate conditions, oxygen combines with the metal to form copper oxide, weakening the metal-to-metal bond. This is even worse if the wire is exposed to salt water. As this oxide forms, the integrity of the copper is weakened, becoming brittle and prone to breaking. Corroded copper wire is less efficient at transmitting electrical current and can pose a safety hazard.

How to Prevent Wire Corrosion

To prevent accelerated corrosion, tinned copper wire conductors can be used as an additional layer of protection.

Tinned copper cables are primarily used in sewage treatment facilities, subway systems, and other environments that are susceptible to long-term water contamination. The tin coating on the copper prevents the wire from corroding and failing prematurely.

Advantages of Tinned Copper:

• Prevents corrosion.
• Extends cable life.
• Easy to solder.
• Same conductivity as bare copper.

Applications of Tinned Copper Wire and Cable

Tinned copper wire is particularly useful in wastewater treatment facilities, underground subway systems, and projects exposed to excessive oil, gas, or water. Tinned copper conductors are commonly used in utility projects in the Northeast and in environments exposed to excessive sodium chloride salts (seawater).

Tinned Copper vs. Bare Copper

When considering bare or tinned copper wire, environmental considerations should be the determining factor in wire selection. Tinned copper wire can extend the life of the cable, but not all projects can be easily retrofitted. Considering and planning for potential corrosive environments ahead of time can avoid a complete cable replacement in the future.