Conductor Options for Custom Wire & Cable

power cable
Galaxy is a leading supplier of custom and stock wires and cables, and there are many different conductor options available. Each conductor option has different physical and electrical characteristics.

Choosing a Conductor

Even when designing a single insulated wire, there are numerous factors to take into consideration. These include, but are not limited to, minimum and maximum temperatures, maximum voltage, and DC resistance of the insulation, as well as the conductor, size limitations, tensile strength and working environment. Galaxy can help guide customers through the selection process.

Conductor List

Galaxy can assist with the selection of the following conductors:

  • Bare Copper
  • Tinned Copper
  • Silver Plated Copper
  • Nickel Plated Copper
  • High Strength Alloys
  • Copper Clad Steel
  • Prebonded Conductor
  • Overcoated Conductor
  • Topcoated Conductor 

Conductor Temperature Specifications

Recommended working temperatures:

Tin Plated CopperSilver Plated CopperNickel Plated Copper
150°C200°C260°C


FAQs

Can a cable be rated to 200 degrees Celsius if some of the conductors are tinned copper while others are silver plated copper?

No, a cable may only be rated as high as its “weakest link”. Tinned copper conductors typically have a maximum service temperature of 150°C. Silver plated copper, however is rated at 250°C. Any insulation must have the same temperature properties to withstand that heat as well.

What is the difference between prebond, overcoat and topcoat conductors?

Prebonded conductors are tinned copper conductors which are heated to flow the tin, which then in essence bonds the individual strands together. Overcoated conductors are individually tinned conductors run through a tin bath to bond the conductors together. Topcoat process is basically the same as overcoat except that the individual conductors are un-tinned.



AWG Stranding Approximate OD
Inches MM
36 7/44 0.006 0.152
34 1/6 0.007 0.191
32 7/40 0.008 0.203
32 19/44 0.009 0.229
30 7/38 0.012 0.305
30 19/42 0.012 0.305
28 7/36 0.015 0.381
28 19/40 0.016 0.406
26 19/38 0.02 0.51
26 7/34 0.019 0.482
24 7/32 0.024 0.61
24 19/36 0.024 0.61
22 7/30 0.03 0.762
22 19/34 0.031 0.788
20 10/30 0.035 0.89
20 19/32 0.037 0.94
18 7/26 0.048 1.22
18 16/30 0.047 1.194
18 19/30 0.049 1.245
16 7/24 0.06 1.524
16 26/30 0.059 1.499
16 19/29 0.058 1.473
14 7/22 0.073 1.854
14 19/27 0.073 1.854
14 41/30 0.073 1.854
12 7/20 0.096 2.44
12 19/25 0.093 2.37
12 65/30 0.095 2.41
10 37/26 0.115 2.921
10 105/30 0.116 2.95
8 133/29 0.147 3.733
6 133/27 0.184 4.67
4 133/25 0.233 5.9
2 133/23 0.291 7.42
1/0 133/21 0.369 9.35
2/0 133/20 0.414 10.52
3/0 259/22 0.465 11.79
4/0 259/21 0.521 13.26
*For reference only, dimensions can vary

 

Contact Galaxy for Wire & Cable Conductor Options

Contact us for further assistance with conductor options for wire and cable products.