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.



AWGStrandingApproximate OD
InchesMM
367/440.0060.152
341/60.0070.191
327/400.0080.203
3219/440.0090.229
307/380.0120.305
3019/420.0120.305
287/360.0150.381
2819/400.0160.406
2619/380.020.51
267/340.0190.482
247/320.0240.61
2419/360.0240.61
227/300.030.762
2219/340.0310.788
2010/300.0350.89
2019/320.0370.94
187/260.0481.22
1816/300.0471.194
1819/300.0491.245
167/240.061.524
1626/300.0591.499
1619/290.0581.473
147/220.0731.854
1419/270.0731.854
1441/300.0731.854
127/200.0962.44
1219/250.0932.37
1265/300.0952.41
1037/260.1152.921
10105/300.1162.95
8133/290.1473.733
6133/270.1844.67
4133/250.2335.9
2133/230.2917.42
1/0133/210.3699.35
2/0133/200.41410.52
3/0259/220.46511.79
4/0259/210.52113.26
*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.