Raytron Technical Review RESEARCH ARTICLE WP-06-09

Aluminum Clad Steel: Strength-to-Weight Optimization

Gao-Lei Xu¹ *

¹RAYTRON Group Technology Research Center, China

^*Corresponding author

Received: 2025-12 Accepted: 2026-02 Published: 03/2026

DOI: 10.1234/raytron.2026.WP-01-19

Abstract

Aluminum clad steel combines the high strength of steel with the lightweight and corrosion resistance of aluminum, offering an optimal strength-to-weight ratio for overhead conductors. This technical analysis examines the mechanical properties, electrical performance, and structural design of ACS conductors, with focus on ACSR and OPGW applications.

Key Findings

Excellent Strength-to-Weight Ratio ACS achieves tensile strength of 1100-1600 MPa with density of only 6.5-7.5 g/cm³, providing excellent strength-to-weight ratio, ideal core material choice for overhead transmission lines.
Excellent Corrosion Resistance Aluminum cladding provides complete corrosion protection for steel core, with long-term stability in harsh environments like industrial and marine, requiring no additional corrosion protection measures.
ACSR Core Application ACS serves as reinforcing core for ACSR (Aluminum Conductor Steel Reinforced), providing mechanical strength support, working synergistically with outer aluminum conductors, enabling economical design of long-span transmission lines.
OPGW Key Material ACS is the foundation material for OPGW (Optical Ground Wire), simultaneously providing mechanical strength, lightning protection, and fiber optic protection functions, enabling power-communication integration.

Keywords

aluminum clad steel;ACS;ACSR;OPGW;strength-to-weight ratio;overhead conductor

1. Introduction

ACSMainACSR Core and OPGWCable 。

2. Material Properties

3. ManufacturingProcess

4. ACSRApplications

ACSR StructureSchematic Diagram — **Fig. 1** ACSR Structure Schematic Diagram

5. OPGWApplications

Create OPGW Structure Diagram

MEDIA TODO

Figure Fig. 2 OPGW Structure Diagram

6. OtherApplications

7. Conclusion

ACSin OverheadTransmission and provides excellent StrengthWeight。

Frequently Asked Questions

What are the advantages of ACS compared to galvanized steel wire?

ACS's aluminum cladding provides better corrosion resistance and conductivity. Compared to galvanized coating, aluminum cladding is thicker, more uniform, more durable, and has better conductivity (20-30% IACS vs galvanized steel's about 10%), suitable for applications requiring conductivity like OPGW and grounding.

What is the role of ACS in ACSR?

In ACSR, ACS wire serves as core providing mechanical strength, supporting the entire conductor structure. Outer aluminum wires provide main conductive channels. This combination achieves balance of high strength (from steel core) and high conductivity (from aluminum wires), being mainstream design for overhead transmission lines.

What application scenarios is ACS suitable for?

ACS is mainly used for: reinforcing core of ACSR conductors, structural unit of OPGW cables, ground wire systems, long-span overhead lines. Any overhead application requiring high strength, corrosion resistance, and certain conductivity can consider ACS.

How is ACS's conductivity?

ACS conductivity is 20-30% IACS, mainly contributed by aluminum cladding. Although lower than pure aluminum (61% IACS) and CCA (62-68% IACS), it is sufficient for ACSR core and OPGW applications, and far higher than bare steel wire (about 2% IACS).

Figures

Create ACSR Structure Diagram

Fig. 1 ACSR Structure Diagram

Create OPGW Structure Diagram

Fig. 2 OPGW Structure Diagram

Tables

Table 1 Physical Properties

Property	ACS
Density (g/cm³)	6.5-7.5
Conductivity (% IACS)	20-30
Thermal Expansion (×10⁻⁶/°C)	13-15

Table 2 Mechanical Properties

Property	Typical Grade
Tensile Strength (MPa)	1100-1600
Yield Strength (MPa)	900-1300
ElongationRate (%)	1-3

Table 3 ACSR Configurations

Designation	ACS Wires	Al Wires	Application
Raven	1	6	Light Load
Penguin	7	18	standards
Cardinal	7	30	Heavy Load

References

ASTM International ASTM B415: Aluminum-Clad Steel Wire ASTM (2020)

Authoritative References

ASTM International IEC (International Electrotechnical Commission) ISO (International Organization for Standardization) SAE International IEEE

Gaolei Xu

Senior Materials Scientist

Credentials & Honors

• CTO, Raytron Group
• Zhejiang Provincial High-level Talent Special Support Program - Young Talent
• Shaoxing "Technology Vice President"
• Shaoxing Science and Technology Commissioner
• Member of National Technical Committee 243 on Heavy Metals (SAC/TC 243/SC2)

National Standards (Lead Author) View Official

GB/T 27671-2011 - Copper Profiles for Electrical Conductors
YS/T 1043-2015 - Silver-bearing Oxygen-free Copper Strip for Motor Commutators
YS/T 974-2014 - Copper and Copper Alloy Strip for Composite Contact Materials
YS/T 1082-2015 - Copper Strip for Lamp Lead Stents

Patents (Inventor) Search Patents

CN104959396A - Production Process of Copper Strip for Composite Contact Materials
CN106077125A - Production Process of Copper Profile for Magnetic Pole Coils
CN201410710206 - Conductive Material for High-speed Railway Traction Motors and Production Method
CN201310719717 - Method for Controlling Strip Shape of Copper Strip Blank by Continuous Extrusion
CN201310720126 - Device for Controlling Strip Shape of Copper Strip Blank by Continuous Extrusion
CN201310376884 - Five-in-one Copper Strip Edge Treatment Equipment for Transformers
CN201420184755 - Continuous Extrusion Die Flow Promotion Device
CN201320761640 - Continuous Extrusion Waste Cleaning Device

Areas of Expertise

Copper-Clad Aluminum (CCA) Technology Copper-Clad Steel (CCS) Manufacturing Bimetallic Composite Materials PV Ribbon for Solar Cells Battery Tab Materials for EV Applications Continuous Extrusion Technology

Selected Publications

• Research and Application of Rolling Method for Manufacturing Metal Laminated Composites, Aluminum Processing Journal, 2008
• Annealing Process Research of Copper-Aluminum Composite Strip
• Research on Preparation Process of Copper/Aluminum Composite Strip for Cables
• Interface Microstructure Evolution of Rolled Copper/Aluminum Composite Strip During Annealing

Mr. Xu Gaolei is a distinguished expert in non-ferrous metal processing with over 15 years of experience. He is recognized as a Young Talent under the Zhejiang Provincial High-level Talent Special Support Program. He leads R&D initiatives in bimetallic composite technologies and has contributed significantly to the standardization of copper and bimetallic materials in China.

Click standard/patent codes to view official documents