What Kind of Wire Is Used for an Engine Harness?

Custom wiring harness refer to the vehicle’s electronic system components and relay power and data to the various subsystems. Engine wires must be constructed with the appropriate level of electrical conductivity as well as insulation to protect them from unwanted shorts. This can be accomplished by using a combination of copper or aluminum wires. Some wire types may have additional elements, such as zinc plating or synthetic insulation, to improve the quality and performance of the wire. This blog post will discuss the types of cables we use for custom harnesses.

Copper and Aluminum Wires

Copper and aluminum are the most common materials used in engine harnesses. These materials have a conductivity rating of between 68 mH/1000 ohms and approximately 90 mH/1000 ohms, depending upon the wire size. The high conductivity of copper wires is attributed to the weight of metals like copper itself and traces of other metals such as nickel and tin-plated over the surface. Aluminum wires have similar characteristics with the addition of a coating of aluminum oxide to prevent corrosion.

Zinc-Plated Wires

Chromium, Zirconium, and Molybdenum are common elements used in manufacturing wire for engine harnesses. These elements are added to the surface of the wire to enhance conductivity and reduce corrosion. The result is a product with a higher conductivity rating than copper or aluminum wires. Zinc plating also helps to prevent corrosion. Zinc is the most commonly used of these elements and is suitable for high-temperature applications. The main advantage of using these wires is that they can handle higher temperatures without losing conductivity.

Synthetic Insulated Wires

These wires feature a special type of insulation that is made from various types of polymers. This insulation helps prevent the electrical signal from being degraded by environmental factors such as moisture, acidity, or extreme temperatures. Synthetic insulation has a conductivity rating of approximately 140 mH/1000 ohms. Synthetic insulation works well in applications with high temperatures, corrosive environments, or exposure to the elements.

Grounding Wires

As with all wiring, the connecting parts need to be adequately grounded and insulated before any data transfer occurs. Grounding wires are used to ground the various aspects of an engine harness, such as fuses, relays, and connectors. These wires feature a layer of aluminum oxide combined with zinc plating to make the metal more resistant to corrosion and provide a greater electrical conductivity. It is important to use aluminum oxide wires for harnesses that are exposed to the elements. This is because aluminium oxide wires are usually resistant to environmental conditions and will not corrode as easily.

Choose the Best Quality for Your Need

There are several considerations to keep in mind when choosing a custom wiring harness. First, the length of time that the wire will remain installed and exposed to the elements should be taken into consideration. The material and coating can determine how well insulated and protected the wire is against moisture, heat, cold, and other environmental factors. For more details on custom wiring harnesses, visit American Auto and Marine Wiring. We will be delighted to show you our extensive catalog of engine wiring harnesses.