Mechanical–Electrical Property Correlation in Copper, Aluminum, and Galvanized Steel Wires: A Comparative Study of Tensile Strength and Conductivity

This study evaluates the mechanical, electrical, and chemical properties of galvanized steel wire, focusing on the relationship between measured values and standard requirements. Mechanical tests showed the wire diameter (1.248 mm) within the desired range (1.18–1.32 mm), elongation (15.8%) above the 10% minimum, and tensile strength (414.9 N/mm²) exceeding the required 340–500 N/mm², confirming good ductility and strength. The breaking load (510.4N) demonstrated adequate structural performance. Electrical measurements indicated a resistance of 103.36 Ω/km, lower than the permissible 112.45 Ω/km, signifying efficient conductivity. Chemical analysis revealed a zinc coating mass of 389.8 g/m², far above the minimum 150 g/m², providing superior corrosion resistance. Adhesion and uniformity tests confirmed coating integrity, with no cracks or copper deposits observed. Further calculations of stress, strain, and energy absorption capacity reinforced the link between mechanical strength, deformation behavior, and electrical efficiency. Overall, results confirm the wire’s compliance with standards and highlight its suitability for structural and industrial applications.