Which Industries Use Copper Alloy Tubes the Most?

• Electrical sector (~35 %): Dominates demand with busbars, connectors, transformer cooling coils, and grounding systems—leveraging copper’s unmatched electrical conductivity and reliability.

• Transportation (~25 %): Used in automotive and EV radiators, battery coolant loops, hydraulic/brake lines, and rail HVAC systems for superior thermal performance and corrosion resistance (Cu-Ni alloys).

• Electronics (~20 %): Powers micro-tubing in data-center cooling loops, precision heat pipes in laptops and smartphones, and high-vacuum components thanks to excellent thermal conductivity and workability.

• Other industries (~20 %): Encompasses marine engineering, HVAC & refrigeration, petrochemical processing, power generation, and desalination—where corrosion resistance, mechanical strength, and longevity are critical.

Copper alloy tubes, whether pure copper, copper‐nickel (Cu‐Ni), or various copper‐based brasses, play an essential role across a range of industries thanks to their excellent thermal and electrical conductivity, corrosion resistance, and mechanical strength. 

Below, we explore these industry segments (focusing especially on “Other” applications such as marine, HVAC, petrochemical, and power generation) outlining why copper alloy tubes remain indispensable.

Copper’s unrivaled electrical conductivity makes copper alloy tubes a go-to choice for electrical applications. In 2023, the electrical industry accounted for roughly 35% of all copper alloy tube demand globally. This segment includes:

• Busbars and connectors: Copper alloy tubes (often oxygen‐free copper or ETP grades) are used for busbars, which distribute power in switchgear, switchboards, and distribution panels. Their high current‐carrying capacity and reliability in hot, humid, or even slightly corrosive environments make them superior to aluminum alternatives.

• Transformers and generators: Many transformers use copper tubes for cooling windings. A robust data point: transformer oil‐cooler coils and hydrogen‐cooled generator coils often employ copper‐nickel tubes to combine electrical performance with corrosion resistance (particularly in utility power plants).

• Power cables and grounding systems: In substations, seamless copper tubing is used for grounding conductors, system bonding, lightning protection, and earthing rods. The combination of ductility and conductivity ensures system safety and longevity.

Because the electrical sector prioritizes conductivity, reliability, and minimal maintenance, copper alloy tubes dominate here. Their recyclability further supports sustainability targets in many regions.

In 2023, 25% of copper alloy tube usage was in transportation, encompassing both automotive and larger vehicles (e.g., rail, marine, aerospace ground systems)(Market Size and Trends, 2025). Key applications include:

• Automotive heat exchangers: Radiators, oil coolers, and air conditioning evaporator coils often incorporate copper or Cu‐Ni alloy tubes paired with aluminum fins. Copper’s superior thermal conductivity (≈401 W/m·K) yields efficient heat rejection, crucial for electric vehicles (EVs) as well as traditional internal combustion engine (ICE) vehicles.

• Hydraulic and brake lines: Copper‐nickel alloy tubes (CuNi 90/10 or 70/30) are frequently used in brake systems and hydraulic lines for high‐pressure, brake‐fluid service, owing to corrosion resistance, pressure‐bearing capacity, and ease of bending.

• Rail and mass transit: HVAC systems in trains deploy copper alloy heat exchanger tubes (often Cu‐Ni in coastal or humid climates). Their proven corrosion resistance—particularly in exposure to de-icing salts and road grime—translates to lower lifecycle costs.

Notable statistic: EV battery thermal management is driving incremental growth in copper tubes used in battery coolant loops, where high conductivity and reliability under cyclic loads are critical. (Verified Market Reports, 2025)

Accounting for 20% of copper alloy tube demand in 2023, the electronic industry relies on copper alloy tubes for:

• Heat sinks and cooling loops: Data centers, server farms, and high‐performance computing (HPC) labs use direct‐to‐chip liquid cooling. Seamless copper micro‐tubing (often 3–6 mm OD) carries dielectric coolant or water glycol, leveraging copper’s thermal properties to maintain sub‐ambient temperatures.

• Compact precision coils: Smartphone and laptop base‐plate heat pipes often contain flattened copper tubes or vapor chambers. These tubes—typically copper with a thin wick lining—enable rapid heat spreading from chips (CPUs/GPUs).

• Electronic packaging: Copper alloy tubes appear in high‐vacuum electronic devices and microwave amplifiers (e.g., traveling‐wave tubes), where precision‐machined copper provides both mechanical support and thermal conduction.

As devices shrink and power densities rise, copper’s combination of workability and thermal conductivity maintains this segment’s robust share.

Though representing a smaller 10% portion in 2023, the space industry’s use of copper alloy tubes is notable for its demanding requirements. Applications include:

• Satellite thermal control: In orbit, thermal gradients can exceed 200 °C. Copper alloy tubes—often Cu‐Ni or specialized high‐strength brasses—are used in loop heat pipes (LHP) and pumped‐loop cooling loops to manage electronics and battery packs. Their reliability under vacuum and broad temperature swings is key.

• Propellant management: Copper-based alloy tubing in spacecraft fuel lines (e.g., hydrazine or cryogenic propellants) benefits from copper’s ease of forming and high leak integrity after brazing or welding.

• Launch platforms: Ground support equipment (GSE) at launch sites uses copper alloy tubing for cryogenic propellant transfer lines and control systems, where low‐temperature toughness is essential.

These tubes undergo rigorous qualification tests—vibration, thermal cycling, and radiation exposure—before flight certification.

The “Other” category (accounting for 10% of demand) encompasses several critical sectors, each warranting a closer look:

Cu‐Ni 90/10 and 70/30 alloys: Widely used in shipboard seawater piping, condenser tubes, bilge and ballast systems, and onboard HVAC (freshwater supplied to cabin air handlers) because of superior seawater corrosion resistance. Cu‐Ni 90/10 tubing has an allowable seawater velocity up to ~3.5 m/s (pipes) and ~2.4 m/s (tubes) before erosion‐corrosion accelerate; Cu‐Ni 70/30 extends that to 4.0 m/s and 3.0 m/s, respectively.

Desalination and offshore platforms: Desalination brine heaters and evaporator tubes often employ Cu‐Ni alloys because of long‐term reliability (0.002–0.02 mm/yr) and negligible pitting in seawater once the protective film matures. Petrochemical processing platforms use Cu‐Ni splash zone sheathings (up to 25 years service life) and seawater piping for fire suppression, seawater ballast, and heat rejection systems.

In the broader copper tubes market, HVAC accounted for ~32% in 2023 (copper, not exclusively alloy) due to copper’s thermal conductivity and ease of forming inner grooves for enhanced heat transfer efficiency (PW Consulting Chemical & Energy Research Center, 2025).

Copper alloy tubes (ETP, DHP, DLP): High‐end HVAC systems increasingly use DHP (Deoxidized High Phosphorus) copper tubes for indoor coils and, in coastal climates, Cu‐Ni for condensers to resist corrosion. The HVAC sector’s regulatory push (e.g., EU Ecodesign requiring 30% efficiency gains by 2030) means copper alloys remain crucial. 

Heat exchanger tubing in refineries: Industrial facilities and power plants have historically been the largest single user of copper‐oriented heat exchanger tubing. Over 40% of heat exchanger tube life‐cycle value (by tonnage) is attributed to utility power plants and petrochemical complexes where high‐pressure, high‐temperature service demands copper‐nickel or specialized brasses for steam, ammonia, and hydrocarbon process streams.

Catalyst support and feed Lines: Corrosive process streams (e.g., hydrocarbon condensers, pre‐coolers, high‐pressure feedwater heaters) use copper alloys (often admiralty brass or copper‐nickel) to resist ammonia attack and chloride stress corrosion cracking.

Condenser and feedwater heater tubes: Steam turbine condensers in fossil and nuclear plants use millions of linear feet of copper tubes (often 70/30 Cu‐Ni) because of low corrosion rates (~0.002 mm/yr at 27 °C) and antifouling properties that reduce heat transfer losses over decades.

Renewables: Concentrated solar power (CSP) and geothermal plants employ Cu‐Ni or high‐copper brasses in exchangers to leverage thermal conductivity and chemical stability in high‐temperature, mineral‐laden fluids.

Evaporator and brine heater tubes: Desalination plants in the Middle East, North Africa, and Australia rely on Cu‐Ni 90/10 and 70/30 tubes. Field data confirm that after an initial 3 month film maturation at ~27 °C, steady‐state corrosion rates drop to ~0.003 mm/yr; over 15 years, average tube thinning remains <0.05 mm.

Type L and M copper tubes: In North America and Europe, Type L (medium thickness) and Type M (thin‐wall) copper tubes (mostly ETP C12200 or DHP C12200) dominate residential plumbing. These tubes accounted for ~15% of total copper tube demand in 2023 (across copper tube market, not only alloy). Their natural antimicrobial properties also meet potable water standards, with minimal maintenance over 30+ years.

• Validate your marine and desalination designs with Cu‐Ni 90/10 or 70/30 to achieve minimal pitting (0 mm/yr) and long life (20–40 years) versus stainless steel.

• For HVAC systems, balance upfront DHP copper tube costs with projected lifecycle savings over plain steel or aluminum in corrosive conditions (where HVAC tubes may fail in <5 years).

• In petrochemical and power generation, prioritize Cu‐Ni alloys in heat exchangers—knowing that average corrosion rates remain below 0.02 mm/yr with proper design and film maturation.

• Leverage copper’s recyclability: More than 80% of copper used in industry is recycled at end of life, minimizing environmental impact and supporting green building certifications.
  

Ready to elevate your next project with industry-leading copper alloy tube applications? Contact Admiralty Industries today for a customized consultation and discover how our precision-engineered tubing can drive efficiency, reliability, and sustainability in your operations.

Market Size and Trends. “Global Copper Alloy Tubes Market By Type, By Application, By Geographic Scope And Forecast.” Market Size and Trends, June 2025, https://www.marketsizeandtrends.com/report/copper-alloy-tubes-market/.

Verified Market Reports. “Copper Alloy Tubes Market Size, Assessment, Growth & Forecast.” Verified Market Reports, Feb. 2025, https://www.verifiedmarketreports.com/product/copper-alloy-tubes-market/.

PW Consulting Chemical & Energy Research Center. “Industrial Insulated Copper Tubes Market.” PW Consulting Chemical & Energy Research Center, 9 Feb. 2025, https://pmarketresearch.com/chemi/industrial-insulated-copper-tubes-market/.