Coaxial cable including tubular bimetallic inner layer with bevelled edge joint and associated methods

A coaxial cable comprising:

• an inner conductor, an outer conductor and a dielectric material layer therebetween;
• said inner conductor comprising a tubular bimetallic layer having a pair of opposing longitudinal edges at a longitudinal seam;
• said tubular bimetallic layer comprising an inner aluminum layer and an outer copper layer bonded thereto;
• each of said opposing longitudinal edges of said tubular bimetallic layer being at least partially bevelled at the longitudinal seam;
• the longitudinal seam comprising a welded joint between at least portions of said inner aluminum layer.

A method for making a coaxial cable comprising an inner conductor, an outer conductor and a dielectric material layer therebetween, the method comprising:

• forming the inner conductor by at least
• forming a bimetallic strip into a tubular bimetallic layer having a pair of opposing longitudinal edges at a longitudinal seam, the tubular bimetallic layer comprising an inner metal layer and an outer metal layer bonded thereto with the inner metal layer having a lower melting temperature than the outer metal layer, and at least one of the opposing longitudinal edges of the tubular bimetallic layer being at least partially bevelled,
• welding the longitudinal seam to form a welded joint between at least portions of the opposing longitudinal edges;
• forming the dielectric material layer surrounding the inner conductor;
• and
• forming the outer conductor surrounding the dielectric material layer.