Solving Electrochemical Corrosion: Technical Applications Of Bimetallic Terminals

In modern industrial power distribution systems, the heterogeneity of materials often presents potential contact hazards. Due to its high cost-effectiveness and lightweight properties, aluminum's share in cable laying has been increasing year by year. However, when aluminum conductors directly contact copper equipment interfaces, the different electrochemical potentials between the two metals easily induce pitting corrosion, a phenomenon particularly pronounced in humid or temperature-sensitive environments.

Mechanical Strength and Conductivity of Heterogeneous Material Connections

bi metal lugs connectors A friction welding process combines electrical aluminum and oxygen-free copper at the atomic level, achieving physical fusion of the two materials. With this special construction method, bi metallic cable lugs can reliably connect the aluminum conductor to the copper terminal, establishing a physical barrier inside the joint.

• Interface Fusion Technology: The bonding layer formed by friction welding has a uniform thickness and extremely high mechanical tensile strength.

• Cross-sectional Area Matching: The diameter of the aluminum tube is thickened to compensate for the slightly higher resistivity of aluminum compared to copper.

• Sealing Treatment: Conductive grease is pre-filled inside the conduit, combined with a rigorous crimping process.

Long-Term Operational Performance in Industrial Power Systems

Power infrastructure typically has a lifespan of decades, and the long-term stability of contact resistance is a core indicator of connection quality. The bimetal cable lug design takes into account the subtle differences in the thermal expansion coefficients of copper and aluminum, absorbing internal stresses caused by thermal expansion and contraction through a flexible transition section.

Using bimetal terminal lug for conversion at the transformer output terminal or inside the switch cabinet has become a standardized operating procedure. This connection method not only improves the uniformity of current carrying capacity distribution but also provides a standardized interface for subsequent inspections and maintenance.