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The electrical systems frequently go through a cycle of thermal expansion and load cycling many times over because of the fluctuations in current, the environmental temperature changes and the intermittent operation. These cycles put stress on electrical connections, especially where dissimilar metals such as aluminium and copper are tied together. BI METALLIC LUGS are made to perform under such stressful conditions for a long time.

The durability of the BI METALLIC LUGS comes from the designed route. BI METALLIC LUGS comprise of an aluminium barrel and a copper palm that is fused together via friction welding. The tough molecular bond that is created between the two materials remains strong even during thermal expansion or contraction as the metals are of different rates. The aluminium barrel holds the conductor tightly while the copper palm connects to terminals or busbars – thus allowing the junction to dissipate thermal stresses without loosening or losing conductivity.

Furthermore, the aluminium side is often pre-filled with an oxide-inhibiting compound that protects the conductor and keeps the electrical contact uniform throughout the cycles. The tin-plated copper palm also adds to the resistance against corrosion and ensures stable performance even in the presence of varying loads.

The leading pultruded BI METALLIC LUGS from the likes of PIONEER POWER INTERNATIONAL undergo strict testing so that they conform to international standards, proving that they are capable of handling high current loads, outdoors, and going through the thermal cycling repeatedly. The application of these lugs grants electrical connections that are safe, long-lasting, and free from maintenance in the fields of industrial, utility, and renewable energy.

Electrical systems undergo continuous modifications due to changes in current, environmental factors, and operational cycles. These variations over the years will lead to the phenomenon of load cycling in which conductors undergo repeated thermal expansion and contraction. When an aluminum conductor and a copper conductor are connected, the difference in their thermal expansion rates can cause a lot of stress at the joint. The reason is that aluminum temperatures fluctuate more than copper's, and if the connection is not properly designed, this repeated movement can not only loosen the joints but also increase resistance at the contact point, lead to overheating, and finally result in system failure. BI METALLIC LUGS are the solutions specifically engineered to tackle these difficulties and ensure safe, reliable, and permanent electrical connections even under drastic conditions.

The unique construction of BI METALLIC LUGS is the source of their strength and durability. An aluminum barrel with a copper palm is used in these lugs, and the two parts are joined together by using friction welding. This process produces a bond that is so strong it cannot be broken, eliminating weak areas that could give way under stress. The interface created by the welding is unlike ordinary mechanical connections and it ensures that the differences in thermal expansion between aluminum and copper won't result in the joint being compromised. The aluminum barrel hugs the conductor firmly, thus assuring the flow of electrical current consistently, while the copper palm keeps the connection to busbars or equipment terminals that can be trusted.