Article -> Article Details
| Title | How do bi-metallic lugs perform under repeated thermal expansion and load cycling? |
|---|---|
| Category | Automotive --> Automotive Parts |
| Meta Keywords | BI METALLIC LUGS |
| Owner | pioneer |
| Description | |
| Electrical systems are subject to temperature changes and varying load conditions, which lead to the frequent expansion and contraction of conductors and connectors. Bi-METALLIC LUGS made to these standards are still able to work on that basis and thus are the main choice in the modern power generation and distribution networks. Bi-metallic lugs consist of an aluminum body and a copper palm, which are joined together by means of friction welding. This process creates an internal bond that is very strong, and therefore, it does not allow the joint to heat up too much even if it is subjected to thermal expansion cycles repeatedly. The thermal expansion process does not cause stress at the connection since the aluminum conductor expands at a rate similar to that of the aluminum barrel. The copper palm that is constructed for bolted connections does not lose contact with the copper terminals during the load cycling due to stable contact. Moreover, the production of BI-METALLIC LUGS involves strict adherence to tolerances and application of tin plating on the surfaces as one of their special features. This process is to a large extent responsible for the prevention of oxidation leading to diminished contact pressure and production of resistance over time. Besides, the use of approved tools for proper crimping guarantees a gas-tight joint which is indispensable for the long-term stability under cyclic loads. Any application on thermal and electrical stress, such as to Substations or Renewable Energysystem, Industrial plants, etc., reliable performance is a must. PIONEER POWER INTERNATONAL & other manufacturers provide BI-METALLIC LUGS that have undergone tests as per international standards, which translates to durability, safety, and consistent performance under repeated thermal expansion and load cycling. In almost all cases, the electrical systems do not work under fixed conditions. Variations in load, temperature, and operating cycles make the conductors and connectors go through a series of heat and cool cycles repeatedly. The thermal expansion and load cycling contribute to the significant mechanical and electrical stress on the connections. Among all, BI METALLIC LUGS are the ones designed specifically to encounter these problems and guarantee longer working periods with stable and reliable performance. Apart from the above-mentioned applications, Bi-metallic lugs are mostly used where aluminum wires must be connected to copper busbars or machines. Metals, like aluminum and copper have different thermal expansion rates, which means they will not only expand and contract differently but also when the temperature changes around them. If these two metals were directly connected to each other, the movement would eventually cause joints to get loose, resulting in the increase of contact resistance, and ultimately leading to overheating or even the failure of the system. BI METALLIC LUGS change the game with their unrivaled design. The aluminium part of the lug that is in direct contact with the metal (aluminium conductor) is crimped on to it which guarantees that during the heating and cooling process, both materials move in tandem. This compatibility is highly effective in alleviating the mechanical stress at the crimped joint. The copper palm that in turn connects to the copper terminals is not only permanently attached but also bonded with the aluminium barrel by either friction welding or any other solid-state bonding method. This process forms a strong joint at the molecular level which is resistant to cracking or weakening under the influence of repeated thermal movement. During load cycling, variations in current result in temperature variations that can trigger contact pressure to relax in poorly designed connectors. The manufacturing of top-quality BI METALLIC LUGS is one of the ways that ensures the constant pressure of contact due to the choice of materials and the extreme precision of tolerances in their making. Furthermore, many lugs have a tin coating which can prevent the formation of corrosion. | |