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In contemporary electrical systems, the use of aluminium conductors for power transmission has become more common because of their lightweight and cost-effective nature, while copper is the preferred choice for terminals, busbars, and equipment because of its superior conductivity. When these two metals are joined together, the point of connection can be the main cause of power loss. In this scenario, BI METALLIC LUGS become indispensable in providing efficient and low-loss electrical connections in mixed-metal systems.

High contact resistance is one of the main reasons for energy losses in mixed-metal connections. The oxidation of aluminium and copper happens differently in the presence of air and moisture, which leads to galvanic corrosion as one of the reactions. The aforementioned reactions cause an increase of resistance at the joint, which then results in the generation of heat and consequently power losses. BI METALLIC LUGS are crafted to work the other way around providing the continuous and steady transition between aluminium conductors and copper terminals.

Bi-metallic lugs are made of an aluminium barrel and a copper palm that are intertwined through a process called friction welding or any other solid-state bonding technique. This method results in a low-resistance joint that is very strong, almost at the molecular level, thus providing maximum electrical continuity between the two metals. By getting rid of weaker contact areas, BI METALLIC LUGS come down drastically on energy losses related to resistance.

Another aspect that plays an important role in the reduction of energy loss is the maintaining of constant contact pressure over time. Electrical connections are frequently subjected to temperature fluctuations and load cycling, and this may lead to loosening with the use of conventional connectors. The best quality BI METALLIC LUGS are crafted in such a way that they can deal with the thermal expansion properties of aluminium and copper separately.