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Bimetallic Lugs (Copper / Aluminum)

Galvanic corrosion and uneven current distribution at copper-aluminum junctions cause dangerous hot spots and premature failures – a persistent challenge in modern electrical infrastructure. Our Bimetallic Lugs eliminate these risks through explosion-welded transition zones that create molecular bonds between metals, ensuring stable conductivity across materials. 

Material Composition

Copper (C10100) barrel + Aluminum (6061-T6) tongue with explosion-welded transition zone

Conductor Size Range

16 mm² to 500 mm² (AWG 6 to 1000 kcmil)

Current Carrying Capacity

100 A to 1500 A (aluminum side derated by 15%)

Dimensions

Copper barrel OD: 10-60 mm; Aluminum tongue thickness: 5-20 mm; Bolt holes: M6-M24

Weight

50 g to 1.8 kg (30% lighter than full-copper equivalents)
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Product Description

Mechanical adapters inevitably loosen under thermal cycling, but our patented design maintains ≤0.5mV contact potential through 5000 extreme temperature transitions (-40°C to +120°C). The tin-nickel hybrid plating delivers dual-layer corrosion protection while achieving 30% weight reduction versus all-copper alternatives 

Barrel Length

25-75 mm (copper side) / 30-80 mm (aluminum side)

Termination Type

Compression barrel (Cu) + slotted tongue (Al) for dual-material termination

Crimping Compatibility

Hexagonal dies for copper (35-100 kN); indent crimping for aluminum (20-60 kN)

Operating Temperature Range

-40°C to +120°C (transition zone stable to +150°C peak)

Surface Finish

Tin-plated copper + nickel-plated aluminum (5-8μm each)

Voltage Rating

Up to 35 kV (transition zone tested per IEC 61439 for partial discharge)

Tensile Strength

250 MPa at transition zone (ASTM B898 Class III compliant)

Environmental Resistance

1000-hour salt spray (ISO 9227 C5) on both materials

Standards Compliance

IEC 61238-1 Class A (Cu), Class B (Al), UL 486B, BS 7889

Installation Method

Sequential crimping (copper first) with torque-controlled bolting (25-200 Nm)

Conductor Compatibility

Copper conductors (barrel) + Aluminum conductors (tongue) with ≤0.5mV contact potential

Technical Advantages

Standard bi-metal lugs fail at the joint, but our explosion-welded interface achieves 250MPa tensile strength which verified by metallurgical cross-section analysis. The transition zone’s 0.2μm interlayer blocks ionic transfer, preventing galvanic corrosion without grease maintenance. 

Independent testing confirms stable contact resistance (<15μΩ) through 5000 thermal cycles. Dual crimp zones (copper barrel + aluminum tongue) accommodate different tooling requirements while meeting both IEC 61238-1 Class A (Cu) and Class B (Al) standards. 

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Industry Applications

Utility Substation Upgrades

Seamlessly connects legacy copper busbars to modern aluminum conductors in circuit breaker retrofits, with 35kV partial discharge rating.

Renewable Energy Farms

Bridges copper inverter outputs to aluminum collector cables in solar/wind installations, surviving 1000+ salt spray hours. 

Industrial Plant Modernization

Enables phased transitions from copper to aluminum in motor control centers without service interruptions.

Marine & Offshore Electrification

Nickel-plated aluminum tongues resist seawater corrosion while copper barrels pflegen conductivity to equipment.

Railway Power Distribution

Withstands 10G vibration in traction power systems, compliant with EN 50152-1 for mixed-material networks.

Data Center Power Chains

Prevents thermal runaway at copper-aluminum junctions in high-density PDUs and busway systems.

The Ultimate Solution for Mixed-Metal Power Systems

Color-coded dies (red for copper, blue for aluminum) and sequential crimp guides eliminate installation errors. Each lug ships with matched hardware kits containing torque-limited bolts (25-200Nm) and anti-oxidation pads. 

Documentation packages include segregated material certifications (EN 10204 3.1 for copper, EN 573-3 for aluminum) with specialized transition zone performance reports. Each lug features laser-etched dual-size identification and compliance markings (UL/IEC) for error-proof installations. 

Bimetallic Lugs

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does your explosion-welding technology ensure long-term reliability?

The explosion-welded interface creates a 0.2μm metallurgical bond with 98% atomic diffusion, forming a permanent molecular connection between copper and aluminum. Independent electron microscopy confirms this bond withstands 5000 thermal cycles without developing micro-fractures or resistance drift. Compared to mechanical joints, our method maintains ≤0.5mV contact potential for over 25 years in field deployments. 

What documentation verifies the transition zone's performance?

Every shipment includes EN 10204 3.1 certificates with microhardness test reports (HV0.3) for the welded interface. Third-party labs validate the 250MPa tensile strength through cross-sectional tensile testing per ASTM B898. These documents also specify the nickel-chromium barrier layer thickness (0.5-1μm) that prevents interdiffusion. 

Can these lugs handle different conductor sizes on each side?

Yes, our asymmetrical designs accommodate size variances up to 2:1 ratio (e.g., 300mm² copper to 600mm² aluminum) without current imbalance. The transition zone is engineered with graduated thickness to distribute current density evenly across different cross-sections. Custom derating charts are provided for each configuration to ensure safe operation. 

How do you prevent installation errors with dual-material lugs?

Color-coded laser etching (red for copper, blue for aluminum) clearly indicates the proper termination sides. Each order includes sequential crimping instructions specifying copper-side compression must precede aluminum-side crimping. Training videos demonstrating the two-stage process are accessible via QR code on every lug. 

What maintenance is required for outdoor installations?

The nickel-tin hybrid plating eliminates need for annual anti-oxidation grease reapplication. Infrared thermography scans during routine inspections can detect any abnormal heating at the transition zone. Replacement is recommended if contact resistance exceeds 110% of initial values or after 15 years in coastal environments. 

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Bimetallic Lugs (Copper / Aluminum)

Need reliable wires and cables for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Get Latest Price

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Bimetallic Lugs (Copper / Aluminum)

Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Get Latest Price

Get Price Form