Engine mounts, chassis parts, and machined components for assembly lines.
High-strength fasteners, landing gear parts, and structural assemblies.
Forged housings, armor brackets, and mission-critical structural parts.
Precision housings, actuator frames, and armature linkages for automation systems.
Metal frames, brackets, and assemblies for appliances and home equipment.
Busbar holders, battery pack parts, and lightweight structural enclosures.
Solar mounting parts, wind turbine brackets, and battery enclosures.
Valve bodies, flange blocks, and downhole drilling components.
Large welded frames, PEB structures, and assemblies for industrial equipment.
High-performance cables and wires engineered for durability and seamless connectivity across applications.
Custom-built wiring harnesses for secure connections and streamlined installations.
Precision-engineered busbars for efficient power distribution and minimal energy loss.
Robust connectors designed for secure locking, reliable conductivity, and long-term performance.
Durable transformers built for consistent performance, energy efficiency, and stable power regulation.
Frigate’s industrial-grade heat sinks provide efficient, customizable cooling for high-performance thermal management.
Diverse solutions covering automotive, electrical, mechanical, and industrial needs with precision-built components.
CNC machining delivers micron precision and tight tolerances for complex geometry.
Frigate CNC Machining offers high-precision, custom solutions for complex casting geometries. Multi-axis capabilities ensure tight tolerances and optimal surface finishes.
Sheet metal fabrication uses laser cutting, punching, and bending for precision.
Frigate Sheet Metal Fabrication utilizes advanced laser cutting and press brake technology for custom casting applications. Tight tolerances, superior welds, and high-strength materials ensure structural integrity.
Injection molding produces high-precision parts with consistent quality.
Frigate Injection Molding delivers custom-engineered parts with micron-level precision and structural integrity. Specialized molds maintain tight tolerances for complex geometries and high-stress applications.
Precision casting ensures accurate, high-quality parts.
Forging services improve material strength with precise tolerances.
Frigate Casting Services provides custom casting with tight tolerances and complex geometries. We enhance material properties using advanced metallurgy, ensuring strength and wear resistance. Our precision methods support high-performance aerospace, automotive, and industrial applications.
End-to-end part production from samples to bulk supply.
Ready-to-use assemblies built to exact fit and function.
Heavy-duty fabrication with high-strength materials for demanding applications. Robust welding for maximum structural durability.
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
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.
Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!
Seamlessly connects legacy copper busbars to modern aluminum conductors in circuit breaker retrofits, with 35kV partial discharge rating.
Bridges copper inverter outputs to aluminum collector cables in solar/wind installations, surviving 1000+ salt spray hours.
Enables phased transitions from copper to aluminum in motor control centers without service interruptions.
Nickel-plated aluminum tongues resist seawater corrosion while copper barrels maintain conductivity to equipment.
Withstands 10G vibration in traction power systems, compliant with EN 50152-1 for mixed-material networks.
Prevents thermal runaway at copper-aluminum junctions in high-density PDUs and busway 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.
Check all our Frequently Asked Question
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.
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.
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.
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.
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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818, Preakness lane, Coppell, Texas, USA – 75019
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ
FRIGATE is a B2B manufacturing company that facilitates New Product Development, contract manufacturing, parallel manufacturing, and more, leveraging its extensive partner networks.
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!