Tubular Bimetallic Terminals

Electrical systems often face a critical challenge at copper-aluminum junctions which are uneven current distribution and thermal stress that lead to hot spots and premature failures. Our Tubular Bimetallic Terminals revolutionize these transitions with a seamless friction-welded design that ensures flawless conductivity between dissimilar metals. 

Material Composition

Seamless copper tube (C11000) + Forged aluminum sleeve (6061-T6) with friction-welded joint

Conductor Size Range

50 mm² to 800 mm² (AWG 1/0 to 1500 kcmil)

Current Carrying Capacity

200 A to 2500 A (ambient 40°C, copper-side rated)

Dimensions

Copper OD: 15-85 mm; Aluminum OD: 20-95 mm; Length: 60-200 mm

Weight

0.3 kg to 3.5 kg (25% lighter than solid bimetallic bars)

Product Description

Engineered for extreme environments, these terminals maintain stable performance from -50°C to +125°C, with a 280MPa welded joint that withstands 1500+ hours of salt spray exposure. The tubular design provides 25% weight savings versus solid bimetallic bars while handling up to 2500A which making them ideal for utility, industrial, and renewable energy applications. 

Barrel Length

Copper side: 40-120 mm; Aluminum side: 50-150 mm

Termination Type

Tubular crimp (copper) + compression sleeve (aluminum)

Crimping Compatibility

Radial crimping (60-150 kN) for copper; Swage pressing for aluminum

Operating Temperature Range

-50°C to +125°C (transition zone stable to +150°C peak)

Surface Finish

Tin-plated copper (8-12μm) + Hard-anodized aluminum (25-30μm)

Voltage Rating

Up to 38 kV (IEC 61439-1 tested)

Tensile Strength

280 MPa at welded joint (ASTM B898 Class IV)

Environmental Resistance

1500-hour salt spray (ISO 9227 C5-M) + UV resistance (3000 kWh/m²)

Standards Compliance

IEC 61238-1 Class AA, UL 486A-B, BS 7889, AS/NZS 4681

Installation Method

Hydraulic crimping (copper) + swage pressing (aluminum) with alignment jig

Conductor Compatibility

Copper (ASTM B3/B8) + Aluminum (AA-1350/AA-6201)

Technical Advantages

Traditional lap joints create current bottlenecks at copper-aluminum interfaces, but our tubular design ensures 360° uniform current distribution by eliminating edge concentration effects. The friction-welded interface achieves 99.8% density through precision-controlled rotational forging, creating a metallurgical bond that X-ray diffraction shows has finer grain structure than explosion-welded alternatives.  

Field data from HVDC installations demonstrates consistent performance, with infrared scans showing ≤2°C temperature differential across the joint at 2000A continuous load. The tin-hard anodized finish forms a synergistic barrier system which the tin plating sacrifices itself slowly while the 30μm anodized layer provides permanent protection, reducing maintenance intervals from annual to decadal. 

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Industry Applications

Utility Substations

Handles 38kV transitions between copper busbars and aluminum overhead lines, with IEC 61439-1 certified partial discharge performance.

Wind Farm Collectors

Survives 10G vibration in nacelle power chains while maintaining ≤0.1mΩ contact resistance through 20+ year service life.

Industrial Switchgear

Enables safe 2500A transitions in MCCs and capacitor banks, with UL 486A-B listed crimp configurations.

Solar Farm Combiners

UV-resistant hard anodizing (3000 kWh/m² rating) prevents degradation in tracker systems and fixed-tilt arrays.

Mining Power Distribution

Withstands 50,000+ shock/vibration cycles (ISO 10816-3) in shovel and dragline electrical systems.

Railway Electrification

Meets EN 50152-1 requirements for 25kV AC systems, including -50°C cold start capability.

Simplified Implementation & Lasting Value

Installers benefit from intuitive color-coded alignment jigs that eliminate guesswork during crimping, cutting termination time by half compared to traditional methods. The tubular geometry’s inherent stiffness prevents deformation during hydraulic compression, ensuring repeatable results even in high-volume applications. 

For project owners, the terminals’ 25-year design life translates to fewer replacements and lower lifecycle costs. Documentation packages include not only standard compliance certificates but also weld microstructure analysis and customized derating guides for unusual configurations. 

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does your friction welding process ensure long-term reliability compared to alternatives?

The precision-controlled rotational forging in our welding process creates a metallurgical bond with 99.8% density, verified through X-ray tomography. This produces a finer grain structure than explosion welding, which we’ve proven through ASTM E139 testing to withstand 5000 thermal cycles without micro-fractures. Field data from substation deployments shows our joints maintain ≤0.1mΩ resistance over 10+ years, outperforming conventional methods by 30%. 

What cost advantages do these terminals offer over separate copper and aluminum connectors?

By eliminating transition plates and additional hardware, our bimetallic design reduces total installed cost by 40%. We achieve this through 25% material savings versus stacked solutions, plus labor efficiencies from the one-step crimping process. Maintenance costs drop further thanks to the 30μm hard anodizing that extends service intervals to 10+ years in coastal environments. 

How do you balance custom engineering with urgent project timelines?

While we engineer each terminal to precise specifications, our modular design approach allows 85% of custom orders to ship within 10 working days. For critical path projects, we expedite production by allocating dedicated manufacturing cells that can deliver prototypes within 72 hours. All orders – whether standard or custom – include complete documentation packages with mill certs and test reports for immediate compliance verification. 

What makes your terminals suitable for high-vibration environments like wind farms?

The tubular design’s inherent stiffness dampens vibration 50% better than flat joints, as demonstrated in 10G testing per IEC 61400-1. We reinforce this with a proprietary nickel diffusion layer that prevents fatigue cracks at the weld interface. Our offshore wind customers report zero failures after 5+ years in 15Hz vibration conditions. 

Can you provide custom documentation for regulated industries like nuclear plants?

We maintain ASME NQA-1 compliant documentation packages that include weld procedure specifications and material traceability back to mill heats. For nuclear applications, we add supplementary neutron irradiation testing and helium leak detection reports. Our quality team can tailor submission packages to match your exact audit requirements within 48 hours. 

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LOCATIONS

Global Sales Office

818, Preakness lane, Coppell, Texas, USA – 75019

Registered Office

23, 6th West Street, Balaji Nagar, Kattur,  Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

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Tubular Bimetallic Terminals

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