A bimetallic connector isan electrical connector made of two different metals, most commonly aluminum and copper, joined to connect conductors of different materials without causing galvanic corrosion. They are designed to provide a secure, low-resistance connection that can withstand thermal expansion and contraction from temperature changes. These connectors prevent issues like corrosion, overheating, and failure that would occur if aluminum and copper were directly joined, and are often friction-welded to create a strong metallurgical bond.
Key features and function
Construction:Composed of two sections, typically an aluminum barrel for the aluminum conductor and a copper palm or barrel for the copper conductor.
Bonding method:The two metal parts are usually joined by a friction welding process, which creates a strong, inseparable metallurgical bond and eliminates bimetallic corrosion.
Corrosion prevention:They are specifically designed to avoidgalvanic corrosion, which happens when two dissimilar metals are in direct contact.
Jointing compound:The aluminum barrel is often filled with a jointing compound to prevent oxidation of the exposed aluminum surface.
Thermal expansion:They accommodate the different rates of thermal expansion between aluminum and copper, ensuring the connection remains secure under temperature fluctuations.
Common applications
Joining aluminum and copper conductors in electrical installations.
Connecting aluminum cables to copper bus bars or terminals, such as in switchgear or circuit breakers.
Used in lightning protection systems when copper is used for earthing in an aluminum system.
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