Bi-Metallic Terminals (Friction Welded)
Bi-Metallic Terminals (Friction Welded)
Bi-MetallicTerminals (Friction Welded) are precision-engineered electrical lugs designed to connect aluminum conductors to copper busbars, terminals, or devices in electrical systems. Manufactured using friction welding technology, these terminals consist of an aluminum barrel and a copper palm that are molecularly bonded without melting. This ensures a high-strength, corrosion-resistant, and electricallyefficient connection. The use of bi-metallic terminals is essential where aluminum cables are used but need to be terminated on copper connections, particularly in power distribution panels, switchgear, transformers, and substations. These lugs comply with international standards (IS/IEC/BS) and are trusted for their reliability, longevity, and superior electrical performance.
Top 10 FAQs of Bi-Metallic Terminals (Friction Welded)
- What are bi-metallic terminals used for?
They are used to connect aluminum conductors to copper terminals or busbars in power systems. - Why is friction welding used in these terminals?
Friction welding creates a strong, solid-state bond between copper and aluminum without melting, ensuring reliability and conductivity. - What are the main components of a bi-metallic terminal?
An aluminum barrel for cable insertion and a copper palm for bolting or connecting to copper surfaces. - Why not use aluminum lugs directly on copper?
Direct aluminum-to-copper contact causes galvanic corrosion, which can lead to failure over time. Bi-metallic lugs prevent this. - Can these lugs be crimped like standard copper lugs?
Yes, they are crimped using standard tools designed for aluminum cable sizes. - What range of cable sizes do they support?
Typically available for conductor sizes ranging from 10 mm² to 400 mm² or higher. - Do they comply with any standards?
Yes, they comply with IS:8309, IS:13573, IEC, and other relevant international standards. - Are these suitable for outdoor installations?
Yes, tin-plated versions offer excellent resistance to environmental corrosion and are ideal for outdoor use. - What is the operating temperature range?
Generally, they operate safely within a range of -20°C to +105°C. - Are insulation sleeves required?
While not built-in, insulation sleeves or heat-shrink tubing can be used for added protection.
Applications of Bi-Metallic Terminals (Friction Welded)
- Electrical Power Panels and Distribution Boards
- Switchgear and Control Cabinets
- Transformers and Circuit Breaker Terminations
- Substations and Grid Installations
- UPS and Backup Power Systems
- Industrial Machinery Power Connections
- Renewable Energy Systems (e.g., solar and wind)
- Marine and Offshore Electrical Systems
- Battery Bank Terminations
- Railway Electrification and Metro Systems
Benefits of Bi-Metallic Terminals (Friction Welded)
- Prevents Galvanic Corrosion: No direct contact between aluminum and copper prevents electrochemical reactions.
- High Electrical Efficiency: Friction-welded bond ensures excellent current flow with minimal resistance.
- Strong Mechanical Bond: Vibration- and heat-resistant joint suitable for heavy-duty applications.
- Long-Term Reliability: Corrosion- and oxidation-resistant for a long service life.
- Cost-Effective Transition Solution: Enables use of cost-efficient aluminum cables with copper systems.
- Thermal Stability: Handles high current loads without overheating or performance loss.
- Standardized Design: Compatible with existing copper busbars and terminals.
- Quick and Easy Installation: Similar installation process to standard lugs; no special handling required.
- Eco-Friendly Manufacturing: Friction welding has low environmental impact and energy consumption.
- Compact & Versatile: Fits in space-constrained panels and enclosures with ease.
Contact us more details :
Call - +91 9023400042, +919099918363
Email - info@aera.in
Address - A-12,MAHADEV ESTATE-2,B/H RAMOL POLICE STATION CTM-RAMOL ROAD RAMOL AHMEDABAD-382449.