Copper Aluminium Bi-Metal Lugs

Copper Aluminium Bimetal Lugs are specialized electrical connectors designed to facilitate safe and efficient connections between aluminium and copper conductors. These lugs eliminate the risk of galvanic corrosion caused by direct contact between dissimilar metals and ensure reliable conductivity, especially in high-current applications. They are commonly used in power distribution, switchgear, transformers, and panel board installations.

Construction:

• Aluminium Barrel: Made from high-conductivity aluminium (typically 99.5% pure), designed for crimping onto aluminium conductors.

• Copper Palm (Pad): Electrolytic copper, friction-welded to the aluminium barrel, providing a copper contact surface.

• Bimetal Joint: Seamless friction welding ensures a strong molecular bond between copper and aluminium, minimizing resistance and thermal stress.

• Surface Treatment: The copper palm is usually tin-plated for oxidation resistance; the aluminium barrel may also be treated to resist corrosion.

Key Features:

• 🔗 Reliable Joint Between Dissimilar Metals

• ⚡ Low Electrical Resistance at Interface

• ❌ Prevents Galvanic Corrosion

• 🔧 Easy Crimp Installation

• 🌡️ Withstands High Temperatures and Mechanical Stress

Applications:

• Power Distribution Boards

• Switchgear Panels

• Circuit Breaker Connections

• Busbar Terminations

• Transformers and Generators

• Solar and Renewable Energy Systems

Advantages:

• ✅ Safe Aluminium-to-Copper Connections

• ✅ High Conductivity and Current Rating

• ✅ Reduced Maintenance from Corrosion or Loose Joints

• ✅ Strong Mechanical Strength and Heat Resistance

• ✅ Time-Saving Installation with Standard Crimping Tools

Installation Guidelines:

• Strip the aluminium conductor clean of oxide or dirt

• Insert into the aluminium barrel of the lug

• Use a suitable hex or indent crimping tool

• Ensure proper torque and alignment

• Apply insulating sleeves or heat-shrink as needed

Standards & Availability:

• Available in a wide range of sizes (10 mm² to 1000 mm²)

• Custom shapes, hole sizes, and palm orientations available on request

Need technical guidance or custom sizing?
Contact us today to discuss your requirements. Our team will assist you with technical details, price quotes, and delivery timelines.