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Defining and using bimetallic lugs


Defining and using bimetallic lugs

Bimetallic lugs are made of a copper palm and an aluminum barrel and are used to connect aluminum conductors to copper bus bars. use of these lugs in solar plant control panels, switchgear, and combiner boxes minimizes corrosion and ensures longevity.

Where do bi-metallic lugs come into play?

An Aluminum Cable must be terminated with a copper bus bar or contact when using bimetallic lugs. When just copper or aluminum cable lugs are employed, a galvanic action develops owing to dissimilar contact. The use of bimetallic lugs ensures a technically sound and long-lasting union. Pioneer Powers International is the greatest option if you're looking for the best Bi-Metallic Lugs.

Why can't we utilize single-metal cable lugs (copper or aluminum)?

When two dissimilar metals come into contact with each other, it results in a phenomenon known as' dissimilar metal corrosion 'or' galvanic action. ' When a copper lug is used to join an aluminum cable, the aluminum cable and the copper lug barrel are two distinct metals, and so galvanic action occurs.

Bimetallic lugs are utilized to prevent this dissimilar contact. When it comes to touch, the aluminum barrel will be in contact with an aluminum cable, and the copper (forged flat palm with a hole) will be in contact with the copper busbar. In addition, the aluminum barrel is friction-welded to the copper palm to improve the transition between the barrel and the palm. Galvanic corrosion is avoided, and a technically sound and long-lasting joint is achieved.

Bimetallic Lugs and Solar Industry Solutions

The solar industry is one of India's most thriving industries. Solar energy is becoming increasingly more affordable and simple to produce. Bi-metallic solutions, such as bi-metallic lugs and joints, are vital in this case. In this post, we'll look at how bi-metallic solutions are becoming more common in the solar sector. So, without further ado, let's begin.

Lugs and Joints Made of Bimetallic

Aluminum cables are commonly utilized in power systems. Furthermore, the bus bars in the huge solar arrays are constructed of copper. As a result, connecting the aluminum wire to a copper busbar causes a contact dissimilarity, which may result in galvanic action, increased contact resistance, and corrosion. Bi-metallic lugs are employed as a solution. Similar metals, such as copper with copper and aluminum with aluminum, are touched, and the lug's dissimilar metal components are friction-welded. The use of bi-metallic lugs ensures that the joints are technically sound and long-lasting.

These bi-metallic lugs serve an important role in a huge solar array. The output of all the solar strings is combined by the inverter in the solar system's combiner box. A copper bus bar connects multiple cables from the solar strings. The power is then transported to the inverter via aluminum cables from here. The use of bi-metallic lugs here assures that each connection is long-lasting, safe, and efficient. The finest option is Pioneers Power International. We are well-positioned among the leading elements, providing a wide range of Bi-metallic lugs. We can provide you with the product at market-leading prices.

Solar tracking bimetallic strip

Because the sun changes direction during the day, the angle of the solar panels should also shift. The bi-metallic strip detects temperature changes and changes the orientation of the solar panels accordingly. Solar tracking becomes automated when a bi-metallic strip is used. The utilization rate of solar energy is rising, while energy loss falls.

Solar cells with bimetallic nanogratings

Thin-film solar cells frequently have low power absorption due to their thinness. However, using Al–Cu nanogratings improve absorption efficiency. The solar cell absorbs light in the long-wavelength band (670–1060 nm) with an average simulated absorption rate of more than 70% when these nano coatings are used. Other critical variables, including photocurrent density, tiny incidence angle insensitivity, tunability, and structural parameter tolerance, have improved significantly.


Bimetallic lugs can be made in a variety of ways -
The electrolytic forged copper palm is friction-welded to the electrolytic aluminum barrel in one technique. Copper and aluminum molecules are linked together in this manner to form a robust and long-lasting joint. Bi-metal in-line connectors are used to link the aluminum and copper cables, with an aluminum barrel for the aluminum cable and a copper barrel for the copper cable. Friction welding is used to join the two pieces (copper and aluminum).

In-line connectors, pin-type connectors, and other connectors are made using bi-metal terminals. There are also several bi-metallic compression joint combinations available. These are designed and manufactured in accordance with the differing current-carrying capacities of various types of cables. To reduce contact resistance and corrosion, aluminum barrels are chemically treated. They are then filled with a corrosion inhibitor to prevent oxidation of exposed surfaces (i.e., conductive type grease with a high dropping point), and the barrel ends are closed to prevent dust entry.


Bi-metallic lugs are most commonly used to connect aluminum cables to a copper bus bar or copper contact. It is both safe and inexpensive. The single-hole Bi-metallic Lug is used to connect aluminum conductors to copper bus bars in electrical applications such as control panels, switchgear, and combiner boxes in solar plants, among others.

Bimetallic lugs are what you need. Pioneer Power International is the answer. Indian manufacturers and exporters of copper, aluminum, and bimetallic cables as well as connectors, earthing rods, and searching accessories. We are India's leading manufacturer and supplier of these items. Our customer base includes large distributors, wholesalers, electricity boards, electrical contractors, maintenance firms, and government organizations, just to name a few of our clients. Since its inception, our organization has had rapid expansion.