Enabling magnetic pulse welding for dissimilar tubular arrester cable joints

Climate change exacerbates the need for resource-efficient and cost-effective production processes across manifold industries, including the field of electrical connections. This specific field is characterized by a conflict of objectives, i.e., weight reductions while maintaining joint strength and electrical conductivity. From a material point of view, the use of aluminum as a conductor material is suitable for this application, as it is lighter than copper, a classical conductor material. Electrical conductors are often used in the form of flexible cables, so-called stranded wires. This type of conductor as well as the fact that the sole use of aluminum in electrical systems is not feasible, e.g., because the predetermined connection terminals of power electronic components are made of copper, creates a substantial demand for dissimilar aluminum-copper cable arrester joints. However, traditional fusion-based welding processes have proved incapable of reliably producing these dissimilar aluminum-copper joints because of thermophysical effects and chemical incompatibilities, the latter eventually leading to the formation of intermetallic phases. These phases adversely affect the quality of the joint in terms of both mechanical and electrical performance. Yet, magnetic pulse welding, a pressure welding process, is ideally suited for producing dissimilar metal joints on the basis of a low energy input during the welding process. Consequently, the formation of intermetallic phases is restrained. However, magnetic pulse welding has not been sufficiently investigated for the reliable contacting of stranded cables to tubular arresters. As a result, this paper focuses on the fabrication of tubular stranded cable arrester joints using magnetic pulse welding. To shed light on possible material combinations, aluminum-to-aluminum and copper-to-copper joints as well as their dissimilar counterparts are welded. Subsequently, the joints are characterized with regard to their microstructure and quasi-static material strength. Electrical characterization comprises the four-wire Kelvin measurement method to evaluate the resistance of the electrical joints. The results demonstrate that magnetic pulse welding is ideally suited to join the aforementioned material combination and joint configuration due to its process characteristics eventually leading to material continuity. As a result, the stranded wires are welded to the tubular arresters rather than crimped. Consequently, a comparative analysis of the joint properties with those of the joining partners shows that the measured electrical resistances and mechanical tensile forces may be considered very good.