Connecting copper and aluminum conductors to electrical equipment. How to connect aluminum and aluminum wire to each other correctly

electrical wiring almost all old apartments and houses are made of aluminum. Therefore, when independently performing electrical work on transferring sockets or when repairing junction boxes, it is often necessary to connect aluminum conductors to each other.

All electricians will agree that aluminum wiring is very capricious in terms of connection: the core often breaks during installation, especially if the wire is quite old. Therefore, it is important to choose the right method so that the connection is reliable and durable. In this article, we will consider the main methods and technologies.

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How it works, components and operations. . Powered by Potatoes: You can cook a bunch at home and generate electricity from potatoes or lemons. In this article, we will not talk about the electricity generated by organic waste, or bacteria that can produce hydrogen from potatoes; on this page we will see how to build a stack in house with simple lemon or potatoes.

soldering method

One of the most reliable connection methods is soldering aluminum wires. In addition to reliability, this technology is simpler than, for example, welding. However, soldering aluminum wires is not as easy as copper wires. The reason for this is the unique ability of aluminum to almost instantly oxidize in air, forming a film that interferes with the normal application of solder.

Potato energy, how does it work?

The principle is simple: two metals come into contact through a liquid called an "electrolyte". The electrolytic solution contains charges that, when they move, cause electricity. Two metal element called electrodes, they are connected by a conductive wire while the metal component is immersed in an electrolytic solution, starting the flow of current. So we need two electrodes to pass current between two metals using an electrolytic solution.

What is needed to produce energy from potatoes

Although the potato pile is the most popular, we recommend doing this experiment with other vegetables or fruits, lemon is perfect for this experiment because it has the appropriate water content.

Therefore, the process of soldering aluminum is quite laborious and requires certain knowledge and skills. To connect aluminum conductors to each other by soldering, it is used mechanical way removal of oxide and simultaneous application of soldering acid to the cleaned areas. Let's consider this process in more detail.

Soldering technology

As a rule, the electrical wiring in the apartment is made with a single-core wire. It is this option that we will consider. So, to solder two aluminum wires together, you need to follow the following instructions:

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How to start producing energy from potatoes or lemons. Connect the other two electrodes to a voltmeter or an alarm clock that will sound. Make sure you insert the two electrodes into the setup sections correctly, as shown in my photo. If, however, you are using a small alarm clock or clock, you will notice that it will run on the electricity produced by a lemon or potato.

Take a potato and cut it in half.
Connect two electrodes with copper wire.

Potato-linked electrodes, it works like a real pile.

The cores are stripped of insulation by about 4–5 cm. Care must be taken not to damage the metal;
Then the bare ends are processed with fine sandpaper and twisted together. It is important that the wires wrap around each other. It is better to avoid winding one core on another: such a connection will be of poor quality, it will not be possible to solder it;
The resulting twist is again processed with sandpaper, after which a little soldering acid is applied to it. This aggressive substance does not allow a film of oxides to form again;
The twist grooves are then carefully filled with molten solder. Due to the acid, the solder adheres well to aluminum;
At the end of the twist, a small thickening of solder is usually made so that the ends do not cling during installation.

After the connection is made, work surface wires must be treated with alkali and rinsed with water to remove acid residues. Otherwise, the acid will continue to corrode the insulation and metal.

Copper metal finger acts as the cathode and aluminum acts as the anode. Potato juice, as well as lemon, olive or other juice, act as an electrolytic solution and allow the flow of electrons moving from the cathode to the anode, which generates electricity.

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After drying the spike, proceed to its isolation. For these purposes, use cambric, caps or ordinary electrical tape. Additionally, you can treat the twist with a waterproof varnish if you intend to use it in a humid environment.

For high-quality soldering of wires, the soldering iron tip must move along the twist all the time so that it does not cool down.
One of oldest problems facing installation and maintenance electrical systems, is the choice of cables. In fact, the usual disk space, less experienced, catalogs all the cables as they are. However, this is not the case; indeed, the opposite is true. Statistical analysis of electrical hazards has placed emphasis as the main cause of accidents on the inadequate cabling of electrical systems. For this reason, companies operating in the manufacturing sector are constantly engaged in the development of products of excellence in order to preserve structures and lives.

Application of welding

Another method that provides a high-quality and reliable connection is the welding of aluminum wires. This method is more complicated in practical implementation than soldering. To make a connection by welding, a special powdered flux is used, which must be diluted with water to a thick paste-like state before work. In addition, a special welding machine operating at low voltage, as well as special knowledge and experience.

Plant inadequacy can be of two types: initially or subsequently. It's original when it comes to the inadequacy or inadequacy of the design, which pushes some people to save money by using products that are not suitable for a specific use, and in more severe cases, unprocessed products. However, this happened later, when new utilities were installed on an outdated electrical system without confirmation of its suitability for the new workload.

In both cases, we are talking about the basic element: the choice of cables. Cable certification that makes them suitable for specific task, is not random. It is the result of careful study of conductive and insulating materials with its characteristics. The most common conductive materials are copper, aluminum and alloys. So the cable is not a simple thread, as is usually stated, but something more. This article will outline the main features of the most common conductors used for the construction of cables providing design ideas.

We'll consider common technology how aluminum wires are connected together by welding:

The ends of the wires are freed from insulation by 4–5 cm.
The cores are twisted together.
A paste flux is applied. It can be applied with a brush or immersed wires 3–5 mm into a container with the composition.
After that, an electrode is brought to the ends of the twist and welding is performed for 1–2 seconds, after which the electrode is retracted.

Thanks to the applied flux, oxygen does not enter the aluminum, and the electrode does not stick to the molten metal. As a result of the manipulations, a neat “drop” of molten aluminum should be obtained at the end of the twist, through which the current flows freely between the wires. The twist itself ensures a reliable connection of the conductors.

The main characteristics of copper

Copper is undoubtedly the material most used as electrical conductor for the implementation of plants and chains various types. The inflationary use of copper for the construction of electrical systems is due to its chemical and physical characteristics that can be catalogued.

Equipped with high electrical conductivity second only to silver. With high permeability, which allows the production of very thin threads. Equipped with a rolling plant. With high mechanical characteristics, which remain unchanged even at very low temperatures.

In most cases, the method of welding aluminum wires together is used in industry, as well as for connecting powerful cables of large cross section.

Note! For welding wires with aluminum conductors with a cross section of up to 16 squares, the TS 700-2 apparatus is widely used. It is specially designed for such purposes and produces an arc with a voltage of 6 to 20 V. This allows you to accurately weld wires with a small cross section (from 2.5 mm 2) at home.
The main characteristics of aluminum
Very recycled. Equipped with discrete resistance to oxidation in contact with the atmosphere. Aluminum, thanks to its obvious cost savings, is an exceptional alternative to copper as an electrical conductor in industrial plants. The specific characteristics of aluminum can be cataloged as follows.

Equipped with a significantly lower specific gravity of copper. With a relatively low market price. It is much cheaper than copper because it is the most popular metal in the world. Equipped with more resistance than copper. In fact, with the same electrical resistance section of aluminum cable is about 60% higher than the section copper cable. However, given that its reduced weight weighs about 35% less.

Mechanical connection methods

In addition to soldering and welding, there are other widely used ways to connect aluminum wires. This is the so-called mechanical connection, most often performed using screw blocks or other similar devices.

Terminal blocks

Such pads with screw terminals are widely used not only in shield, but also in junction boxes in apartments and houses. They are reliable and provide good contact.

Aluminum vs Copper Design Ideas

With high flexibility, making it malleable and suitable for all plastic processing. Comparative characteristics tabletop aluminum copper alloy. Aluminum, as mentioned earlier, is much lighter than copper. Therefore, it does not need many support points and is especially suitable for airliners. This solution is widely used especially for the implementation industrial works, but the use of this solution should not be underestimated, in particular in an agricultural and peripheral context.

The economics of aluminum and its wide market presence make it particularly suitable for theft prevention. In fact, as is well known in the report, copper is subject to constant theft from petty crime. This insidious behavior can be overcome with remarkable economic returns by using aluminum cables that guarantee the same efficiency as copper.

For connecting wires subjected to heavy loads, it is better to use branded black pads. impact-resistant plastic. In them, the aluminum core is clamped with a small square plate, which eliminates damage to the core. Terminal blocks from white plastic suitable for connecting wires with a small cross section, for connecting low-power consumers.

The physical characteristics of aluminum make it particularly suitable for the production of long pieces with few joints, reducing dispersion. This solution is also very suitable for industrial applications. As far as laying methods are concerned, they are very similar, even if the aluminum gives more ductility.

The average service life of an aluminum cable is the same as that of a copper cable. Laying in damp or damp environments depends on other factors such as branch ducts or insulating materials and cable protection. Without the use of aluminum wire today there is not a single manufacturing industry.

To ensure a larger wire contact area in the block, it is recommended to round the bare end of the core around the screw.

Self-clamping terminals

Great popularity for domestic use purchased self-clamping terminals and blocks from various manufacturers. Such devices are both detachable (reusable) and one-piece (disposable).

Low cost, corrosion resistance, high thermal conductivity, electrical conductivity, low magnetic properties. He appreciates his resistance to atmospheric and soil moisture, as well as biological inertia. It meets all sanitary and hygienic requirements for equipment and instruments.

Purpose and production technology

Welding with an aluminum electrode allows not only to get very durable, but also plastic - this is a seam that will be resistant to atmospheric influences. Because of high content silicon and copper it is characterized high hardness. Up to High-strength duralumin can also be due to the marking of alloy B To increase it chemical resistance anodic oxidation and sheathing are used. There are two types of conductors - pressed and infused.

Inside plastic case such a device has a clamping metal plate, which fixes the wire and ensures good contact with the conductive bus. The housing can be made of black or colored plastic, transparent terminal blocks are also available.

Self-clamping terminals have from 2 to 8 connectors, which allows you to make various connections, as well as branch wiring.

In the hardening process, the ductility and formability of the material are greatly improved, and cold deformation contributes to the solidification of the alloy. food industry, construction, mechanical engineering. It is used in the production of cables, wires, furniture fittings, decorative elements. Without this, he cannot get into the sausage industry, the beer industry or the transport industry. It is used in welding such as electrode swimming or tie.

Aluminum wire is indispensable for welding those projects that have direct contact with soil or atmospheric moisture, which guarantees protection against thermal cracks, a smooth seam, improves corrosion resistance, as well as ductility. To get a more ductile and corrosion resistant seam, enjoy fewer aluminum alloy electrodes. When welding aluminum alloys a wire is used that has chemical forms as close as possible to the smallest details. The fact is that magnesium evaporates during the welding process.

When choosing such blocks and terminals, you need to pay attention to the marking: it displays the number, cross section of the cores for which the device is intended.

crimp method

If you need to connect several solid wires or stranded cable in one connector of the block, special crimp sleeves can be used. The stripped ends of the wiring are wound into an aluminum or copper sleeve. And the sleeve itself is crimped with special tongs: as a result, reliable contact is obtained. This method is often used when connecting several powerful consumers, as well as for connecting wires to each other.

Therefore, you should use a conductor in which the percentage of magnesium is much higher than in the composition of the information itself. An example of a badge can serve in this post. It denotes a welding wire, a monolithic alloy made of aluminium, in gravity state, 5 mm, suitable for bays.

Where to buy aluminum wire, wholesale or rebate? Always available aluminum wire, the price is optimal from the seller. Wholesale customer prices are preferred. In stock available big choice aluminum wires and its alloys. order quantity and additional terms delivery depends on the price. Our managers are always ready to provide expert assistance. A large assortment will not leave you without a choice. All products are certified.

Instead of a simple sleeve, special NKI tips can be used. They have a small crimp sleeve at one end, into which the wire is inserted. At the other end, there is a slip ring that allows for a simple and secure connection to the screw terminal.

Bolt connection

Sometimes two or more aluminum wires are connected together using a conventional bolt and nut. To do this, make a circle around the bolt from the stripped ends, place them between the washers and tighten with a nut - the connection is ready.

Summing up

We have considered several ways to ensure a reliable connection and good contact between aluminum wires. Some methods require special equipment, knowledge and experience. And in some cases, you can get by with improvised means.

Without a wiring connection, even the simplest electrical devices. The slightest deviation from the connection rules can bring huge troubles. There is electrical wiring in a private house or apartment even in the most remote and small settlements.

Power consumption is constantly increasing, and as a result, the load on wire connections is increasing. Requests for them are intensifying and becoming stricter, because any negligence or imperfection can turn into a disaster.

Everyone now knows that it is necessary to stretch the wiring connection sections well, but not everyone knows about electrochemical compatibility.

Scope of connections

The increase in electricity consumption is becoming the reason for tightening the requirements for wire connections, aimed at improving the quality of fire and electrical safety.

What determines the reliability of connections:

Density of contact alignment.
Compatibility of wires according to electrochemical parameters.

Almost everyone can twist the wires tightly, the second requirement is often ignored, connecting two wires (even incompatible ones) in a direct way. It is for this reason that problems arise during the operation of the wiring organized by their aluminum and copper wires.

Electrochemical corrosion

Aluminum – chemical element with high oxidation capacity. The oxide film that appears on an aluminum wire under the influence of dampness has an increased resistance. This adversely affects the ability to conduct electric current at the connection sites.

Copper- a substance with low chemical activity on which an oxide film forms worse and, moreover, it has less resistance.

aluminum and copper conductors, together creates a short-circuited galvanic circuit - when such a contact is moistened, the rapid oxidation of the aluminum contact begins.

A layer of metal oxide with high resistance appears between 2 conductors, as a result, the conduction of electric current is difficult, the electrolysis process occurs, sparks appear at the contact junction, the metal heats up, and shells form, all this can cause a fire:

These substances have a significantly different coefficient of thermal expansion. At the time when an electric current is passed through them, they change their dimensions in different ways, after the current is turned off, they cool down in different ways. As a result of the contraction and expansion of metals, it changes their geometry, which worsens the contact. And as a result, in areas with poor-quality contact, the metal heats up, which further worsens the contact;
There is a non-conductive oxide film on the surface of aluminum, which also worsens the quality of the contact and contributes to the destruction of the metal;
Copper and aluminum produce a "galvanic couple", which also heats the metal and contributes to its oxidation.

These shortcomings can be eliminated if direct contact of these metals is not allowed. There are several options for connecting conductors made of copper and aluminum, creating a reliable and safe contact.

Note that with an increase in air humidity, all of the above processes are significantly enhanced. A layer of aluminum oxide that conducts electrons poorly and a significantly different thermal expansion are factors that aggravate the situation.

The most common connection options

Twisting

For a short time, this method of connection is suitable, indoors it will last for a certain period, with high humidity or on the street, the service life of this pair is significantly reduced.

But it is often required to join several cables made of copper and aluminum. This happens during the restoration or repair of the electrical system in buildings where aluminum wiring is used.

Crimping- this is a kind of twist, with this method, the twist is crimped with a specially prepared sleeve made of copper or aluminum with an internal section equal to the cross section of the twist. I would like to say that this option is simple and fast in execution, at the same time very reliable. The finished connection is isolated in the usual way - using electrical tape or with heat shrink paste.

Bolted connection and terminal blocks

To correct some of the shortcomings of twisting, combining wires from two different metals using one of these methods will help. Using bolted or, we eliminate the direct contact of the copper-aluminum pair.

There are several types of terminal blocks:

A proven and long-used method is the use of "nuts", they are so called due to the fact that they look like nuts. Such products are made of three plates, with the help of which copper or aluminum cables are clamped. positive quality The "nuts" is that to create a branch from the main wire, it does not need to be cut. It is only necessary to unscrew the two bolts, place the stripped cable core between the two plates, and tighten the bolts again. The core for creating a branch is placed between the middle and one of the extreme plates;
Also, WAGO-type terminal blocks are often used. With this method, it is only necessary to remove the insulation by 10-15 mm, insert the cleaned places into special holes and the contact is ready for service. Inside the terminal block there is a special lubricant that protects the wire from oxidative processes. This option is best used only with a lighting device. They should not be used for power circuits, a high load can cause heating of the springy contacts, and as a result, cause deterioration of the contact;
In addition, they often use terminal blocks, they look like a bar with special terminal blocks. It is only necessary to prepare the ends as described above, insert one of them into the hole, and fix it with a bot. The prepared end of the second wire is placed in another hole and fixed.

Copper and aluminum wires are joined together using a bolted method, if it is necessary to obtain a reliable and safe contact. Two cable cores are twisted with a bolt, placing an anodized steel washer between them. All installation work must be carried out by an experienced professional.

Bolted and screw connections must be certain period audit: for aluminum wires, the check is made once every six months, for copper wire, the frequency of checks is every two years.

Soldering

The most durable and reliable option for joining copper and aluminum wires. Its disadvantages are technological complexity, increased installation time and labor intensity. When an electrician makes electrical wiring, it most often de-energizes the room and there is no way to heat the soldering iron.

Homemade adapter

You can independently make an adapter that will allow you to mount the electrical network without a soldering iron using the soldering method.

Before starting the installation, two wire cuts are soldered on the table - aluminum and copper, leaving two free ends. It turns out a kind of homemade adapter for connecting wires.

It is best to make several of them, after which they de-energize the power grid and produce necessary installation, connecting the aluminum tip to the aluminum wire, and the copper to the copper, isolate in the usual way.

Welding

The method is similar to soldering, but it will require special equipment and is practically not used when connecting copper and aluminum wires, since the melting points of these metals are different.

During its execution, copper and aluminum cable tightly twisted, and the end of the resulting flagellum is carefully welded by contact welding, as a result, a small ball of metal should appear at the end of the twist. The contacts are connected almost tightly and there is perfect contact between them.

All connections must be securely insulated.
It is advisable to place them in special ones. laying down copper-aluminum connection into the wall, you block access to it if necessary, it will be impossible to revise the connections without damaging the wall.
If there is no experience with soldering, then the best option becomes a terminal box.

Of course, without having the necessary experience in electrical work, it is better not to risk your life and property and contact a specialist.