The Bi-metal Crimp Lug for Power represents the pinnacle of high-voltage connection technology, engineered specifically to handle the demanding current requirements of medium to high-voltage power distribution systems.
DTL-5
Mingxu
This precision component utilizes high-pressure friction welding to create a molecular bond between its aluminum conductor barrel and copper terminal section, eliminating galvanic corrosion issues in dissimilar metal connections. Compliant with IEC 61238-1 and ANSI C119.4 standards, it supports conductor cross-sections from 50 mm² to 1600 mm² in systems operating up to 33 kV. Its robust design ensures reliable power transmission in utility networks, renewable energy installations, and industrial power systems where connection integrity directly impacts operational reliability and safety.
The lug features a 99.6% pure aluminum barrel optimized for crimping to aluminum power cables and a 99.9% ETP copper terminal section for connection to copper busbars and equipment. This material combination balances conductivity with mechanical strength, while the friction-welded joint achieves a tensile strength exceeding 180 MPa and maintains a resistivity of ≤1.2 µΩ·cm across the metal interface.
Designed for power transmission applications, the lug supports continuous current ratings up to 1500A for the largest size, with short-circuit withstand capacity of 40 kA for 1 second without performance degradation. This makes it suitable for primary distribution circuits and substation connections where fault current handling is critical.
Featuring a triple-crimp zone design, the lug ensures uniform pressure distribution across the conductor, with clear visual markers guiding proper tool alignment. The aluminum barrel incorporates micro-roughened internal surfaces that increase conductor grip by 35% compared to smooth designs, maintaining connection integrity under thermal cycling and vibration.
The transition between copper and aluminum sections features a gradual profile that minimizes electrical field concentration at the junction, meeting the dielectric requirements of high-voltage systems up to 33 kV. This optimized geometry prevents corona discharge and insulation breakdown in medium-voltage applications.
In electrical substations, the lug creates secure transitions between aluminum feeder cables and copper busbars in transformer yards and switchgear installations. Its high current capacity supports the heavy power loads encountered in transmission and distribution networks.
The lug plays a critical role in utility-scale solar farms and wind energy installations, connecting aluminum collection cables to copper inverter terminals and combiner boxes. Its corrosion resistance ensures long-term performance in outdoor renewable energy environments.
In heavy industry, the lug provides reliable connections between aluminum feeder cables and copper terminals on large motors, generators, and power distribution panels in steel mills, chemical plants, and manufacturing facilities with high-power requirements.
The lug is suitable for underground cable terminations in medium-voltage distribution systems, providing reliable connections between aluminum cables and transformer terminals in buried installations where corrosion resistance is essential.
The optimized transition geometry between copper and aluminum minimizes electrical field concentration at the junction, while the smooth, void-free surface finish prevents corona discharge. This design allows proper stress relief application, meeting the dielectric requirements of high-voltage systems.
Installation requires hexagonal crimp dies specifically calibrated for bi-metal power connections, used with hydraulic tools capable of delivering 25-50 tons of force depending on lug size. Tools must meet ISO 6722 standards for crimping accuracy to ensure proper conductor deformation.
The friction welding process creates a metallurgical bond without electrolyte gaps, while an intermetallic compound layer (≤5 µm thickness) formed during welding acts as a diffusion barrier between copper and aluminum, eliminating galvanic action that causes corrosion in mechanical connections.
The lug maintains stable performance across a temperature range of -40°C to 150°C, accommodating the thermal fluctuations common in power distribution systems during both normal operation and fault conditions, including the high temperatures generated during short circuits.
| ltem No. | φ±0.3 | D±0.2 | d±0.2 | L±2 | L1±2 | W±0.2 | S±0.2 |
| DTL-5-16 | 10.5 | 16 | 5.5 | 80 | 40 | 20 | 4.0 |
| DTL-5-25 | 10.5 | 16 | 7.0 | 80 | 40 | 20 | 4.0 |
| DTL-5-35 | 10.5 | 16 | 8.2 | 80 | 40 | 20 | 4.0 |
| DTL-5-50 | 12.8 | 20 | 9.2 | 90 | 43 | 25 | 5.5 |
| DTL-5-70 | 12.8 | 20 | 11.2 | 90 | 43 | 25 | 5.5 |
| DTL-5-95 | 12.8 | 20 | 12.5 | 90 | 43 | 25 | 5.5 |
| DTL-5-120 | 12.8 | 25 | 14.0 | 112 | 58 | 30 | 6.5 |
| DTL-5-150 | 12.8 | 25 | 16.5 | 112 | 58 | 30 | 6.5 |
| DTL-5-185 | 12.8 | 32 | 18.5 | 122 | 60 | 35 | 7.0 |
| DTL-5-240 | 12.8 | 32 | 20.0 | 122 | 60 | 35 | 7.0 |
| DTL-5-300 | 12.8 | 34 | 23.5 | 125 | 65 | 35 | 7.0 |
| DTL-5-400 | 17.0 | 40 | 26.0 | 160 | 90 | 36 | 7.0 |
| DTL-5-500 | 17.0 | 40 | 29.5 | 160 | 90 | 36 | 7.0 |
This precision component utilizes high-pressure friction welding to create a molecular bond between its aluminum conductor barrel and copper terminal section, eliminating galvanic corrosion issues in dissimilar metal connections. Compliant with IEC 61238-1 and ANSI C119.4 standards, it supports conductor cross-sections from 50 mm² to 1600 mm² in systems operating up to 33 kV. Its robust design ensures reliable power transmission in utility networks, renewable energy installations, and industrial power systems where connection integrity directly impacts operational reliability and safety.
The lug features a 99.6% pure aluminum barrel optimized for crimping to aluminum power cables and a 99.9% ETP copper terminal section for connection to copper busbars and equipment. This material combination balances conductivity with mechanical strength, while the friction-welded joint achieves a tensile strength exceeding 180 MPa and maintains a resistivity of ≤1.2 µΩ·cm across the metal interface.
Designed for power transmission applications, the lug supports continuous current ratings up to 1500A for the largest size, with short-circuit withstand capacity of 40 kA for 1 second without performance degradation. This makes it suitable for primary distribution circuits and substation connections where fault current handling is critical.
Featuring a triple-crimp zone design, the lug ensures uniform pressure distribution across the conductor, with clear visual markers guiding proper tool alignment. The aluminum barrel incorporates micro-roughened internal surfaces that increase conductor grip by 35% compared to smooth designs, maintaining connection integrity under thermal cycling and vibration.
The transition between copper and aluminum sections features a gradual profile that minimizes electrical field concentration at the junction, meeting the dielectric requirements of high-voltage systems up to 33 kV. This optimized geometry prevents corona discharge and insulation breakdown in medium-voltage applications.
In electrical substations, the lug creates secure transitions between aluminum feeder cables and copper busbars in transformer yards and switchgear installations. Its high current capacity supports the heavy power loads encountered in transmission and distribution networks.
The lug plays a critical role in utility-scale solar farms and wind energy installations, connecting aluminum collection cables to copper inverter terminals and combiner boxes. Its corrosion resistance ensures long-term performance in outdoor renewable energy environments.
In heavy industry, the lug provides reliable connections between aluminum feeder cables and copper terminals on large motors, generators, and power distribution panels in steel mills, chemical plants, and manufacturing facilities with high-power requirements.
The lug is suitable for underground cable terminations in medium-voltage distribution systems, providing reliable connections between aluminum cables and transformer terminals in buried installations where corrosion resistance is essential.
The optimized transition geometry between copper and aluminum minimizes electrical field concentration at the junction, while the smooth, void-free surface finish prevents corona discharge. This design allows proper stress relief application, meeting the dielectric requirements of high-voltage systems.
Installation requires hexagonal crimp dies specifically calibrated for bi-metal power connections, used with hydraulic tools capable of delivering 25-50 tons of force depending on lug size. Tools must meet ISO 6722 standards for crimping accuracy to ensure proper conductor deformation.
The friction welding process creates a metallurgical bond without electrolyte gaps, while an intermetallic compound layer (≤5 µm thickness) formed during welding acts as a diffusion barrier between copper and aluminum, eliminating galvanic action that causes corrosion in mechanical connections.
The lug maintains stable performance across a temperature range of -40°C to 150°C, accommodating the thermal fluctuations common in power distribution systems during both normal operation and fault conditions, including the high temperatures generated during short circuits.
| ltem No. | φ±0.3 | D±0.2 | d±0.2 | L±2 | L1±2 | W±0.2 | S±0.2 |
| DTL-5-16 | 10.5 | 16 | 5.5 | 80 | 40 | 20 | 4.0 |
| DTL-5-25 | 10.5 | 16 | 7.0 | 80 | 40 | 20 | 4.0 |
| DTL-5-35 | 10.5 | 16 | 8.2 | 80 | 40 | 20 | 4.0 |
| DTL-5-50 | 12.8 | 20 | 9.2 | 90 | 43 | 25 | 5.5 |
| DTL-5-70 | 12.8 | 20 | 11.2 | 90 | 43 | 25 | 5.5 |
| DTL-5-95 | 12.8 | 20 | 12.5 | 90 | 43 | 25 | 5.5 |
| DTL-5-120 | 12.8 | 25 | 14.0 | 112 | 58 | 30 | 6.5 |
| DTL-5-150 | 12.8 | 25 | 16.5 | 112 | 58 | 30 | 6.5 |
| DTL-5-185 | 12.8 | 32 | 18.5 | 122 | 60 | 35 | 7.0 |
| DTL-5-240 | 12.8 | 32 | 20.0 | 122 | 60 | 35 | 7.0 |
| DTL-5-300 | 12.8 | 34 | 23.5 | 125 | 65 | 35 | 7.0 |
| DTL-5-400 | 17.0 | 40 | 26.0 | 160 | 90 | 36 | 7.0 |
| DTL-5-500 | 17.0 | 40 | 29.5 | 160 | 90 | 36 | 7.0 |
