DTL-2
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.
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. The friction-welded joint achieves a tensile strength exceeding 180 MPa and maintains a resistivity of ≤1.2 µΩ·cm, ensuring minimal power loss across the metal interface.
Designed for power 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.
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 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.
The optimized transition geometry between copper and aluminum minimizes electrical field concentration at the junction, while the insulation-compatible 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.
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.
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.
| ltem No. | Φ±0.3 | D±0.2 | d±0.2 | L±2 | L1±2 | W±0.2 | S±0.2 |
| DTL-2-10 | 10.5 | 14 | 5.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-16 | 10.5 | 16 | 6.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-25 | 10.5 | 16 | 7.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-35 | 10.5 | 16 | 8.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-50 | 12.8 | 20 | 9.8 | 90 | 43 | 25 | 4.5 |
| DTL-2-70 | 12.8 | 20 | 11.5 | 90 | 43 | 25 | 4.5 |
| DTL-2-95 | 12.8 | 20 | 13.5 | 90 | 43 | 25 | 4.5 |
| DTL-2-120 | 12.8 | 25 | 15.0 | 114 | 60 | 30 | 5.5 |
| DTL-2-150 | 12.8 | 25 | 16.5 | 114 | 60 | 30 | 5.5 |
| DTL-2-185 | 12.8 | 32 | 18.5 | 118 | 60 | 35 | 6.0 |
| DTL-2-240 | 12.8 | 32 | 21.5 | 118 | 60 | 35 | 6.0 |
| DTL-2-300 | 12.8 | 34 | 23.5 | 127 | 72 | 35 | 6.0 |
| DTL-2-400 | 17.0 | 40 | 26.0 | 160 | 93 | 36 | 7.0 |
| DTL-2-500 | 17.0 | 47 | 29.5 | 160 | 94 | 36 | 7.0 |
| DTL-2-630 | 17.0 | 47 | 32.5 | 180 | 94 | 50 | 9.0 |
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.
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. The friction-welded joint achieves a tensile strength exceeding 180 MPa and maintains a resistivity of ≤1.2 µΩ·cm, ensuring minimal power loss across the metal interface.
Designed for power 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.
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 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.
The optimized transition geometry between copper and aluminum minimizes electrical field concentration at the junction, while the insulation-compatible 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.
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.
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.
| ltem No. | Φ±0.3 | D±0.2 | d±0.2 | L±2 | L1±2 | W±0.2 | S±0.2 |
| DTL-2-10 | 10.5 | 14 | 5.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-16 | 10.5 | 16 | 6.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-25 | 10.5 | 16 | 7.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-35 | 10.5 | 16 | 8.5 | 80 | 42 | 20 | 3.0 |
| DTL-2-50 | 12.8 | 20 | 9.8 | 90 | 43 | 25 | 4.5 |
| DTL-2-70 | 12.8 | 20 | 11.5 | 90 | 43 | 25 | 4.5 |
| DTL-2-95 | 12.8 | 20 | 13.5 | 90 | 43 | 25 | 4.5 |
| DTL-2-120 | 12.8 | 25 | 15.0 | 114 | 60 | 30 | 5.5 |
| DTL-2-150 | 12.8 | 25 | 16.5 | 114 | 60 | 30 | 5.5 |
| DTL-2-185 | 12.8 | 32 | 18.5 | 118 | 60 | 35 | 6.0 |
| DTL-2-240 | 12.8 | 32 | 21.5 | 118 | 60 | 35 | 6.0 |
| DTL-2-300 | 12.8 | 34 | 23.5 | 127 | 72 | 35 | 6.0 |
| DTL-2-400 | 17.0 | 40 | 26.0 | 160 | 93 | 36 | 7.0 |
| DTL-2-500 | 17.0 | 47 | 29.5 | 160 | 94 | 36 | 7.0 |
| DTL-2-630 | 17.0 | 47 | 32.5 | 180 | 94 | 50 | 9.0 |
