APPLICATION OF ALUMINIUM TERMINAL EXTENDERS FOR MOULDED CASE CIRCUIT BREAKERS By S.S.A.

Rajapaksa MIET, MIEEE Assistant training manager Rotax ltd Colombo 04 Introduction As per the data available from theLondon metal exchange the world copper prices increased by 334% with comparision to aluminium as at july 2010.This price escalating tendency of copper will prevail in future as well due to the difficulties faced by mine owners to unearth copper material.Therefore the electrical manufacturers have progressively commenced the manufacture of current carrying components made of copper replaced by aluminium alloys.It was observed that the properties of aluminium will significantly changed for the electrical use by adding alloys(aluminium alloy 6101). This paper discuss the possible problem areas encountered during the above transition and solutions adopted by them. Comparision chart for properties of Aluminium vs; Copper properties weight Conductivity(electrical) Conductivity(thermal) Tensile strength Increase of cross section for same conductivity Thermal expansion Specific resistance Copper (%) 100 100 100 100 100 100 100 Aluminium (%) 55 56 55 64 156 143 180

Properties of conductor materials Aluminium Aluminium is the most freely available of all metals and never found in its pure state because of its likeness to associate with other metals.This feature of Aluminium enables a wide range of alloying characteristics, however it also increases refinement costs and lowers the conductivity..The other properties of Aluminium are good ductility(easily worked by rolling,drawing,forging etc),very good corrosion resistanance(except in salt layden atmosphere) by forming a tough very hard invisible and high resistanance oxide,resists pitting(eroding) from arcing effects, galvanic action where aluminium acts as an anode when placed with copper.Aluminium alloy 6101 comprices of .5% silicon and .6% magnesium in addition to its aluminium content. Copper Copper a reddish material found in its almost pure state therefore refining costs are minimized with comparision to aluminium. The other properties are good ductility, corrosion resistance action by forming a thin easily removable copper oxide layer faced

with atmosphere.When copper is heated more oxides are formed and continue to increase the resistanance of the location of heat. Solution based problem solving Problems encountered Tensile strength of aluminium is less than copper.Therefore meeting the stresses under short circuit fault conditions has to be addressed Connecting Copper and Aluminium together with moisture in the joint due to humidity will form a galvanic cell.Therefore aluminium as the anode will start pitting(eroding) The thermal expansion of Aluminium is greater than Copper.Therefore with the increase and decrease of temperature at the joint(due to the current flow) the clamping force of the mounting bolt can get effected. Formation of oxides in both metals will increase the resistance Solutions adopted With the increase of cross sectional area of Aluminium to meet the current carrying capacity the tensile strength of the Aluminium material will automatically get corrected Tin plating the Copper and Aluminium material will prevent the formation of a galvanic cell. The steel bolts also shall be nickel plated. Selection of nickel plated spring/lock washers and tightning the bolt to the mccb manufacturer,s recommendation using a torque wrench will solve this problem Tin plating both meterials

Conclusion Many people understand the cost difference between copper and aluminium but do not have personnel experience with the usage of moulded case circuit breakers comprises of aluminium terminal extension bars and are hesitant to change. A typical example is the introduction of auto transmission and constant velocity joints for the motor vehicles where people found reluctant to buy such vehicles for years due to no valuable reasons.Therefore we are compelled to explore the possibilities of usage of Aluminium for the current carring components of Mccb without delay.

References 1.Prior,Schlobohm, and Brownell senior specification engineers of GE consumer and industrial facility a comparision of alumenium vs. copper as used in electrical equipment 2.facilities engineering branch US bureau of reclamation-electrical connections for power circuits