CONNECTING

UNLIKE METALS
How to connect aluminum
flat pad to copper or brass
T
he making of a good electrical connection
involves more than what initially meets the
eye. The act of uniting or compressing the
connector to the conductor is a given, but
metals have to be prepared beforehand to
ensure a good connection. Such is the case when
connecting an aluminum flat pad connector to a copper
or brass flat pad. Making a proper transition between the
two metals is essential to obtaining a dependable
connection thats going to perform its job and last.
Follow the steps outlined here for high performance
connections and long service life.
Step 1:
Vigorously clean both the alumi-
num and copper/brass contact
surfaces with a stainless-steel wire
brush. A typically bright surface
should be obtained.
UNITED STATES 210 N. Allen Centralia, Mo 65240 Phone: 573-682-5521 Fax: 573-682-8714 e-mail: hpscontact@hps.hubbell.com
CANADA 870 Brock Road South Pickering, Ontario L1W 1Z8 Phone: 905-839-1138 Fax: 905-831-6353 e-mail: jpearl@hubbell-canada.com
MEXICO Av. Coyoacan No. 1051 Col. Del Valle 03100 Mexico, D.F. Phone: 525-575-2022 Fax: 525-559-8626 e-mail: vtasdf@hubbell.com.mx

Copyright 2000 Hubbell 210 North Allen Street Centralia, MO 65240 A9605

ANDERSON

Step 3:
Pads should be bolted together using galva-
nized-steel or stainless-steel hardware. Tighten
hardware to the recommended torque value for
the particular size bolts that are used. Care
should be taken to prevent sealant from being
applied to the hardware because this will affect
the torque values.
As a further precaution to prevent galvanic
corrosion when joining aluminum to copper or
brass in the field, the aluminum should always
be placed above the copper to prevent copper
salts from leaching over the aluminum in the
form of rainwater and attacking the aluminum.
Follow the steps outlined above when uniting
aluminum and copper or brass connections and
youll have dependable connections.
Step 2:
Immediately coat both contact surfaces with a
liberal amount of non-gritted contact sealant.
Good connections begin
at the Anderson foundries
Aluminum:
In our aluminum foundry, the permanent-mold pro-
cess is used in the manufacture of high-
volume aluminum castings which ex-
hibit excellent physical properties,
surface finish and dimensional con-
formance.
Conventional sand molding of alu-
minum is utilized for low-volume
casting production common to
many substation and EHV trans-
mission applications. A multiplic-
ity of molding stations and types
and crucible melting furnaces pro-
vide the flexibility required to en-
sure optimum cast quality. Heat treating and aging of
aluminum castings are performed under the control of
experienced operators. Post heat- treat physical proper-
ties are confirmed through test-bar analysis.
Brass:
The Anderson high volume brass foundry was installed
in 1983. It is built around an automatic cope and drag
molding machine. All process elements are sequenced
automatically using programmable controls. Volume
red brass and aluminum bronze castings are efficiently
produced in this process. Conventional sand molding
of brass and bronze is utilized for lower volume casting
production. A pallet line pro-
cess allows many flexibilities
unique to the production of
substation and special distri-
bution connectors.
All brass and bronze melting is
accomplished in electrical in-
duction melting equipment.
Advantages include good mix-
ing of alloying ingredients and
resistance to atmospheric contamination.

POWER
SYSTEMS, INC.
573-682-5521 Fax 573-682-8714 http://www.hubbellpowersystems.com
NOTE: Because Hubbell has a policy of continuous product improvement, we reserve the
right to change design and specifications without notice.
TiPS NEWS
Reprinted from
Vol.2, No. 4
AUGUST 1996
&
A9605