Electrical connection for aluminium conductors in automotive applications : Prestudy of available solutions for electrical connection methods of aluminium cables

Abstract: Due to increasing weight of electrical component and wiring harnesses in a vehicle contrary to the demand of light constructed vehicles as well as the constantly increasing and fluctuating price of copper compared to aluminium’s stable and far lower price, the use of aluminium conductors as an alternative have been promoted.  This thesis work lay theoretical research of the available methods used for electrical connection of aluminium conductors in order to increase the knowledge about the available termination techniques.  Due to aluminium’s characteristics such as lower conductivity and strength, tendency to form oxides and relax over time, differences in thermal expansion coefficient and high potential for galvanic corrosion, there is a risk of deterioration and degradation of the connection if the termination of aluminium conductors is not done correctly without being aware of the challenges when it comes to aluminium connection.  The founded solutions are different welding and soldering techniques such as friction welding, ultrasonic welding, resistance welding, plasma soldering and many other modifications of conventional crimp.  A robust termination system that faces all those challenges and ensure a reliable connection during the entire life length of the vehicle and in order to inhibit corrosion different type of sealing of the contact interface will be required.  In order to evaluate the performance of the founded connection method, testing with evaluation of, tensile strength of conductor to contact attachment, tightness demand, corrosion resistance, vibration and heat evolution at the contact attachment have to be conducted.