Electrical connection to Aluminium Subtrate 1

[paulmech01]

I am trying to make an electrical connection between an electrical cable and aluminium, currently brass pins are soldered to the aluminium and the wire is soldered to the pin.

We need to move away from the solder used to join the brass pin to the aluminium as it contains lead, but no ther lead free alternatives available to join aluminium to brass.

Can somebody offer an alternative.

 

[itsmoked]

Sounds like you need to move to clips or clamps?

If that is really not possible then consider spot or ultrasonic welding of Al wire onto your Al then transition the wire.

Keith Cress
Flamin Systems, Inc.-

http://www.flaminsystems.com

 

[paulmech01]

The core of the cable that is connected to the aluminium is tinned copper.
Could this be spot welded or induction or some other resistance weld joined to the aluminium.

The aluminuim is quite thin, Dia 12mm x 1mm wall.

 

[itsmoked]

Hi paul,

I don't know enough metallurgy to give you any better answer than the previous one as I know those things are possible.

I would suggest you head over to the forum330 which is a metallurgy forum. Those sharp individuals will steer you right.

Keith Cress
Flamin Systems, Inc.-

http://www.flaminsystems.com