The processing of Aluminium compression cable lugs and connectors


Aluminium has special properties and a precise processing procedure is therefore a must. Ideally, proceed as follows to make a clean connection:


  1. Remove the insulation from the aluminium conductor. 
  2. Carefully treat the bright end of the conductor with a blade or wire brush for example, to coarsely remove the oxide layer and produce a clean contact surface. Make absolutely sure that that no metal traces remain on the conductor after cleaning, as this could lead to contact corrosion. 
  3. Insert the conductor into the cable lug or connector to the full insertion length of the sleeve. The contact grease will flow out to the side, thereby creating an air seal which prevents reoxidisation. 
  4. You can now make the hexagonal or indent crimp using the suitable tool. Before the actual crimping process, a single or multi-stranded sector-shaped conductor must be prerounded using a suitable round crimping die. 
  5. Finally remove the discharged contact grease. 




Aluminium cable lugs have alternative markings for narrow and wide crimps. The advantage of the wide variant is that the number of crimps required is halved. However, note that a correspondingly powerful crimping tool should be used. With sector-shaped conductors, you can use Klauke prerounded dies. Unlike with copper conductors, sleeves cannot be used with multi-stranded sector-shaped conductors.

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