What Are Bi-Metal Lugs and Why Are They Used?
BI METAL LUGS are electrical connectors of a special kind which are intended to connect aluminum wires to copper terminals without the risk of corrosion or overheating. In many electrical installations, aluminum metal cables are used due to their light weight and lower price compared with copper, while copper is often found in switchgear, busbars, and equipment terminals thanks to its relatively high conductivity. However, direct connection of aluminum and copper can result in galvanic corrosion, increased contact resistance, and overheating. This is the situation when BI METAL LUGS come into the picture.

BI METAL LUGS are made by permanently joining a high-conductivity aluminum barrel to a copper palm, generally, by either friction welding or molecular bonding. This type of construction keeps the two dissimilar metals apart and thus, minimizes corrosion and maintains a low-resistant electrical connection. The aluminum side is made for crimping aluminum conductors, and the copper palm is meant for securely bolting to copper terminals.

These lugs are used extensively in power distribution panels, transformers, control panels, and industrial electrical systems, where mixed-metal connections are unavoidable. BI METAL LUGS, by dissipating heat, preventing joint failure, and improving long-term reliability, contribute to both safety and performance.

Among the manufacturers of BI METAL LUGS PIONEER POWER INTERNATIONAL supplies, high-quality products that meet the global standards, which translates into durability, installation ease, and electrical performance consistency even in the most demanding applications.