DTL-95 Copper-Aluminum Transition Cable Lug

DTL-95 is a copper-aluminum transition cable lug specially designed for connecting 95mm² aluminum conductors to copper equipment terminals. It resolves the issues of electrochemical corrosion and thermal expansion/contraction in direct copper-aluminum connections through specialized processes, serving as a critical connector widely used in power distribution systems.

1. Basic Specifications and Parameters

Main Dimensions (mm)

1.Differences Between Grade A, Grade B and Non-standard Products

Grade A Products (Recommended)

Material: Copper purity ≥99.9%, aluminum purity ≥99.6%, minimal impurities

Performance: DC resistance ≤1.1 times the conductor resistance, low temperature rise, high mechanical strength (tensile strength ≥120MPa)

Process: High-precision friction welding, no air bubbles or gaps at the bonding interface, uniform resistance

Service Life: Up to 30 ani, suitable for critical connections requiring long-term operation

Preţ: Approximately 10-15 CNY per unit

Grade B Products

Material: Purity slightly lower than Grade A, but still meeting the basic requirements of national standards

Performance: Resistance ≤1.3 times the conductor resistance, tensile strength ≥100MPa, satisfying general application needs

Process: Qualified welding quality, but minor air bubbles may exist

Preţ: Approximately 5-8 CNY per unit, cost-effective and suitable for general-purpose connections

Non-standard Products

Material: Mostly recycled copper / mixed aluminum, with unguaranteed purity and frequent impurities

Process: Mostly cold-pressed or low-quality brazed, the bonding interface is prone to separation, with high and unstable resistance

Risks: Prone to heating and oxidation, short service life, potential fire hazard. Strictly prohibited for critical applications

Preţ: Approximately 3-5 CNY per unit, only suitable for temporary or low-current (≤10A) scenarios

III. Performance Parameters and Application Scenarios

Core Electrical Performance

Curent nominal: Approximately 230A (at ambient temperature of 40℃), meeting the current-carrying requirements of 95mm² aluminum cables

Operating Temperature Range: -55℃ ~ +150℃, adapting to a wide range of environmental conditions

Insulation Class: Can achieve IP68 protection when paired with heat-shrinkable tubes (for outdoor applications)

Resistance Characteristics: Resistance of the copper-aluminum transition zone ≤1.3 times that of copper conductors with the same cross-section (ensuring low heat generation)

Scenarii tipice de aplicare

1. Connection between low-voltage side of transformer and aluminum busbar: Resolving the copper-aluminum interface issue of large-scale equipment
2. Connection between copper busbar and aluminum cable in power distribution cabinets: Standard application in power distribution systems
3. Industrial motor wiring: Especially for power supply connection of large motors (above 75kW)
4. Connection between outdoor overhead lines and equipment: Grade A products are required to enhance weather resistance
5. Building electrical systems: Reliable connection solution for power distribution trunk lines in high-rise buildings
6. Key Points for Selection and Quality Identification

Selection Guidelines

1. Confirm Conductor Specifications: Must match 95mm² aluminum-core cables, with aperture = conductor outer diameter + 0.2~0.5mm
2. Select Grade Based on Application Scenarios:

Critical equipment, outdoor use, high-voltage systems → Grade A

General low-voltage, indoor fixed wiring → Grade B

Temporary power supply, small loads → Use Grade B with caution or non-standard products are not recommended

3. Environmental Considerations:

Humid / corrosive environments → Select tin-plated type (tin plating thickness on copper end ≥5μm)

High-temperature locations → Select high-temperature resistant type (operating temperature up to 150℃)

Golden Rules for Quality Identification

1. Visual Inspection:

Copper end presents purplish-red color (not brass color), aluminum end presents silvery white color with uniform luster

The copper-aluminum bonding interface transitions smoothly without obvious gaps or protrusions

Smooth surface finish, uniform tin plating (if applicable), no missing plating areas

2. Dimension Measurement:

Measure aperture with calipers: Tolerance ≤±0.1mm for Grade A, ≤±0.3mm for Grade B

Head thickness: ≥3.0mm for Grade A, ≥2.0mm for Grade B, usually <2.0mm for non-standard products

3. Simple Material Testing:

Hardness test: Lightly scratch the copper end with a knife; the internal and external colors are consistent (both purplish-red)

Magnet test: Neither copper nor aluminum is attracted by magnets; magnetic attraction indicates iron impurities

1. Key Installation Steps
2. Preparation Work:

Strip insulation layer: Length = terminal insertion depth + 5mm (approximately 55mm)

Clean conductors: Thoroughly remove oxide layer with sandpaper to expose metallic luster

Apply conductive paste: Evenly coat the conductor surface to reduce contact resistance

2. Crimping Operation (Hydraulic crimping pliers must be used; hammering manually is strictly prohibited):

Select special mold for 95mm², matching the terminal specifications

Crimping sequence: Crimp sequentially from the root to the open end of the terminal, ensuring 1/3 overlap of crimp marks

Crimping force: Reach the specified depth of the mold, with clear and crack-free crimp marks and uniform terminal deformation

3. Protection Treatment:

Install heat-shrinkable tube (length covering 20mm at both ends of the crimped area) and heat evenly for shrinkage

For outdoor or humid environments: Additional waterproof heat-shrinkable tubes or waterproof sealant should be applied

1. Summary and Recommendations

DTL-95 copper-aluminum cable lug is a standard solution for connecting 95mm² aluminum conductors to copper equipment. Do not choose non-standard products for cost savings, as poor contact may lead to heating, fire and other safety hazards.

Recommended Procurement Plan:

– Critical projects / long-term operation → Grade A products (aproximativ 12 CNY per unit), ensuring 30-year maintenance-free service

– General engineering projects → Grade B products (aproximativ 6-8 CNY per unit), balancing performance and cost

– Temporary power supply → Grade B products can be considered with regular inspections; non-standard products are not recommended

Remember: Electrical connections are not trivial matters, and you get what you pay for in terms of safety!