Electronics > Projects, Designs, and Technical Stuff
Electrical contacting on aluminium busbar
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dmills:
For this I would absolutely be going with copper bars, ally is just a pain in the arse for electrical connections (It can be done, but **EVERYTHING** has to be perfect or it fails high resistance after a while).

A 1.3M long copper busbar is a perfectly standard requirement, and it would not need to be anything like 56mm^2 CSA for 120A in copper (More like 20mm^2 probably, but you might want more for mechanical reasons).

Be a little careful of the brasses, and especially things like ally-bronze, they tend to be surprisingly resistive.

Any non ferrous stockholder will be able to supply raw copper bar in 1.3M lengths, no problem at all.

I would note that copper is a bugger to tap, clearance holes and bolted connections will make everyones life easier, or do the helicoil thing. Current should mostly be transferred by the contact between the face of the bar and the face of the lug anyway, the bolt should not normally be a major current path, a disk spring is useful here to take up thermal expansion and prevent loosening in the long term.

Regards, Dan.
damien22:
Thanks for the input dmills.

In my region seems very difficult to get unfortunately.

Would stainless helicoil thing be a good solution ? Unfortunately we cannot bolt as the bar lay flat on an insulator to which they are fixed and on the other side the PCB are mounted.

The PCB does contact with the bars so most of the current would go through there.

MagicSmoker:
Plate the aluminum bus bars with nickel; problem solved.

wraper:

--- Quote from: MagicSmoker on February 27, 2019, 11:30:49 am ---Plate the aluminum bus bars with nickel; problem solved.

--- End quote ---
Nothing solved. It's easier, cheaper and much better to just not use aluminium.
damien22:

--- Quote ---Plate the aluminum bus bars with nickel; problem solved.
--- End quote ---

As discussed, we couldn't find any supplier that can do this sort of plating beyond 1m length
 
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