Corrosion

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Corrosion is an important factor to be considered in the selection of conductor materials. The two types of corrosion which exhibit greatest influence on the electrical properties of a metal are oxidation and galvanic corrosion. Since most of the commonly used electrical conductors are resistant to oxidation the latter type is the more important. As previously mentioned both copper and aluminum have a high resistance to oxidation because of the manner in which their surfaces oxidize. In the case of both metals an oxide film is formed on their surfaces. This film becomes a protective coating which offers resistance to any further oxidation. In the corrosion of steel, however, a different type of action takes place. The oxide film does not form an adherent coating but lifts off the surface, permitting a clean metallic surface to be exposed to the oxidizing atmosphere. The action progresses in this manner until all of the metal is consumed. In preventing the oxidation of steel a galvanized coating is suitable protection, however, only in dry climates. In moist atmosphere near the seashore or industrial sections where gases are generated the galvanized coating is destroyed by the chemical corrosion of salts and mild acids, exposing the steel to the oxidizing atmosphere. The latter mentioned type of corrosion, the galvanic corrosion, which is caused by the difference in electrical potential between two or more metals, has to be given careful consideration when selecting conductor metals. Two or more different metals in contact with each other in the presence of an electrolyte will cause current to flow through their point of contact at the expense of the metal with the higher potential which is gradually consumed in the Electro-chemical reaction.

Electropotential Series of Metals

Metal Potential, Volts Potassium +2.92 Sodium +2.71 Calcium +2.20 Magnesium +1.87 Aluminum +1.30 Manganese +1.07 Zinc +0.758 Chromium +0.600

Metal Potential, Volts Tin +0.136 Lead +0.122 Hydrogen 0.000 Antimony -0.190 Arsenic -0.320 Bismuth -0.330 Copper -0.345 Mercury -0.799

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Iron +0.441 Cadmium +0.398 Nickel +0.220 Cobalt +0.290

Silver -0.800 Platinum -0.863 Gold -1.100

In a number of instances it is necessary to connect aluminum and copper conductors together. From the table it can be seen that a high potential of 1.645 volts will be set up between these metals in the presence of an electrolyte. If the two metals made contact with each other, in a period of time the aluminum would be corroded away in the reaction, since, of the two metals, it possesses the higher potential. Without an electrolyte between two contacting metals of a high potential difference, no galvanic action takes place. For this reason, in dry climates metals of a considerable potential difference may be used in contact with each other without any concern for galvanic action. In moist industrial areas harmful electrolytes are formed by the absorption of gases by rain and fog to form acids and salts, while in seaside areas they are formed by the combination of salt with the moisture latent atmosphere to form saline solutions. To prevent this galvanic or Electro-chemical corrosion in the case of copper and aluminum the following methods may be employed: (1) Sealing the joint from the atmosphere by taping with a moisture proof tape or use of some suitable sealer. (2) Soldering the contact surfaces together. (3) Plating the contact surfaces with some rust resisting metal whose potential lies between that of copper and aluminum. (4) Application of corrosion inhibitor compound to minimize the introduction of harmful electrolytes.

Aluminum because of its lightness of weight, strength, and electrical conductivity has become a major conductor material whose use is constantly growing. In consequence, the development and output of connectors suitable for use with aluminum has had to keep abreast of this growth. For aluminum to aluminum connections it is a recommended practice to use wherever possible all-aluminum connectors. For such connectors, we refer the reader to our catalog AP-53 which represents a complete line of aluminum connectors for power and substation applications. Where a connection comprising a junction of an aluminum and copper conductor is to be considered, several conditions must be observed in the selecting of the most appropriate connection. Aluminum because of its high Electro-potential with respect to that of copper will, in contact with copper and in the presence of an electrolyte, corrode progressively in the ensuing Electro-chemical reaction until contact between the two metals is destroyed. For this reason a protective coating at the contacting interface must be introduced to minimize this corrosion. The most effective coating for this purpose has been found to be a hot-tin dip plating. As the expression implies, the entire copper connector or the section to be treated is dipped in a molten bath of tin rich alloy which creates a fully bonded plate of uniform thickness over the entire surface of immersion. The tin serves as suitable intermediate metal between that of copper and aluminum and can be applied uniformly to thickness of one mil or greater. The next point of consideration in the connecting of aluminum and copper conductors is the inherent difference in thermal expansion

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between the two metals. Aluminum has a higher coefficient of thermal expansion than that of copper and in consequence for a given temperature rise will expand to a greater degree than an equal size of a copper member. For this reason when large conductors are involved and sizeable temperature variations can be expected. It is an undesirable practice to employ a copper connector for use with aluminum. Failure to observe this principle and the use of copper connector possessing no resilience or follow-up action to thermal changes could lead to early joint deterioration. Resistance build up to cause this deterioration is effected by this action. When the temperature rises, both the copper and aluminum expand, but to a differential degree. The copper, not being able to expand as greatly as the aluminum, restricts the aluminum and causes it to flow. Upon cooling a dimensional difference begins to set up creating greater resistance and higher temperature rise. As the repeated cycles continue the resistance and temperature become progressively greater until ultimate failure occurs. ALUMINUM TO ALUMINUM AND ALUMINUM TO COPPER CONNECTOR ORDERING RECOMMENDATIONS

Aluminum To Aluminum
(1) For aluminum to aluminum connections, connectors should be aluminum bodied and supplied with aluminum alloy fasteners. For such connectors refer to catalog AP-53. As most all-aluminum connectors, with a few exceptions, carry a catalog number suffix -AA, any desired connector whose catalog number is suffixed with -AA will be supplied for appropriate use with the aluminum conductors so designated in the catalog number.

Aluminum To Copper
(1) Where Aluminum is predominantly the larger conductor: (A) An all-aluminum connector should be specified (Suffix selected aluminum connector Cat. No. -AA.) OR (B) An all-aluminum connector should be specified with a copper liner bonded in copper bearing surface or on copper contact Terminal Pad. (Suffix selected aluminum connector Cat. No.-CL-AA). OR (C) An all-aluminum connector should be specified with a hot tin dip coating. (Suffix selected aluminum connector Cat. No. -AA-HSN). This recommendation is confined mainly to small parallel groove clamps and service connectors. (2) Where copper is predominately the larger conductor: (A) An all-copper alloy connector with a hot tin dip coating should be specified (Suffix selected copper alloy connector Cat. No. -HSN)

DOSTEX Oxide Inhibitor

For the preparation and maintenance of efficient connections with aluminum, the use of Dostex is recommended. Its effectiveness in maintaining sound electrical connections has been proven by test as well as through operational service. Dostex is a grease-like base compound containing chemical inhibitors which make it actively resistant to oxidation and corrosion. Its universally adhesive quality and its permanent plasticity render it a tenacious coating.

Dostex exhibits the following functional benefits:

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(1) Dostex forms an impenetrable protective film against all conditions of weather thereby preventing air or moisture from coming in contact with the vulnerable metallic surfaces. (2) Dostex possesses inhibitors which render it inert to the influences of corrosion and oxidation. (3) Dostex when applied to stranded conductors assures the continuance of uniform interstrand current distribution and prevents current concentrations and the resulting effect of localized heating. This is an important function of Dostex since operational temperatures can only be held to a minimum when all parts of the conductor are effectively carrying their share of the load. In preparing a connection with aluminum it is recommended that the aluminum contact surfaces be cleaned by abrasion and then be lightly coated with Dostex. Since an oxide film is immediately formed when aluminum is exposed to the atmosphere a second cleaning through the Dostex coating should then be done by wire brushing or rubbing with an emery cloth. This secondary cleaning through the protective film abrades the immediately formed oxide and provides a clean metal surface under the protective Dostex coating. At this point a more liberal application of Dostex may be made to assure good coverage in the assembled joint. If the metallic surfaces are reasonably clean, the initial cleaning, prior to application of Dostex, may be eliminated. Tinned or plated copper contact surfaces should not be cleaned by abrasion, however, an application of Dostex may be made on such surfaces to insure an adequate amount in the assembled joint.

Dostex compound is available in three types as follows:

Type AP - An inert grease base compound containing oxidation inhibitors. Universally used for aluminum to aluminum and aluminum to copper connections and for protecting metallic surfaces. Type ZS - An inert high temperature stable compound containing zinc particles uniformly dispensed in complete suspension. Used for aluminum and aluminum to copper connections. Type ZH - An inhibitor compound identical to type ZS except especially compounded for use on insulated connections 600 volts and higher.

PACKAGED QUANTITIES 5 Oz. Tubes 8 Oz. Squeeze Bottles Pint Can Quart Cans Gallon Pails 5 Gallon Pails

INHIBITOR ZH AP, ZS AP, ZS, ZH AP, ZS, ZH AP, ZS, ZH AP, ZS

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