Contact surfaces, regardless of how well they are machined, will not match each other perfectly so that

when first brought together, only three points of actual contact exist. As force is applied to the contacts, the points deform into minute areas of contact and allow additional points to come into contact. The deformation of contact points and the creation of additional points is dependent upon the force applied and the hardness of the contact material. Theory states that the resistance at the interface of two clean contact surfaces is non-existent and that the apparent contact resistance is due entirely to the longer paths which the current must follow when actual contact is limited to a number of points. Figure here below illustrates this concept and it will be seen that, all other things being equal, material with a low unit resistivity will have low contact resistance. It is also apparent that increasing the number of points of contact decreases contact and this is facilitated by high contact forces acting on relatively malleable materials. Thus, the characteristics of a connector material, which produce low contact resistance, are : High unit conductivity. Surface malleability to obtain intimate contact under clamping pressure. Ductility to permit a wrapping action about the conductor, thereby obtaining efficient current transfer all around the periphery of the conductor.

CONNECTOR AND CONDUCTOR PREPARATION

To obtain optimum performance from any connector, the conductor surface must be thoroughly cleaned before installation. The surface oxides that form on all conductors act as insulation. Failure to remove them can result in a high resistance joint and, ultimately, failure. Conductor contact surfaces should be scratch brushed until bright. Immediately apply contact paste to the conductive surfaces. For EHV applications, remove all excess contact paste after installation. The contact paste is a natural (petroleum) base compound with evenly suspended zinc particles. It is recommended for aluminium to aluminium connections for all voltages and aluminium conduit threads. It aids in the establishment of low resistance joints and prevents aluminium oxide from reforming. It is not recommended for use with rubber or polyethylene insulated conductors. Contact paste is a synthetic base compound with evenly suspended copper particles. It is supply, on request, for copper to copper, copper threads and all grounding applications. In preparing contact surfaces (connector and conductor) for welding, all surface oxides and oils must be removed by scratch brushing with a stainless steel wire brush and wiped clean with a degreasing agent. All filler material used in making the weld must be clean and dry. Improperly prepared surfaces can cause pitted, porous welds, which can be a source of trouble or failure.

CORROSION
The most common methods of preventing the corrosion of aluminium surfaces in contact with copper include : Sealing the contact with petroleum zinc chromate red lead or other inert means to prevent penetration by corrosive media or electrolyte to the contact surfaces. Plating contact surfaces with tin, cadmium, zinc or some other metal between copper and aluminium in the galvanic series. Insertion of a bimetallic sheet of aluminium-copper between the metals, the aluminium face in contact with the aluminium and the copper face with the copper. Soldering of the two surfaces together.