Novel Electrical Joints Using Deformation Machining Technology—Part II: Experimental Verification
This is the second part of the paper related to the exploration of deformation machining technology (DMT), originally developed at Bauman Moscow State Technical University, as it may apply to making electrical joints and comparing their performance to bolted and welded electrical joints. The DMT process is used to generate tooth-like profiles on two opposing surfaces that make the electrical joints which are later joined by applying a mechanical load. Part I contained a more detailed explanation of the DMT process and the description of the results of computer modeling of DMT joints in copper and aluminum. This paper provides the experimental results of the mechanical and electrical performance of copper and aluminum DMT joints which were compared to bolted and welded electrical joints of identical geometries. Measurements of tensile strength and electrical resistance, after thermal cycling and short-circuit testing, show equivalent or better performance of copper DMT joints compared with copper bolted and welded joints. In addition, it is observed that copper DMT joints have superior performance when compared with aluminum DMT joints, this was attributed to lesser gap filling and the springback effect that occurs after the mechanical load for making the joint is removed. The computer modeling results reported in Part I of this paper support these observations.
New Method of Quench Surface Turning
The heating, generated in the process of deformational cutting without chip separation used for phase transformation in steel during lathe machining. Chips are not separated from the workpiece and remain on the surface thus forming a special reinforced structure. The result of processing is a steel surface quenching up to 1 mm deep. The proposed method also makes it possible to obtain hardened surface structures with alternating inclined layers of different hardness. The article presents calculations of heating and cooling rates, types of hardened structures, hardness investigation of hardened steel surfaces.
Model to assess the reliability of electrical joints
Electrical joints can be weak points in the electric supply system. Based on theoretical and experimental investigation, a mathematical model is presented which describes the resistance characteristic of joints depending on parameters such as conductor material, load, design, assembly quality and its surroundings. Furthermore, using the example of busbar joints, a possibility of how limiting values for the joint resistance can be determine using a mathematical model.