Materials Science and Engineering

Corrosion behavior and performance degradation of aluminum-copper cable joints with magnetic pulse crimping in salt spray environment

  • 姚源恒,王绍螺,蒋 浩,崔俊佳,李光耀,罗开东,夏铃华
Expand
  • 1. State Key Laboratory of Advanced Design and Manufacturing Technology for Vehicle, Hunan University, Changsha 410082, China;
    2. Shenzhen Automotive Research Institute, Beijing Institute of Technology, Shenzhen 518118, China;
    3. The First Product Department, FinDreoms Battery Co., Ltd., Huizhou 516083, China;

Online published: 2025-11-04

Abstract

The corrosion resistance of aluminum (Al) cable-copper (Cu) terminal joints fabricated by magnetic pulse crimping (MPC) and hydraulic clamp crimping (HCC) was compared. Performance degradation was evaluated by mechanical and electrical properties. Additionally, corrosion behavior was analyzed by electrochemical testing. Microscopic characterization was performed by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Results show that the tensile strength of the corroded joints is reduced. However, due to the advantages of high-speed forming and contact tightness unique to MPC, the contact resistance of the corroded joints still maintains excellent. Electrochemical tests demonstrate that the MPC joints have higher corrosion potentials and smaller corrosion currents, providing better corrosion resistance. The formation of a primary battery between Al and Cu at the lap joint leads to the formation of severer corrosion pits.

Cite this article

姚源恒,王绍螺,蒋 浩,崔俊佳,李光耀,罗开东,夏铃华 . Corrosion behavior and performance degradation of aluminum-copper cable joints with magnetic pulse crimping in salt spray environment[J]. Transactions of Nonferrous Metals Society of China, 2025 , 35(6) : 1937 -1955 . DOI: 10.1016/S1003-6326(25)66792-6

Outlines

/