Investigation of the electrical quality and long-term stability of aluminum ground stud connections in automotive applications

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY
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Abstract

The rapid advancement in the electrification of modern vehicles has led to a continuous increase in electrical consumers for various comfort and safety functions. Ground studs serve as the electrical interface between the conductive vehicle body and the onboard network. Drawn arc stud welding is an economical and established joining process for producing ground stud joints. The circuits in the onboard network are increasingly subject to greater demands regarding current-carrying capacity and long-term stability. Reliable signal and power transmission require minimal contact resistance at the electrical connection points of the ground stud system and must withstand various operating and environmental conditions over the entire service life. In this study, a ground stud made of AlMg5, with a ZnNi-coated steel cap nut was used on a 2.0 mm thick sheet of AlMg3. The electrical connection of the ground studs was made using tinned copper cable lugs and 35 mm² cables. To analyze the electrical resistance behavior in an accelerated test, the ground studs were subjected to a superimposed load with a cyclic current profile for 1008 h under changing climatic conditions. The results show that under the chosen operational and environmental conditions, accelerated aging and intermittent resistance behavior occur. A characteristic drop in resistance during the test indicates the failure point of the electrical connection. The cause of failure can be attributed to media penetration into the electrical contact zone. A failure of the electrical connection was observed after 512 h.
汽车应用中铝接地螺栓连接的电气质量和长期稳定性调查
随着现代汽车电气化的快速发展,用于各种舒适和安全功能的用电量不断增加。接地螺栓是导电车身与车载网络之间的电气接口。拉弧螺柱焊接是生产接地螺柱接头的一种经济、成熟的连接工艺。车载网络中的电路对载流能力和长期稳定性的要求越来越高。可靠的信号和电力传输要求接地螺柱系统电气连接点的接触电阻最小,并且必须在整个使用寿命期间经受住各种操作和环境条件的考验。在这项研究中,在 2.0 毫米厚的 AlMg3 板上使用了由 AlMg5 制成的接地螺柱,该螺柱带有一个 ZnNi 涂层钢帽螺母。接地螺栓的电气连接使用镀锡铜电缆耳和 35 mm² 电缆。为了分析加速试验中的电阻行为,接地螺栓在不断变化的气候条件下承受了 1008 小时的周期电流曲线叠加负载。结果表明,在选定的操作和环境条件下,会出现加速老化和间歇性电阻行为。测试期间电阻下降的特征表明了电气连接的故障点。故障原因可能是介质渗入电气接触区。512 小时后观察到电气连接失效。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
CiteScore
7.10
自引率
9.80%
发文量
58
审稿时长
44 days
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