Fatigue characteristics, failure mechanism and life prediction of copper–aluminum cable joints formed by magnetic pulse crimping

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-03-04 DOI:10.1016/j.engfailanal.2025.109483

Shaoluo Wang , Xiangyu Gao , Zhiquan Huang , Hao Jiang , Guangyao Li , Junjia Cui

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引用次数: 0

Abstract

Magnetic pulse crimping process has significant potential for high-voltage cable joint manufacturing due to its green, eco-friendly, efficient, and reliable advantages. In this paper, the fatigue characteristics and fracture behaviors of Cu-Al dissimilar cable joints prepared by magnetic pulse crimping (MPC) and hydraulic crimping (HC) were explored and compared. The fatigue life prediction models for the two cable joints at different reliability levels were developed. The contact resistance change features, crack propagation laws and fatigue failure mechanisms of cable joints were revealed. Results showed that the failure modes of cable joints at different stress levels could be divided into Al harness fracture (S_M ≥ 45.7 MPa), Cu terminal fracture (S_M < 34.3 MPa), and mixed fracture of the two (S_M = 34.3 MPa). As the stress level decreased, the fatigue life of cable joints gradually increased, and the failure mode gradually transitioned from Al harness fracture to Cu terminal fracture. The contact resistance of MPC and HC cable joints presented opposite changes during the fatigue process. Fretting wear at the Al-Cu contact generated Al₂O₃ particles. The initial fatigue cracks mainly initiated at the surface damage of Al harness in the crimping area and at the intersection of the tube end and the plate end on the upper surface of Cu terminal. Because there were significant stress concentrations at these two locations. The fatigue fractures all had typical crack initiation zones, crack propagation zones and instantaneous fracture zones.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.