Aluminum cable on a nickel-plated copper terminal


An aluminum cable with a cross section of 120mm2 needs to be welded to a nickel-plated copper terminal. To add a further challenging aspect, the weld needs to be as narrow as possible for construction reasons. The tensile strength and shearing load also have to meet specified values.


In this case, the task was solved with the torsional PowerWheel® technology on a system such as the Telso®Terminal TT7 with a maximum power output of 14.4kW. The system is equipped with a sound protection casing that is accessible from three sides. The welding process is controlled and monitored using the Telso®Flex control software with touchscreen.

Advantages of this configuration

PowerWheel® technology is able to distribute the welding force so that only 26mm needs to be welded instead of 30mm (as is the case in a linear process) while still protecting the aluminum cable. The nickel plating on the terminal increases corrosion protection on the one hand, while achieving better strength values on the other. Tensile strength of up to 5000N can be achieved.

Aluminum cable on a nickel-plated copper terminal

Illustrations may show optional equipment