电动汽车高压线束铜铝连接的可靠性研究

Reliability Study of Cu-Al Connection for HV Harness in Electric Vehicle

当电动汽车使用铝导体作为高压线束时,需考虑铝导体与铜端子之间的可靠连接,保证充放电的安全性。针对铜铝连接可能存在的问题,设计了铜铝连接强度、电阻、载流试验;根据试验结果,提出可靠的铜铝连接方法。结果表明:搅拌摩擦焊是铜铝可靠连接的方式之一;未电镀铝排与任何一种状态的导体连接,盐雾前后温度差异接近100℃~200℃。这表明在非密闭环境中使用铜铝连接时,铜铝表面需进行电镀和防腐保护,使铜铝连接处不形成电化学腐蚀,从而获得可靠的电气连接和机械连接。

When aluminum conductor adopted as the HV harness conductor in electric vehicle,the connection reliability between the aluminum conductor and copper contacts should be taken into consideration to assure charge and discharge safty.To solve the possible problems in the copper-aluminum connection,the tests of its trength,resistance and current capacity are designed.With the test results,a reliable method for copper-aluminum connection is proposed.The conclusion is that friction stir welding is one of the reliable methods for the copper-aluminum connection.When bare aluminum row is connected with conductor in any state,the temperature difference before and after salt spray is close to 100℃-200℃,wich means that copper-aluminum joint surface,when used in an open environment with moist media,needs sealing and coating protections,avoiding electrochemistry corrosion in joints and obtaining reliable electric and mechanical connections.