Novel Electrical Joints Using Deformation Machining Technology—Part II: Experimental Verification

This is the second part of the paper related to the exploration of deformation machining technology (DMT), originally developed at Bauman Moscow State Technical University, as it may apply to making electrical joints and comparing their performance to bolted and welded electrical joints. The DMT process is used to generate tooth-like profiles on two opposing surfaces that make the electrical joints which are later joined by applying a mechanical load. Part I contained a more detailed explanation of the DMT process and the description of the results of computer modeling of DMT joints in copper and aluminum. This paper provides the experimental results of the mechanical and electrical performance of copper and aluminum DMT joints which were compared to bolted and welded electrical joints of identical geometries. Measurements of tensile strength and electrical resistance, after thermal cycling and short-circuit testing, show equivalent or better performance of copper DMT joints compared with copper bolted and welded joints. In addition, it is observed that copper DMT joints have superior performance when compared with aluminum DMT joints, this was attributed to lesser gap filling and the springback effect that occurs after the mechanical load for making the joint is removed. The computer modeling results reported in Part I of this paper support these observations.