{"id":119843,"date":"2026-08-15T23:37:49","date_gmt":"2026-08-15T20:37:49","guid":{"rendered":"https:\/\/gahzly.com\/?post_type=product&#038;p=119843"},"modified":"2026-08-17T03:28:30","modified_gmt":"2026-08-17T00:28:30","slug":"%d9%83%d9%88%d8%b3-%d9%81%d8%b1%d9%8a%d9%83%d8%b4%d9%86-%d8%a7%d9%84%d8%b3%d9%88%d9%8a%d8%af%d9%8a-friction-welded-bimetallic-lugs","status":"publish","type":"product","link":"https:\/\/gahzly.com\/en\/product\/%d9%83%d9%88%d8%b3-%d9%81%d8%b1%d9%8a%d9%83%d8%b4%d9%86-%d8%a7%d9%84%d8%b3%d9%88%d9%8a%d8%af%d9%8a-friction-welded-bimetallic-lugs\/","title":{"rendered":"\u0643\u0648\u0633 \u0641\u0631\u064a\u0643\u0634\u0646 \u0627\u0644\u0633\u0648\u064a\u062f\u064a (Friction Welded Bimetallic Lugs)"},"content":{"rendered":"<h1>Elsewedy Friction-Welded Lugs \u2014 Friction-Welding Technology for Joining Dissimilar Metals<\/h1>\n<h2>Introduction: Beyond Mechanical Connection \u2014 The Friction-Welding Revolution<\/h2>\n<p>In major electrical projects, connecting aluminum cables to copper busbars is no longer just a mechanical assembly task; it is a physical challenge that requires a molecular-level solution. Aluminum and copper can react aggressively when placed in direct contact in the presence of current and moisture, causing galvanic corrosion that can quickly destroy the connection.<\/p>\n<p>This is where<strong>Elsewedy friction-welded lugs<\/strong>provide the definitive solution through<strong>friction welding<\/strong>This technology does not rely on intermediate filler metals that may weaken over time. Instead, it joins the two original metals directly into a single inseparable component, enabling current to flow with extremely low resistance.<\/p>\n<hr>\n<h2>Chapter One: The Science Behind Friction-Welding Technology<\/h2>\n<h3>1. How does friction welding work?<\/h3>\n<p>The friction-welding process in Elsewedy factories is entirely mechanical:<\/p>\n<ul>\n<li>The copper section, or palm, is held stationary while the aluminum section, or barrel, is rotated at very high speed under strong axial pressure.<\/li>\n<li>The kinetic energy generated by friction turns into intense heat at the interface, bringing both metals into a plastic state without reaching full melting temperature.<\/li>\n<li>At a precise moment, rotation stops and a final upsetting force is applied, bonding the copper and aluminum molecules while forcing oxides and impurities outward.<\/li>\n<\/ul>\n<h3>2. Advantages of the Molecular Bond<\/h3>\n<p>The result is a transition zone free from structural defects and air voids. This type of weld provides:<\/p>\n<ul>\n<li><strong>Excellent mechanical strength:<\/strong>The welded area is often stronger than the aluminum metal itself.<\/li>\n<li><strong>Ideal electrical conductivity:<\/strong>There are no microscopic gaps to impede electron flow, which reduces heat losses.<\/li>\n<\/ul>\n<hr>\n<h2>Chapter Two: Technical Anatomy and Material Specifications<\/h2>\n<p>Elsewedy follows strict standards when selecting materials for friction-welded lugs:<\/p>\n<h3>1. Aluminum Alloy \u2014 Aluminum Barrel<\/h3>\n<p>The barrel is manufactured from pure aluminum at a minimum purity of<strong>99.5%<\/strong>at least.<\/p>\n<ul>\n<li><strong>Blocked barrel:<\/strong>The barrel is designed to be completely sealed at the copper end, preventing capillary action from drawing moisture or oils from inside the cable toward the connection area.<\/li>\n<\/ul>\n<h3>2. Pure Red Copper \u2014 Copper Palm<\/h3>\n<p>The palm is manufactured from pure red copper at a purity of<strong>99.9%<\/strong>.<\/p>\n<ul>\n<li><strong>Optional plating:<\/strong>For certain special specifications, the complete lug may be tin-plated to improve protection in harsh chemical environments, although Elsewedy copper and aluminum already provide high natural durability.<\/li>\n<\/ul>\n<h3>3. Internal Joint Compound<\/h3>\n<p>The aluminum barrel is prefilled with a special technical compound.<\/p>\n<ul>\n<li><strong>Function:<\/strong>This compound contains metallic particles that help abrade the aluminum oxide layer during crimping, creating metal-to-metal contact from the moment of installation.<\/li>\n<\/ul>\n<hr>\n<h2>Chapter Three: Applications of Elsewedy Friction-Welded Lugs in Strategic Projects<\/h2>\n<p>These lugs are considered the gold standard for the following applications:<\/p>\n<ol start=\"1\">\n<li><strong>Transformer stations and medium-voltage systems:<\/strong>For connecting outgoing aluminum cables from transformers to copper busbars inside main LV panels.<\/li>\n<li><strong>Solar farms:<\/strong>Where long aluminum cable runs require highly efficient connection points to copper inverter terminals.<\/li>\n<li><strong>Energy-intensive factories:<\/strong>Such as steel and aluminum plants, where vibration and high loads can loosen conventional connections while friction-welded lugs remain secure.<\/li>\n<li><strong>International power-interconnection projects:<\/strong>Where technical specifications require extremely long connection life with minimal maintenance.<\/li>\n<\/ol>\n<hr>\n<h2>Chapter Four: Technical Guide to Installation and Hydraulic Crimping<\/h2>\n<p>To obtain the full benefit of friction-welding technology, follow the correct installation protocol:<\/p>\n<ol start=\"1\">\n<li><strong>Conductor preparation:<\/strong>Carefully strip the aluminum cable and clean the strands with a wire brush dedicated to aluminum.<\/li>\n<li><strong>Insertion:<\/strong>Insert the cable fully into the barrel; a small amount of pre-applied compound emerging is a sign that the internal gaps have been filled.<\/li>\n<li><strong>Die selection:<\/strong>Use a hexagonal die that exactly matches the size stamped on the lug.<\/li>\n<li><strong>Crimping sequence:<\/strong>Crimp from the copper side, near the weld area, toward the cable. This sequence expels air and helps achieve a secure mechanical grip.<\/li>\n<li><strong>Heat-shrink insulation:<\/strong>Use adhesive-lined heat shrink to cover the lug barrel and part of the cable insulation to help prevent oxygen ingress.<\/li>\n<\/ol>\n","protected":false},"excerpt":{"rendered":"<p>\u062a\u064f\u0645\u062b\u0644 <b><strong>\u0623\u0643\u0648\u0627\u0633 \u0641\u0631\u064a\u0643\u0634\u0646 \u0627\u0644\u0633\u0648\u064a\u062f\u064a (Friction Welded Lugs)<\/strong><\/b><\/p>\n<p>\u00a0\u0627\u0644\u0630\u0631\u0648\u0629 \u0627\u0644\u062a\u0642\u0646\u064a\u0629 \u0641\u064a \u062a\u0635\u0646\u064a\u0639 \u0645\u0644\u062d\u0642\u0627\u062a \u0627\u0644\u0643\u0627\u0628\u0644\u0627\u062a\u060c \u062d\u064a\u062b \u062a\u0639\u062a\u0645\u062f \u0639\u0644\u0649 \u0639\u0645\u0644\u064a\u0629 &#8220;\u0627\u0644\u0644\u062d\u0627\u0645 \u0627\u0644\u0627\u062d\u062a\u0643\u0627\u0643\u064a&#8221; \u0644\u062f\u0645\u062c \u0645\u0639\u062f\u0646\u064a \u0627\u0644\u0623\u0644\u0648\u0645\u0646\u064a\u0648\u0645 \u0648\u0627\u0644\u0646\u062d\u0627\u0633 \u0641\u064a \u0642\u0637\u0639\u0629 \u0648\u0627\u062d\u062f\u0629 \u0644\u0627 \u062a\u0642\u0628\u0644 \u0627\u0644\u0627\u0646\u0641\u0635\u0627\u0644. \u064a\u0648\u0627\u062c\u0647 \u0642\u0637\u0627\u0639 \u0627\u0644\u0645\u0642\u0627\u0648\u0644\u0627\u062a \u0648\u0627\u0644\u0643\u0647\u0631\u0628\u0627\u0621 \u062a\u062d\u062f\u064a\u0627\u064b \u062f\u0627\u0626\u0645\u0627\u064b \u0639\u0646\u062f \u0645\u062d\u0627\u0648\u0644\u0629 \u0631\u0628\u0637 \u0627\u0644\u0645\u0648\u0635\u0644\u0627\u062a \u0627\u0644\u0645\u062e\u062a\u0644\u0641\u0629 (\u0643\u0627\u0628\u0644 \u0623\u0644\u0648\u0645\u0646\u064a\u0648\u0645 \u0628\u0628\u0627\u0631\u0629 \u0646\u062d\u0627\u0633)\u060c \u062d\u064a\u062b \u064a\u0624\u062f\u064a \u0627\u0644\u0627\u062a\u0635\u0627\u0644 \u0627\u0644\u0645\u064a\u0643\u0627\u0646\u064a\u0643\u064a \u0627\u0644\u062a\u0642\u0644\u064a\u062f\u064a \u0625\u0644\u0649 \u062a\u0622\u0643\u0644 \u0643\u064a\u0645\u064a\u0627\u0626\u064a \u0633\u0631\u064a\u0639 (\u062a\u0622\u0643\u0644 \u062c\u0644\u0641\u0627\u0646\u064a) \u064a\u0631\u0641\u0639 \u062f\u0631\u062c\u0629 \u062d\u0631\u0627\u0631\u0629 \u0627\u0644\u0648\u0635\u0644\u0629 \u0648\u064a\u0633\u0628\u0628 \u0643\u0648\u0627\u0631\u062b \u0643\u0647\u0631\u0628\u0627\u0626\u064a\u0629. \u0623\u0643\u0648\u0627\u0633 \u0627\u0644\u0641\u0631\u064a\u0643\u0634\u0646 \u0645\u0646 \u0627\u0644\u0633\u0648\u064a\u062f\u064a \u062a\u062d\u0644 \u0647\u0630\u0647 \u0627\u0644\u0645\u0639\u0636\u0644\u0629 \u062c\u0630\u0631\u064a\u0627\u064b\u061b \u062d\u064a\u062b \u064a\u062a\u0645 \u0635\u0647\u0631 \u0633\u0627\u0642 \u0627\u0644\u0623\u0644\u0648\u0645\u0646\u064a\u0648\u0645 \u0645\u0639 \u0642\u0631\u0635 \u0627\u0644\u0646\u062d\u0627\u0633 \u062a\u062d\u062a \u0636\u063a\u0637 \u0645\u064a\u0643\u0627\u0646\u064a\u0643\u064a \u0648\u062f\u0648\u0631\u0627\u0646 \u0647\u0627\u0626\u0644\u064a\u0646\u060c \u0645\u0645\u0627 \u064a\u062e\u0644\u0642 \u0631\u0627\u0628\u0637\u0629 \u062c\u0632\u064a\u0626\u064a\u0629 \u0642\u0648\u064a\u0629 \u062c\u062f\u0627\u064b \u062a\u0636\u0645\u0646 \u0627\u0646\u062a\u0642\u0627\u0644 \u0627\u0644\u0625\u0644\u0643\u062a\u0631\u0648\u0646\u0627\u062a \u0628\u0633\u0644\u0627\u0633\u0629 \u062a\u0627\u0645\u0629 \u0648\u0643\u0623\u0646\u0647\u0627 \u0641\u064a \u0645\u0639\u062f\u0646 \u0648\u0627\u062d\u062f \u0645\u062a\u0635\u0644.<\/p>\n<p>\u064a\u062a\u0645 \u062a\u0635\u0646\u064a\u0639 \u0647\u0630\u0647 \u0627\u0644\u0623\u0643\u0648\u0627\u0633 \u0645\u0646 \u0623\u0644\u0648\u0645\u0646\u064a\u0648\u0645 \u0625\u0644\u0643\u062a\u0631\u0648\u0644\u064a\u062a\u064a \u0646\u0642\u064a \u0628\u0646\u0633\u0628\u0629 \u062a\u0632\u064a\u062f \u0639\u0646 <b><strong>99.5%<\/strong><\/b> \u0648\u0646\u062d\u0627\u0633 \u0623\u062d\u0645\u0631 \u0646\u0642\u064a \u0628\u0646\u0633\u0628\u0629 <b><strong>99.9%<\/strong><\/b>\u060c \u0648\u0647\u064a \u0645\u0632\u0648\u062f\u0629 \u0628\u0633\u0627\u0642 \u0623\u0637\u0648\u0644 \u0644\u0636\u0645\u0627\u0646 \u0645\u0633\u0627\u062d\u0629 \u0643\u0628\u0633 \u0643\u0627\u0641\u064a\u0629\u060c \u0648\u0645\u062d\u0642\u0648\u0646\u0629 \u0628\u0645\u0631\u0643\u0628 \u0643\u064a\u0645\u064a\u0627\u0626\u064a (Joint Compound) \u064a\u0645\u0646\u0639 \u0627\u0644\u0623\u0643\u0633\u062f\u0629 \u0641\u0648\u0631 \u062a\u0631\u0643\u064a\u0628 \u0627\u0644\u0643\u0627\u0628\u0644. \u0625\u0646 \u0645\u064a\u0632\u0629 &#8220;\u0627\u0644\u0641\u0631\u064a\u0643\u0634\u0646&#8221; 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