Bimetallic Power Cable Joint Structure for Dissimilar Metal Welding
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Solution Overview
Problem
Existing power cables with bimetallic conductors face challenges in joining the bimetallic conductor with another conductor due to difficulties in welding different metallic materials.
Innovation Solution
A power cable design featuring a conductor with a first conductor section comprising a central element made of one metal and an outer structure made of another metal, transitioning into a second conductor section made of the second metal, facilitated by a weld metal at the interface, allowing for effective joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If dissimilar metals are joined directly, then structural integrity is maintained, but welding quality and joint reliability deteriorate
Solution Approach 1:
Different sections of the conductor have different metal compositions optimized for their specific functions: aluminum for cost efficiency and skin effect optimization, copper for welding compatibility and electrical conductivity at the joint interface. This local quality variation ensures both structural integrity and joint reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design facilitates the jointing of the bimetallic conductor with another conductor by ensuring a seamless transition from the bimetallic section to a single-metal section, enhancing the welding process and the overall integrity of the power cable.
Implementation Method 1
a weld metal located axially between the first conductor section and the second conductor section, wherein the second end of the second axial part and the first outer metal structure are welded to the second conductor section by means of the weld metal
Implementation Method 2
the second end of the first axial part is friction welded to the first end of the second axial part
Data Source
AI summary
A power cable includes a conductor having a first section, a second section, and a weld metal located axially between the sections. The first section includes a central element made of a first metal and an outer structure made of a second metal surrounding the central element. The second section includes the second metal. An axial end section of the first section extends to the weld metal and includes a central axially extending member surrounded by the outer structure, wherein the member includes a first axial part made of the first metal and a second axial part made of the second metal. The first axial part has a first end welded to the central element and a second end welded to a first end of the second axial part. A second end of the second axial part and the outer structure are welded to the second section via the weld metal.