This work proposes a novel deformable self-clinching fastener for producing hidden lap joints suitable for both structural and electric power distribution applications. The fastener, characterized by an axisymmetric concave shape, is employed to fabricate hybrid busbar joints between electrically conductive strips of different materials and thicknesses. The self-clinching process with the new deformable fastener involves machining dovetail holes in both conductors and applying a squeezing force to the fastener to create a form-closed mechanical joint. The work encompasses both experimental investigations and numerical modeling using finite element analysis and is carried out on unit cells made from aluminum and copper conductors, which are representative of the joining process. The investigation evaluates force requirements, conducts destructive testing, and performs thermo-electric characterization of the new joints to conclude on the suitability of the new deformable self-clinching fastener for electric power distribution applications. Results indicate that while copper fasteners necessitate greater squeezing forces, they offer superior mechanical and thermo-electrical performance compared to aluminum fasteners in hybrid busbar joints.

中文翻译：

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一种新型可变形自压紧固件

这项工作提出了一种新型可变形自铆紧固件，用于生产适用于结构和配电应用的隐藏搭接接头。该紧固件具有轴对称凹形形状，用于在不同材料和厚度的导电带之间制造混合母线接头。新型可变形紧固件的自铆接工艺包括在两个导体上加工燕尾孔并向紧固件施加挤压力以形成形状封闭的机械接头。这项工作包括实验研究和使用有限元分析的数值建模，并在由铝和铜导体制成的单元电池上进行，这些单元电池代表了连接过程。该研究评估了力的要求，进行破坏性测试，并对新接头进行热电特性分析，以得出新型可变形自压铆紧固件是否适合配电应用的结论。结果表明，虽然铜紧固件需要更大的挤压力，但与混合母线接头中的铝紧固件相比，它们提供了卓越的机械和热电性能。