Power lines often use copper and aluminum conductors, but connecting them directly can lead to a problem known as electrolytic corrosion. This occurs because copper and aluminum have different electrochemical potentials—approximately 1.7 volts difference between them. When moisture or water vapor is present, this potential difference can trigger an electrochemical reaction, causing the contact surface to corrode and oxidize over time. As a result, the connection becomes less effective, increasing resistance and potentially leading to overheating, which can be a fire hazard.

To prevent this issue, it's essential to implement proper anti-corrosion measures when joining copper and aluminum wires. One common solution is to use copper-to-aluminum transition clips or connectors, which are specifically designed to reduce the risk of corrosion. These devices create a stable and safe connection by acting as a barrier between the two metals.

Another effective method is to tin the copper wire before making the connection. By coating the end of the copper conductor with a thin layer of tin, you create a protective barrier that prevents direct contact between copper and aluminum. Although tin has lower conductivity than copper, it forms a thin oxide layer when exposed to air. This oxide layer acts as a protective film, preventing further oxidation of the underlying copper. Additionally, the tin oxide has good electrical conductivity and minimizes the risk of contact corrosion when connected to aluminum. This approach helps maintain a reliable connection and reduces the likelihood of overheating or electrical failure.

In summary, direct connections between copper and aluminum wires should be avoided due to the risk of electrolytic corrosion. Instead, using transition fittings or tinning techniques ensures safer and more durable electrical connections, especially in environments where moisture may be present.

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