I need to modify a small battery jump pack cable, adding a Tee / Wye where shown below. I'm free to cut the cable here, too - i just haven't in case the right solution would benefit from it intact. I have more of this cable, so the Tee can be to more pure aluminum (or also copper / CCA if applicable)
Leads are 8 gauge stranded aluminum with very finely stranded wire. The joint will see short duration high current loads (100A+), similar to the initial design of the device (which was jumping ICE cars)
The goal is to have a good, durable electrical connection. The device will be kept out of the elements, but exposed to normal humidity and such - hoping to have it last / not destroy itself with galvanic corrosion, etc.
I'm skeptical of soldering this as there doesn't seem to be an accessible, agreed/common flux+solder pair that works; but I have a controlled iron, a hot air reflow gun, and oxy-fuel, if that's how it should be done. The several other questions on soldering aluminum successfully don't seem to offer a concrete recommendation. Note, however:
- that the OEM has soldered the wire to copper contacts.
- Johnson implies that their Alumiweld Tin/Zinc solder is appropriate for electrical use; and also sell a eutectic Sn/9Zn that would help me not outright melt these hair-thin wires. I cannot find an online source, though.
I have also looked into crimping, but don't find much for
ferrules intended for aluminum wire - which may be as-expected due to the creep Aluminum will exhibit.