Cable connectors material
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  1. #1
    Join Date
    Feb 2011
    Location
    Vancouver, Canada
    Posts
    22

    Cable connectors material

    I need to make some connectors like these with my lathe. Looks like brass but would steel or aluminum be suitable? It's for a 200A stick welder. Infrequent use
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  2. #2
    Join Date
    May 2010
    Location
    ct.
    Posts
    1,207

    Re: Cable connectors material

    I’d be concerned with steel connectors rusting and
    not making a good connection.
    Plenty of electrical hardware is made from aluminum,
    despite it’s relatively high resistance.
    Maybe aluminum mating surfaces would get torn up
    because of material being softer?
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  3. #3
    Join Date
    Feb 2011
    Location
    Vancouver, Canada
    Posts
    22

    Re: Cable connectors material

    It's inside all the time so no rust issues. very occasional use so AL may be ok

  4. #4
    Join Date
    Jun 2017
    Location
    AJO, ARIZONA
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    2,324

    Re: Cable connectors material

    My old Midstates has taper plugs that were hand fashioned from steel, they seem to work fine.
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  5. #5
    Join Date
    Jan 2004
    Location
    city of Four Flags
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    1,865

    Re: Cable connectors material


  6. #6
    Join Date
    Jul 2019
    Location
    Arkansas
    Posts
    21

    Re: Cable connectors material

    Watch out for dissimilar metal corrosion. I haven't looked at electro-negativity values for copper, aluminum, iron lately but the farther apart they are the worse the corrosion problem. If I remember right steel and aluminum are the worst. I just found some drill rod that came in contact with aluminum rod on my shelf and the pitting was pretty bad. Keep in mind it doesn't take a lot of resistance at the connector to make a significant I^2R heating with high currents at the connector.

  7. #7
    Join Date
    May 2007
    Posts
    2,681

    Re: Cable connectors material

    my dialarc 250 had a similar setup as yours, that i didnt like. i replaced it w/ 1/2" bolts/studs, and put #2 female tweco quick connects on it

  8. #8
    Join Date
    Jan 2016
    Location
    northeast USA
    Posts
    4,969

    Re: Cable connectors material

    I would go with brass, aluminum may heat up and expand and stick in the socket... they are cheap enough to buy, if you cant get exact size can you buy over sized diameter and cut them down on your lathe?

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