Originally Posted by dpinvidic
What about simple copper clad aluminum wire. Sounds like that would self destruct. Also, how do the "Copalloy" products work?
My understanding is you need some form of electrolyte to get galvanic action, and a proper connection "should" be air tight. What am I missing?
The only thing I know is that copper clad aluminum wire is used in limited applications and involves actual welding of the copper to the aluminum in the manufacturing process.
This type of interconnection is completely sealed to the elements and therefore the galvanic reaction does not occur.
At Amp we manuactured specialty copper terminals (Trademark Copalum) to terminate Aluminum conductors for the utility transformer manufacturers. This involved a normal copper wire barrel with a perforated sleeve and a very radical configuration "bar crimp" to force the aluminum to extrude through the perforated sleeve and generating a void-less crimp, i.e. completely sealed.
The trick is getting that interface sealed and electrolyte free.
As you point out, a proper connection would be void free, however in reality most connections are made with whatever tool the electrician had in his tool belt, especially in RV manufacturing facilities.
Don't know anything about the other product that you mentioned.