Evaluation of selected connectors for aluminum wire in residential structures

Systems of connecting aluminum wire for possible use in receptacle outlets and elsewhere in 15 and 20 ampere branch circuits in residences are discussed. The alternative systems are based on the principle of high deformation of the wire in the connection to achieve more permanent metal-to-metal fittings and/or wire splice devices of several designs. They involve either crimping the device around the wire or swaging the wire into the device with special tools. Based on tests, basic connection performance of several high-deformation connectors was established. The results indicate that certain designs of connectors operate with stability and without dangerously over-heating under accelerated laboratory tests.