Comparative Thermal Analysis of Sleeve Connection Methods for Aluminum and Copper Conductors

Aluminum conductors are used in overhead transmission lines, while copper is used in underground and submarine cables. This study analyzed thermal characteristics of compression, bolted, and welded sleeves for aluminum, and compression and bolted sleeves for copper. Conductive compound and moisture compound removal effects on sleeve heating were evaluated under varying conditions. Thermal cycling tests per ANSI C119.4 and C119.0 standards (60-90℃) measured temperature differences between sleeves and reference conductors. Statistical analysis using Weibull and normal distributions showed bolted connection had best performance. Conductive compound applied with two outer moisture layers removed showed the lowest temperature. Similar patterns were observed at 600 A for aluminum and 900 A for copper, confirming aluminum's lower conductivity affects heating. Results provide baseline data for evaluating 70 kV aluminum underground and submarine cable joints..