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Using tinned copper wire, lugs, bus bars in marine environments

BillCaswell

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I found this today from the Blue Sea web site:

”Corroded connections are the main cause of high resistance connections that cause equipment to quit working or to work poorly. Frequently high resistance connections are the result of corrosion on the surface of unplated brass and copper conductors. Of the common plating materials used in electrical applications Nickel (Ni), Gold (Au), Tin (Sn) and Silver (Ag), tin is the best choice for marine electrical applications.


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Although tin does corrode (oxidize), the tin oxide layer is a thin brittle layer and the tin is very ductile. When two tin plated surfaces are mated under pressure the brittle surface layer of tin oxide will crack and displace allowing the lower pure tin layers to cold weld, forming An airtight bond that inhibits further oxidation in the connection.

Tin is, interestingly, not a particularly good conductor, but since the thickness of the plating is usually only about .0005", the distance the current travels is very short and therefore not high in resistance.”

I was confused because of this chart which shows the conductivity/resistance of tin compared to copper. I plan to use tinned copper wire, lugs and bus bars. But am curious about mixing nickel plated bus bars with tinned wire and lugs?
 

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Can you not just use some silicone paste in these applications to get a similar protective effect?
 
Can you not just use some silicone paste in these applications to get a similar protective effect?
I would not use silicone paste, but something like NOLOX can help a little. However, trying to seal the wire from the salt air will only slow it down for a while. No matter what you do, if the wires are not tined they WILL corrode in a salt marine environment. I have seen boat wires where the corrosion went a couple of feet up the wire under the insulation.
 
I would not use silicone paste, but something like NOLOX can help a little. However, trying to seal the wire from the salt air will only slow it down for a while. No matter what you do, if the wires are not tined they WILL corrode in a salt marine environment. I have seen boat wires where the corrosion went a couple of feet up the wire under the insulation.
I've seen the same from boat wiring from the 90's and early 2000's. Most of the new terminals that I see are tinned, and closed at the end. So you crimp and then use a shrink tube with a good adhesive. This helps a lot.
 
Can you not just use some silicone paste in these applications to get a similar protective effect?
Silicone paste has some usefulness in various applications. Not for what you described, however.
In a saltwater environment as the other poster mentioned, closed, tinned, crimped terminal ends with heat shrink are the first step. Second step is assembly of the terminals while clean and dry. Third step is to apply an expensive brand of dialectic grease liberally over all exposure of the terminal assembly- or what I’ve had successful results in combating electrical terminal problems because of salty, slushy roads in winter here is to use aerosol-can fluidfilm after proper torquing of the connectors.
QUESTION:
was confused because of this chart which shows the conductivity/resistance of tin compared to copper
Tin is, interestingly, not a particularly good conductor, but since the thickness of the plating is usually only about .0005", the distance the current travels is very short and therefore not high in resistance
 
Silicone paste has some usefulness in various applications. Not for what you described, however.
In a saltwater environment as the other poster mentioned, closed, tinned, crimped terminal ends with heat shrink are the first step. Second step is assembly of the terminals while clean and dry. Third step is to apply an expensive brand of dialectic grease liberally over all exposure of the terminal assembly- or what I’ve had successful results in combating electrical terminal problems because of salty, slushy roads in winter here is to use aerosol-can fluidfilm after proper torquing of the connectors.
What brands of dielectric come in aerosol? - I have never seen one.
 
What brands of dielectric come in aerosol? - I have never seen one.
Not aerosol but pressurized dispensing.

Fluidfilm is a spray can. It’s an oxygen blocker in essence, and being available in a spray can is why I said aerosol.
 

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