Electronic – Safety of Aluminium for enclosure earthing

corrosionmaterialssafety

To earth an Aluminium enclosure, is it safe to use a welded Aluminium stud and then use a nut and washer to attach a hook-ended earthing wire to the stud?

Aluminium oxidises to develop a thin insulating layer of Aluminium Oxide. Could this increase the resistance of the earth path and render this solution unsafe?

Also, galvanic corrosion between steel and Aluminium seems to be an additional potential problem at the interface between Aluminium and Steel. Does this limits the types of materials usable for the nut, washer and hook?

Best Answer

After some more research, I have made some progress towards an answer. Here it is the key info of what we have, in case it can help others.

The surface of the Aluminium enclosure, or any other uncoated Aluminium part, is oxidised by atmospheric air, always ending up with a thin (a few nanometers) layer of Aluminium Oxide. This layer is an electrical insulator, but since it is extremely thin, it will be scratched off easily when trying to measure its resistance with a probe or when applying several volts.

Yet, it can be a problem for long-term good earthing.

This problem is obviously very important in aviation, where Aluminium is often used and electrical earthing is improtant.

The suppliers of earthing studs (for aviation and other industries) have come up with a solution. Aluminium studs are coated with a passivation layer (e.g. Titanium) that protects against oxidation but is highly conductive. This is the key bit of info.

Aluminium earthing studs (with a Titanium coating) are welded to Aluminium enclosures. Then nuts/washers/and hook-ended wires can be tightened to the stud making the connection to earth.

BTW, we have also learnt that only Aluminium welds to Aluminium. This is why I am mentioning only Ti-coated Aluminium studs when discussing ways to connect to earth an Aluminium enclosure.

PS: There is of course another possibility, to simply use a through hole, nut and bolt (and washer). No welding. But in this case the oxidation of the Aluminium enclosure (in particular the area below the nut) could lead to high resistance. It seems that welding would be the best solution.