The paper describes the mechanical and electrical contact properties of a typical fired wedge-connector. The measured forces and displacements in the connector components are compared with the predictions of a Finite Element Analysis (FEA) of a wedge-connector interfaced with solid aluminium conductors. The distribution of mechanical stresses resulting from typical applied mechanical loads are evaluated using a nonlinear FEA code. The nonlinear input data for the FEA calculations were obtained from mechanical testing of metal specimens obtained from connectors used in the investigation. Measurements of contact resistance of the electrical interfaces are also reported. The wipe-off of surface oxide films from the electrical interfaces during connector installation is described.
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