Fatigue Performance of CCAA Conductors

1. Introduction

1.1 Fatigue Importance

1.2 CCAA Fatigue Advantage

2. Fatigue Fundamentals

2.1 Fatigue Mechanism

1. Crack initiation at surface defect
2. Crack propagation under cyclic stress
3. Final fracture

2.2 Key Parameters

2.3 S-N Curve

3. CCAA Fatigue Characteristics

3.1 S-N Data

CCAA-5052 (70% Cu cladding):

3.2 Comparison with Other Conductors

At 100 MPa stress amplitude:

3.3 Effect of Temperature

3.4 Effect of Mean Stress

4. Testing Methods

4.1 Standard Tests

4.2 Test Setup

4.3 Data Analysis

• S-N curve fitting
• Statistical analysis
• Endurance limit determination

5. Design Approaches

5.1 Safe-Life Design

Design for infinite life at operating stress:

5.2 Finite-Life Design

For known cycle requirements:

5.3 Example Calculation

Given:

• Required life: 10⁷ cycles
• Application: Automotive engine bay
• Temperature: 100°C

For CCAA-5052:

• Endurance limit at RT: 85 MPa
• At 100°C: 85 × 0.7 = 60 MPa
• With SF = 2: Allowable = 30 MPa

5.4 Design Recommendations

6. Conclusion

6.1 Summary

6.2 Design Implications

• CCAA significantly improves fatigue life over CCA
• Proper grade selection critical for fatigue applications
• Temperature effects must be considered

7. References

1. ASTM E466. (2021). Fatigue Testing.
2. Suresh, S. (1998). Fatigue of Materials.