Determining the Optimal Copper and Brass Connector Type for High Current Generators Used in Aircraft Lightning Test

Abstract

Aircraft in the aviation sector are required to meet stringent certification criteria established by civil aviation authorities. One crucial method to assess this
compliance is through high current testing, which evaluates how electrical and electronic systems respond under specific conditions. Modern aircraft are
equipped with a wide array of electronic systems, making electromagnetic compatibility (EMC) a critical consideration. High current pulse generators play a key
role in conducting EMC tests, ensuring that onboard systems can operate harmoniously with each other and resist interference from external electromagnetic
fields. High current tests of electrical and electronic systems evaluate system performance against sudden voltage changes, electrical noise, and other electrical problems that may be encountered under normal operating conditions. High current pulse generators ensure avionics equipment’s operational quality and
reliability by testing pulses for these systems. This study focuses on the performance of copper and brass fasteners commonly used in high current generators.
In the experiments, output signals were observed in contact made using copper and brass connectors with diameters of 10 mm, 5 mm, and 1 mm. The effect
of contact type on resistance is emphasized. The study reveals that the contact type provides low contact resistance in metal-metal contacts and contributes to
the contacts’ longevity by reducing the welding method’s oxidation effects. The results show the effects of material selection, contact shape, and type on the
contact resistance, increasing the energy transmission efficiency of a low-resistance circuit. It provides important information on how to extend the contact life.

Cite this article as: Demirdelen T, Kabasakal HA, Esenboğa B, Hizal M. Determining the optimal copper and brass connector type for high current
generators used in aircraft lightning test. Turk J Electr Power Energy Syst., Published online October 20, 2025. doi: 10.5152/tepes.2025.25028.