What is a solution to prevent oxidation in aluminum busbars?

The most effective solution to prevent oxidation in aluminum busbars is tin plating at bar joints. Aluminum readily forms a thin layer of aluminum oxide when exposed to air, which can inhibit electrical conductivity. By tin plating the joints, the surface is protected from the environmental conditions that lead to oxidation, and the tin provides a barrier that retains electrical conductivity over time.

Tin has a strong affinity for aluminum, forming an intermetallic compound that helps to maintain a good connection at the joint while also protecting the aluminum underneath from further oxidation. This method is particularly beneficial in electrical applications where maintaining conductivity is critical for performance and reliability.

Other methods mentioned, while they may have some benefits in specific contexts, do not specifically address the direct issue of oxidation in the immediate way that tin plating does. For example, coating with copper strips could introduce galvanic corrosion issues, using high-strength aluminum alloys does not inherently prevent oxidation, and applying a protective layer of plastic may not be suitable for high-current applications where heat generation can occur. Thus, tin plating at bar joints stands out as the best solution for mitigating oxidation in aluminum busbars.