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LT4516 – Ferrules Direct 4 AWG Compression Lug 5/16" Stud Size
Available now on the Airparts.aero Marketplace.
The LT4516 is a commercial-grade, high-conductivity electrical terminal compression lug manufactured by Ferrules Direct. It is engineered to establish a low-resistance, high-current interconnection for 4 AWG power distribution cables, battery banks, and ground straps in specialized aviation ground support equipment (GSE), power plants, and secondary electrical systems. Designed with a 5/16" (M8) stud clearance hole, this heavy-duty terminal ensures a secure mechanical and electrical bond when fastened to busbars, terminal blocks, or structural grounding points, mitigating the risks of voltage drop and localized thermal runaways.
Fabricated from seamless, high-purity electrolytic copper tubing, the LT4516 undergoes a precision manufacturing process that optimizes mechanical malleability and cold-work response. The terminal is finished with an electro-tin plating to prevent surface oxidation, a crucial feature for minimizing contact resistance over years of environmental exposure. Featuring a standard-length barrel with a color-coded gray identifier, this compression lug is engineered to accommodate standard crimp profiles, ensuring deep plastic deformation and gas-tight contact when compressed with certified tooling.
The LT4516 offers engineers, maintenance supervisors, and procurement specialists a field-proven solution for high-amperage applications up to 35 kV. Its seamless construction eliminates the risk of barrel splitting—a common failure mode in lower-tier stamped-and-rolled connectors under cyclic vibration. For airframe modifiers and repair facilities, implementing the LT4516 guarantees consistent electrical performance and structural longevity across high-power infrastructure installations.
Key Features
Seamless Electrolytic Copper Construction: Extruded from high-conductivity, seamless copper tubing to prevent structural failure or cracking along stress lines during crimping.
Electro-Tin Plating: Provides excellent galvanic corrosion resistance and oxidation protection, preserving electrical contact integrity in humid or marine environments.
Gray Color-Coded Barrel: Simplifies field installation by identifying the correct die index and crimp tool settings required for safe execution.
Chamfered Barrel Entry: Features an internal bevel at the barrel opening to guide stranded 4 AWG conductors smoothly into place without strand fold-back.
High Voltage Rating: Rated for applications up to 35 kV when appropriate insulation techniques and spacing margins are applied.
Technical Specifications
Part Number: LT4516
Component Type: One-Hole Compression Lug / Eyelet Terminal
Manufacturer: Ferrules Direct
Wire Gauge Size: 4 AWG (Stranded Copper)
Stud Clearance Size: 5/16" (M8)
Barrel Type: Tubular Standard Barrel
Color Code / Die Index: Gray
Material: High-Purity Electrolytic Copper
Finish: Electro-Tin Plated
Maximum Voltage Rating: 35,000 Volts (35 kV)
Maximum Ampacity: 85 Amps (Continuous load vary by insulation class)
Maximum Operating Temperature: 90°C
Overall Length (L): 2.80 in (71.1 mm)
Barrel Length (L1): 1.75 in (44.5 mm)
Tang Width (B): 0.90 in (22.9 mm)
Aircraft & Equipment Compatibility
Ground Support Equipment (GSE): Aircraft tugs, external GPU power carts, and high-amperage battery charging stations.
Secondary Electrical Distribution: Auxiliary power systems, non-flight-critical cabin modifications, and test bench power arrays.
Note: Refer to the equipment or aircraft Illustrated Parts Catalog (IPC), Engineering Wiring Diagrams, or STC documentation for installation effectivity verification.
Applications
Power Plant Distribution: Routing primary DC power feeds from battery boxes to secondary relay blocks.
System Grounding and Bonding: Establishing low-impedance earth grounding loops for electronic component racks and electrical structures.
Battery Cable Terminations: High-current links for heavy-duty storage arrays and emergency standby power networks.
Why Choose LT4516?
Utilizing a verified heavy-duty compression lug like the LT4516 eliminates the underlying vulnerabilities introduced by non-certified or inferior electrical terminals. Substandard lugs are prone to stress corrosion cracking and micro-arcing across loose crimp strands, which deteriorates structural integrity and risks thermal fires. Ferrules Direct ensures that the LT4516 maintains uniform material grain structure, providing the repeatable mechanical deformation necessary to clear safety standard requirements and reduce unscheduled maintenance cycles.
The LT4516 relies on the engineering principles of plastic deformation and cold welding to create a gas-tight electrical interface. When a high-tonnage crimping tool forces the gray die into the seamless barrel, the copper material yields beyond its elastic limit, flowing into the interstitial gaps between individual strands of the 4 AWG copper wire. This action eliminates microscopic air pockets, transforming the multi-strand bundle and barrel into a single, homogeneous conductor that minimizes contact resistance. The choice of pure electrolytic copper ensures maximum electrical conductivity and thermal dissipation, while the electro-tin plating provides a protective boundary against intergranular corrosion driven by exposure to sulfurous or humid atmospheres. The flat, work-hardened tang is engineered to maximize surface area contact against busbars; when torqued down via a 5/16" fastener, it optimizes the electrical path and prevents localized thermal expansion arising from high current densities.
Note: Installation of the LT4516 compression lug must be performed by qualified personnel using calibrated hex or indent crimp tooling specified for 4 AWG gray-coded terminals. Over-crimping or under-crimping will compromise the gas-tight seal, leading to catastrophic cable failure or resistive heating. Ensure proper strain relief and heat-shrink insulation sleeve applications (such as 3:1 adhesive-lined dual-wall polyolefin tubing) are installed to isolate the terminal barrel in accordance with standard electrical practices and AC 43.13-1B guidelines.
