Multi-Criteria Evaluation and Scenario-Driven Selection of Grounding Connectors Across Materials and Joining Processes

Grounding connectors critically influence the safety and long-term reliability of earthing systems through coupled electro-thermal, mechanical, and corrosion behaviors, yet no standardized quantitative framework exists for jointly evaluating these performance dimensions across diverse deployment scenarios. This study introduces a unified multi-criteria evaluation framework applied to six grounding connector configurations spanning four alloy families and three joining technologies. Electro-thermal response was characterized by coupled finite element simulations (0–100 A), mechanical reliability by quasi-static tensile testing (n = 10 per configuration), and corrosion durability by accelerated salt-spray exposure with image-based corroded area fraction quantification. Performance metrics were normalized and aggregated using equal-weight, Analytic Hierarchy Process, and Shannon entropy weighting schemes, with the Technique for Order of Preference by Similarity to Ideal Solution applied for multi-scenario ranking. One-way analysis of variance confirmed statistically significant effects of connector type on tensile performance (F(5, 54) = 3154.90, p < 0.001). The exothermic welded joint achieved the highest mean ultimate tensile load (61.5 ± 1.5 kN), while copper mechanical connectors exhibited the lowest steady-state temperature rise (~2 K above ambient at 100 A). Compression-crimped connectors ranked first under both equal and Analytic Hierarchy Process weighting (closeness coefficients 0.737 and 0.807, respectively), while stainless steel connectors ranked first under corrosion-critical deployment scenarios. Scenario-weighted analyses demonstrate that the optimal material–process combination shifts with environmental severity, current duty, and mechanical demand, providing a reproducible, evidence-based basis for context-dependent connector specification.