Projection Welding Assemblies
Products Description
Projection welding assemblies are critical electrical connection components that precisely weld silver contacts to a copper substrate using resistance welding. This process utilizes pre-formed bumps on the substrate as current concentration areas, generating localized high temperatures upon application of voltage, achieving a metallurgical bond between silver and copper. This welding method offers significant advantages such as high connection strength, low resistance, and a small heat-affected zone, making it particularly suitable for applications requiring highly reliable electrical connections, such as relays, circuit breakers, and contactors.
Product Features and Functions
Low Contact Resistance
The natural high conductivity of Electric Resistance Welding Silver Contacts, combined with the precision welding process, achieves extremely low contact resistance, improving energy efficiency.
High-Strength Connection
The metal fusion layer formed by projection welding has high strength, is vibration-resistant and fatigue-resistant, and is suitable for dynamic working environments.
Excellent thermal stability
Joining Silver Contacts with Copper Bars through Brazing maintains stable performance at high temperatures, making them suitable for frequent switching or high-current applications.
Corrosion and oxidation resistance
The silver layer of the Resistance Butt Welding Silver Contact is not easily oxidized, and the copper substrate has good environmental adaptability, ensuring long-term, reliable contact.
Metal forming process
| Precision stamping of copper busbars | High-precision stamping equipment is used to form the copper material, ensuring that the dimensional tolerance of the copper busbars is controlled within ±0.05mm, providing a precise substrate for subsequent welding. |
| Silver contact pretreatment | The silver contacts undergo pretreatment processes such as cleaning and polishing to remove the surface oxide layer and impurities, improving the bonding strength of joining silver contacts with copper bars through brazing processes. |
| Projection welding positioning | A special projection welding die is used to position the copper busbars and silver contacts, utilizing resistance heating to achieve localized melting and bonding. The welding pressure and current are precisely controllable, preventing deformation of the Silver-Tipped Electrical Contacts substrate. |
| Post-processing and shaping | After welding, the assembly undergoes deburring, dimensional calibration, and other post-processing to ensure that the appearance and dimensions of the Welding Electrical Silver Contact Tip Assembly meet installation requirements, improving assembly efficiency. |
Structural Disassembly and Detailed Display
Structural Layer Analysis
From top to bottom, the layers are a silver contact layer, a weld transition layer, and a copper support layer. Metallographic examination of the weld interface ensures it is free of cracks and porosity.
Microscopic Display of the Welded Area
Electron microscopy reveals a uniform weld nugget formed between the silver and copper in the Electric Resistance Welding Silver Contact, achieving true metallurgical bonding.
Dimensional Accuracy Display
Measured data and tolerance range diagrams for key dimensions of the Resistance Butt Welding Silver Contact are provided, such as the diameter and height of the silver contact, and the weld area.
Surface Condition Description
The weld area of the Projection Welding Assemblies is smooth and flat, free of sputtering and oxide discoloration, with rounded edges and no sharp burrs.
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