Cold Forming Process Contacts
Products Description
Cold Forming Process Contacts (hereinafter referred to as "composite contacts") are metal connectors formed by room-temperature plastic deformation (cold heading/cold extrusion). They are composed of a silver alloy functional layer and a copper substrate, and can be customized as moving contacts (which switch on and off with the movement of the mechanism) or stationary contacts (fixed-end contacts). Their core innovations lie in:
Material Synergy: Silver alloys (such as AgCu28, AgSnO₂) provide high conductivity (≥80% IACS) and resistance to arc erosion, while copper (T2 grade) serves as the substrate to ensure structural strength (tensile strength ≥200MPa) and heat dissipation efficiency (thermal conductivity 398W/m·K);
Process Advantages: The cold-forming process refines the material grain (grain size reaches 8-10 grades), increasing the strength of contacts by 30% compared to hot-formed contacts, while achieving "near-net-shape forming" (material utilization >95%), reducing subsequent machining.
Product Properties and Core Features
Cold-Formed Integrated Composite Structure
A high-strength mechanical composite of silver alloy and copper is achieved through multiple cold-forming processes, avoiding material performance degradation caused by high-temperature welding.
Clear Division of Functional and Conductive Layers
The silver alloy handles electrical contact and arc resistance, while the copper substrate provides current conduction and structural support, achieving optimal performance allocation.
Accommodation for Moving/Static Contact Designs
The structure can be customized based on Electrical Contact Point movement, stress state, and assembly method.
High Consistency in Mass Manufacturing
Cold forming technology is naturally suited for large-scale production, resulting in minimal fluctuations in Silver Alloy Electrical Contact Rivets size, shape, and performance.
Detailed Display: The Devil Hides in the Micrometers
Silver Layer Bond Surface Inspection
Under a metallographic microscope, we can see a wavy, mechanically interlocking structure at the silver-copper bonding interface, without any cracks or pores. This is a unique microscopic feature of the cold forming process, representing an unbreakable bond.
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Surface Finish
The cold-formed surface, without subsequent cutting, retains the smoothness of the mold, with an Ra value below 0.8. A smooth surface is not only aesthetically pleasing but also less prone to dust and oxide accumulation, contributing to Electrical Contact Silver Point stability.
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Chamfering and Deburring
All sharp edges undergo precise deburring or are directly rounded to prevent scratching the wire insulation or operators during installation for Silver Electrical Contact.
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Hardness Consistency
Due to work hardening, the hardness of the Cold Headed Electrical Contacts is uniformly distributed along the axial direction. The tail section used for riveting has moderate hardness, allowing for secure riveting through plastic deformation without being too soft to be cut off.
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Application Advantages: Empowering Electrical Equipment Upgrades
1. Industrial Control and Automation: Used in high-performance contactors and relays, providing millions of reliable operations to ensure uninterrupted production line operation. Stable low contact resistance reduces heat buildup, allowing equipment to operate in higher ambient temperatures or more compact enclosures.
2. New Energy Sector: In DC contactors and circuit breakers used in photovoltaic inverters, energy storage systems, and electric vehicle charging stations, the arc erosion resistance and low energy consumption characteristics of this product are crucial in the face of higher voltage, larger current, and more frequent switching operations.
3. Smart Home and Building Automation: Provides quiet, reliable, and long-life Oxidized Electrical Contacts for miniature circuit breakers and smart switches, meeting the high demands of modern life for electrical safety and durability.
4. Power Transmission and Protection: Used in critical Cold Forming Metal of medium and low voltage circuit breakers, its strong short-circuit current carrying capacity, weld resistance, and long electrical life are the fundamental guarantee of power grid reliability.
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