Trimetal Composite Rivet Terminals
Products Description
The Trimetal Composite Rivet Terminals are essentially an engineering application of Functionally Graded Material (FGM) in microscale electrical components. Its structural features are characterized by a longitudinally symmetrical three-layer heterogeneous metal combination: the top and bottom ends are functional silver alloys such as AgNi, AgCdO, or AgSnO₂, with a T2 copper (C11000) matrix in the middle. This configuration breaks through the design logic of traditional single-material contacts-the silver alloy layer undertakes the core functions of arc erosion and contact resistance control, while the copper core provides structural support and a longitudinal conductive path.
The core feature of the product lies in its bidirectional functional equivalence. Unlike single-headed rivets, which are only suitable for unidirectional conduction scenarios with stationary contacts, the symmetrical silver layer distribution of the three-composite structure makes it naturally suitable for transfer contact applications in industrial relays-when the armature drives the contact bridge to swing left and right, regardless of whether it moves towards the normally open or normally closed side, the silver alloy working surface provides consistent contact resistance characteristics and anti-welding capability. This feature makes it the standard configuration for the moving contact in a double-throw relay (DPDT/4PDT).
Technical Barriers: Why is the Manufacturing of Tri-Metal Composite Rivets Extremely Difficult?
Precise Control of the Ultra-Thin Silver Layer
During high-speed cold forging, the thickness of the silver layer at the head and foot must be precisely controlled at the micrometer level with minimal deviation. This places extremely stringent requirements on mold precision and equipment stability.
Atomic-Level Bonding at the Tri-Metal Interface
Unlike simple welding, we employ solid-state composite technology, allowing atomic diffusion and penetration between silver and copper at the interface. This ensures that the silver layer will not peel or delaminate under millions of high-frequency impacts.orem ipsum dolor sit amet consectetur adipisicing elit.
Coaxiality and Geometric Tolerances
The three layers of materials differ in their deformation resistance. Ensuring the overall geometric symmetry of the rivet requires extremely deep technological expertise.
Detailed Specifications: Microscopic Quality Determining Reliability
Silver Layer Thickness Uniformity
Verified by metallographic sections and scanning electron microscopy (SEM), silver layer thickness fluctuations are controlled within ±10%, ensuring consistent electrical performance across batches.
01
Interface Morphology
The bonding zone formed by diffusion welding exhibits a gradual compositional transition with no obvious mechanical boundary line. The interface shear strength is≥80 MPa, far exceeding the mechanical stress level generated by riveting processes.
02
Surface Roughness Control
The working surface of the contact point has Ra≤0.4μm, reducing current concentration and material transfer at micro-bumps and extending contact life.
03
Internal Defect Control
Ultrasonic testing ensures that the composite blank is free of metallurgical defects, such as porosity and inclusions, thereby avoiding the risk of partial discharge in high-voltage applications.
04
Coating Integrity
Optional nickel underlayer (1-3μm) and tin toplayer (3-5μm) show no corrosion after 48 hours of neutral salt spray testing (NSS), meeting long-term storage requirements in humid environments.
05
Application Advantages: Focused Industrial Control Relays
Industrial Control Relays: Serving as mechanical companions to PLC interface relays, intermediate relays, and solid-state relays (SSRs), these relays meet the frequent switching requirements of 24VDC/230VAC control circuits (electrical life ≥ 100,000 cycles).
Power Relays and Contactors: Used in electromagnetic contactors for motor control, heating equipment, and lighting systems, these relays carry 10A-100A load currents. The high conductivity of the copper core reduces contact voltage drop and temperature rise.
Automotive Electronic Relays: Used in engine control units (ECUs) and body control modules (BCMs), these relays adapt to the vibration environment and wide temperature range requirements (-40℃~125℃) of 12V/48V automotive electrical systems.
New Energy and Energy Storage Systems: DC relays in photovoltaic inverters and power storage converters (PCSs) utilize the anti-welding properties of silver alloys to safely interrupt DC arcs.
Security and Instrumentation: Signal relays in alarm systems and testing equipment rely on the low contact resistance of the silver layer to ensure accurate transmission of millivolt-level signals.
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For industrial relay manufacturers, choosing the right contact structure not only affects product performance but also overall manufacturing costs and long-term reliability. Tri Metal Contacts, through optimized material structure, effectively reduce the amount of precious metals used while ensuring electrical contact performance, representing a significant technological direction in the current industrial control contact field.
If your project requires a balance between contact performance, reliability, and optimized material costs, our engineering team can provide professional contact solutions tailored to your relay structure and application needs.
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