Products Description
This Brass Welding Contact Assembly employs a clearly defined composite structural design:
Brass substrate: Serving as the structural framework and conductive carrier, providing excellent mechanical strength, thermal conductivity, and machinability.
Silver-based contact material: Located in the current contact and disconnection areas, responsible for low contact resistance and resistance to arc erosion.
Metallurgical welding interface: Achieving stable bonding through a specialized welding process, avoiding the risks of incomplete welds and delamination.
This structure is not a simple material stacking, but rather a systematic design centered around current paths, heat conduction paths, and mechanical stress paths, ensuring a balance between electrical and structural performance during long-term operation.
Product In-Depth Analysis: Performance Stems from a Balance of Materials and Design
Our assemblies are specifically designed for circuit breakers (MCB/MCCB), AC contactors, relays, and various high-performance switches. By precision welding silver alloy (AgNi, AgSnO2, AgCdO, etc.) contacts onto a high-conductivity brass substrate, a closed loop of excellent conductivity and wear resistance is achieved.
1. Core Material Advantages
Composite Silver Alloy Contacts: We offer silver alloys with different ratios to meet customers' electrical load requirements. For example, silver tin oxide (AgSnO2) has extremely strong resistance to welding and arc erosion, making it an ideal choice for environmentally friendly requirements and high-load environments.
High-Purity Brass Substrate: Using high-quality H62/H65 brass ensures excellent mechanical strength and thermal conductivity of the substrate, rapidly dissipating the instantaneous heat generated during switching operations.
1. Underlying Diffusion Barrier: A special transition layer is added between silver and copper to effectively prevent abnormal diffusion of metal atoms over long-term operation, ensuring the long-term stability of weld strength.
2. Design and Structural Features:
Streamlined Contact Surface Design: Spherical, planar, or specially textured Brass Parts surfaces are provided to minimize contact resistance for different switch closing trajectories.
Vibration-Resistant Reinforcement: The component is precision-formed in a single stamping process, combined with reinforcing ribs to ensure no physical deformation occurs under high-frequency operation.
Manufacturing Process: A Seamless Industrial Manufacturing Process
Precision Brass Machining
High-grade free-machining brass bars (such as C3604/C3605) or strips are selected and machined using high-speed longitudinal cutting lathes or multi-station cold heading machines to produce precision carriers with features such as threads, countersunk holes, and grooves.
Surface Cleaning and Pre-treatment
Environmentally friendly chemical cleaning processes are used to thoroughly remove cutting oil, oxide layers, and dust from the brass surface. For difficult-to-solder brass materials, we also perform special surface micro-etching treatment to increase surface activity and improve welding bonding strength.
High-Precision Positioning Welding
High-precision fixtures are used to position the silver contacts at predetermined locations on the brass carrier, with an error controlled within 0.02mm. The welding program is initiated, and current flows instantly, fusing the and the metal into one piece. Simultaneously, welding current and voltage fluctuations are monitored in real time, and defective products are rejected.
Post-processing and functional testing
After welding, the Welded Brass Terminal Assemblies undergo deburring and polishing and are subjected to torque testing, pull-out force testing, and high-voltage testing to ensure that each component meets the electrical and mechanical performance requirements.
Application Advantages: Preferred Solution for Medium and Low Voltage Electrical Appliances
Contactor and Relay Auxiliary Contacts
This is its most typical application. Brass Relay Pin Welding does not need to interrupt large currents in the main circuit; heat dissipation requirements are not high, but strict requirements are placed on mechanical life and cost control. Brass assemblies perfectly meet this need.
Molded Case Circuit Breaker (MCCB) Alarm and Tripping Contacts
Used in microswitches and trip indicators of circuit breakers. The brass carrier ensures the sensitivity of the mechanism's operation, while the Welded Brass Socket Contacts ensure the reliability of the alarm signal.
Universal Changeover Switches and Pushbuttons
In industrial control panel switches, Custom Brass Welded Components serve as contact bridges, providing a robust current path, and their nickel-plated appearance gives them a high-end and professional look.
contact us
If you are looking for contact solutions with greater engineering assurance in terms of long-term reliability and manufacturing consistency for your circuit breaker or contactor projects, our technical team can provide you with professional support based on actual application conditions.
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