What are Projection Welding Assemblies?
For electrical engineers and global procurement managers from Tier 1 suppliers, dependable Projection Welding Assemblies directly determine the service life and operational safety of current‑carrying components. These precision parts are built for harsh working scenarios, including 800 V HVDC EV contactors, smart‑meter latching relays and industrial MCCBs. They form ultra‑low‑resistance conductive paths to cut thermal loss under continuous high‑load conditions.
We are an original manufacturer delivering custom Brazed Contact Assemblies according to official engineering drawings. High‑conductivity copper bases are matched with arc‑resistant AgSnO₂ or AgNi contact tips to achieve strong weld shear strength. Our automated lines adopt microprocessor‑managed resistance welding, real‑time displacement tracking and SPC process control, holding stable ±0.02 mm dimensional tolerance for high‑volume manufacturing. Certified to IATF 16949, RoHS and REACH standards, we supply prototype development, destructive testing and flexible batch shipments to support a steady global component‑supply chain.
Technical Specifications & Materials of Brazed Contact Assemblies
| Feature | Specification |
| Weld Shear Strength | >350 MPa |
| Surface Treatment | Silver, Nickel, or Tin plating (optional) |
| Dimensional Tolerance | ±0.02 mm |
| Standards | IATF 16949, ISO 9001, RoHS, REACH |
Manufacturing Process of Welded Assembly of Silver Electrical Contacts
Raw Material Selection
We screen high‑purity silver stock and metal base blanks, and complete chemical composition and material property inspection before incoming use. Raw‑material qualification directly forms the quality foundation of Resistance Brazing Electrical Contacts, eliminating material‑related defects at the source.
01
Precision Machining
CNC machine tools carry out turning, milling, and drilling for component blanks. Cutting speed, feed rate, and depth of cut are locked as fixed process parameters for each part number to stabilize dimensional precision and surface finish of finished Brazed Contact Assembly machined substrates.
02
Precise Projection Welding
Dedicated projection‑welding machines are deployed for joint forming between silver contact tips and metal substrates. Welding current, electrode pressure, and hold‑time parameters are configured separately according to each part drawing specification, to obtain stable bonding and consistent weld quality across production batches.
03
Post‑Processing and Testing
Welded Low Voltage Electrical Contacts go through surface cleaning and anti‑oxidation treatment. The inspection workflow covers visual appearance check, dimensional verification, weld shear strength test, and electrical conductivity measurement. Non‑conforming units are isolated before packing.
04
Application Engineering of Resistance Brazing Electrical Contacts
DC Contactors & EV Charging: Spot Welding Assemblies in DC contactors for 800V HVDC systems must manage both high inrush currents and DC arc interruption. AgSnO2 contacts offer the arc resistance required for DC switching, where the arc lacks a natural zero-crossing for extinction.
Power Relays & Contactor Control: In power relays (40-100A) and contactors, Brazed Contact Assemblies form the fixed contact or movable bridge contact structure. The weld joint must withstand mechanical impact from contact closure and bounce, typically surviving 1-2 million mechanical operations without fatigue failure.
Miniature Circuit Breakers & Thermal Protection: Circuit breaker applications demand contact materials with low welding tendency under short-circuit currents. The Resistance Brazing Electrical Contacts in MCBs must maintain contact force stability over decades of thermal cycling without relaxation at the weld joint.
Smart Meter Latching Relays: Latching relays for smart electricity meters utilize the assemblies where the carrier contacts both the moving armature and the fixed terminal. The assembly must exhibit low and stable contact resistance over the meter's 10-15 year service life, with resistance drift below 10% from initial values.
contact us
Partner with an expert in Projection Welding Assemblies to ensure your relay performance never falters. Our engineering team is ready to review your technical drawings and provide a feasibility study and competitive quotation. Send your specifications to our technical department today and secure a reliable, high‑precision supply chain for your electrical components.
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