What is the EBW Manganese Copper Shunt for Relay?
The EBW Manganese Copper Shunt for Relay is a precision current‑sensing component constructed from 6J13 manganin resistance alloy and T2 copper. Vacuum electron beam welding bonds these two dissimilar metals, followed by progressive stamping to create relay‑specific shapes. The 6J13 manganin segment acts as the resistance element for current sampling, whereas T2 copper delivers high‑current conductive paths connecting the shunt to relay circuits. This material‑function separation prevents the drawbacks of using a single metal for both resistance measurement and heavy‑current conduction.
Target applications cover magnetic latching relays, smart meters, three‑phase energy meters and power‑metering current‑sampling circuits. Its workflow includes copper processing, electron beam welding, precision progressive stamping, resistance sorting, forming and surface passivation. Bending angles and hole diameters are held to ±0.02 mm, alongside full post‑forming resistance testing. Custom orders are available per client drawings or samples, covering terminal layouts, mounting holes, bending profiles and defined resistance values. Custom‑built units support current ratings from 10 A to 120 A, subject to finalized electrical and mechanical design.
Product Details and Features of Electron Beam Welding Manganin Shunt
Welding Details
For Electron Beam Welding Manganin Shunt, electron‑beam welding creates metallurgical bonding between manganin and copper. The fusion zone contains no porosity, cracks or delamination. Uniform resistivity on bonding surfaces reduces sampling deviation caused by local heating.
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Stamping Details
Electron Beam Welding Manganin Shunt is produced by single‑hit precision progressive‑die stamping. Bending angle and hole diameter tolerances are held at ±0.02 mm. Uniform‑size mounting holes and positioning bosses support automated assembly and avoid part jamming.
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Resistance Sorting Details
Each finished shunt goes through full‑piece resistance inspection with high‑precision digital micro‑ohmmeters. Units are sorted and packaged by actual resistance values to keep batch resistance dispersion within industry‑accepted levels.
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Forming Details
Manganin Shunt Resistor for Electrical Meters has no cracking or work‑hardening fracture at bending sections. Edges are deburred and passivated to prevent scratches to relay plastic housings and PCB traces during assembly.
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Key Selling Points of Electron Beam Welded Shunt
Electron Beam Welding Technology
EBW vacuum welding creates metallurgical bonding between 6J13 manganin and T2 copper. It avoids incomplete joints and resistivity shifts found in conventional brazing assemblies.
Own-Manufactured Full-Chain Factory
Manganese Copper Resistance Shunt operations include copper cutting, progressive‑die stamping, vacuum electron‑beam welding, resistance sorting, and surface passivation. All processes finished in‑house.
Dual-Material Complementary Performance Design
Electron Beam Welded Shunt adopts 6J13 manganin to handle the current‑sampling function; T2 copper carries high‑current load. This composite structure balances sampling precision and current‑carrying capacity.
Full-Scale ODM Customization
We develop Electron Beam Welding Shunt Resistors per customer drawings or physical samples for latching relay and three‑phase energy‑meter projects, covering the 10A‑120A current range.
Frequently Asked Questions about Electron Beam Welding Shunt Resistor Shunt
What is the difference between EBW welding and traditional welding methods?
Electron beam welding is performed in a vacuum environment, resulting in no oxidation, a minimal heat-affected zone, and a high weld depth-to-width ratio. It is particularly suitable for precision connections of dissimilar metals, such as Electron Beam Welding Shunts and Resistor Shunts. Compared to resistance welding, EBW joints have lower contact resistance and better long-term stability.
Can it be compatible with third-party magnetic latching relays?
Yes. Please provide the relay terminal drawing, and we can match the pin positions and mounting hole positions of the Manganese Latching Relay Shunt.
Does the component require any special surface finish to prevent oxidation?
While supplied as unplated bare copper by default, optional protective tin or nickel electroplating with controlled thicknesses of 3 to 5 micrometers can be applied upon request.
Which relays is this product suitable for?
This product is suitable for magnetic latching relays, latching relays, etc., and is particularly suitable for Three-Phase Magnetic Latching Relays in smart meters.
contact us
If you have any needs for sample testing or bulk purchase of EBW Manganese Copper Shunt for Relay, please send us your product drawings and parameter requirements at any time, and our engineering team will immediately cooperate to conduct technical coordination and quotation calculation.
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