What is the Shield Cover for New Energy HVDC?
High-voltage direct current (HVDC) contactors operating in 800V EV power distribution units require ultra-low magnetic interference to protect sensitive electronic drive circuits from arc-induced electromagnetic field noise. Designed for high-frequency switching and rapid isolation, this Shield Cover for New Energy HVDC components utilizes high-purity DT4C soft magnetic electrical iron to isolate magnetic flux loops while guaranteeing rapid de-energization without magnetic sticking. Factory-direct OEM production provides strict dimensional accuracy and custom plating finishes engineered for severe automotive and energy storage environments.
Technical Specifications & Materials of Pure Iron shell for DC Relay
| Parameter / Technical Dimension | Specification / Metric Value |
|---|---|
| Electrical Conductivity | ≥ 10.2 %IACS |
| Magnetic Coercivity | ≤ 48 A/m (After magnetic annealing) |
| Saturation Flux Density | ≥ 2.15 Tesla |
| Hardness (HV1) | 85 HV – 110 HV (Post-annealed) |
| Operating Temperature | -40°C to +150°C |
Surface Treatment Process of shielding cover for EV DC contactor
Anti-Corrosion Electroplating
Automated barrel plating lines apply uniform 3–8 μm nickel or tin coatings across complex deep-drawn stamping geometry. Micro-pore sealing prevents atmospheric oxygen from degrading the pure iron substrate during high-humidity operation.
Continuous Hydrogen Annealing
Stamped shields undergo thermal processing in a hydrogen atmosphere at temperatures exceeding 850°C. This stress-relief cycle restores magnetic soft properties, reduces internal lattice dislocations, and lowers magnetic hysteresis losses.
Precision Deburring and Degreasing
Ultrasound solvent baths eliminate lubricants and fine particulate residue post-stamping. Automated vibration tumbling eliminates sharp sheared edges, preventing micro-flaking inside high-voltage contact chambers.
Plating Adhesion and Thickness Verification
X-ray fluorescence (XRF) analyzers verify plating thickness across flat surfaces and inner wall radii. Thermal shock tests (-40°C to +125°C for 100 cycles) ensure zero flaking or blister formation on finished batches.
Frequently Asked Questions about Shield Cap for HEV DC Relay
What raw material grade is used for this Shielding Cover for New Energy High Voltage DC Contactor?
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We utilize high-purity DT4C or DT4E electrician-grade pure iron (carbon content ≤ 0.008%). This soft magnetic material provides high magnetic saturation and low coercivity, ensuring strong electromagnetic shielding without retaining residual magnetic drag.
How do you eliminate residual magnetism after stamping operations?
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Mechanical cold working increases dislocations and magnetic coercivity. All stamped parts undergo a vacuum or hydrogen-atmosphere magnetic annealing process at 850°C to relieve stress, restoring soft magnetic performance to 48 A/m or lower.
Can you provide custom shield cover designs based on 3D CAD files?
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Yes. We manufacture custom tooling directly from STEP or IGES files. Our engineering team conducts DFM analysis to evaluate draw ratios, bend radii, and material utilization before initiating tooling fabrication.
What certifications back your manufacturing process?
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Our production facility operates under IATF 16949 automotive quality management system standards. Raw DT4C materials, electroplating lines, and finished components comply fully with RoHS 2.0 and REACH environmental directives.
What is the standard lead time for tooling and sample production?
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New progressive stamping dies require 10 to 15 working days for fabrication, trial, and initial sample inspection reporting (ISIR/PPAP Level 3). Mass production delivery averages 10 to 15 days following sample sign-off.
contact us
Whether you have strict requirements for electromagnetic shielding or need a customized size to adapt to a specific installation environment, we can meet your needs. Our professional team is always ready to answer your questions, provide technical support, and create the most suitable Shield Cover for New Energy HVDC solution for you. Looking forward to your call, let us contribute to the development of new energy together.
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