Brazed Contact Assembly: A Key Technology For Precision Electrical Connections

Brazing contact assembly utilizes a brazing material with a lower melting temperature than the parent metal, achieving the connection without melting the parent metal. To ensure a good bond with the parent metal, flux is added to the brazing material.

Brazing Silver Contacts to Copper Bars is used in applications such as pipes, connectors, and valves that require airtightness; pressure vessels that require a certain level of pressure resistance and airtightness; and components of vehicles, including automobiles and motorcycles, that require corrosion and heat resistance. Furthermore, soldering, which uses conductive solder with a lower melting temperature, is widely used in electronic circuits, electrical connectors, and precision electronic components.

In recent years, a brazing technology called "laser brazing" has also gained traction.

"Resistance Brazing Electrical Contacts" involves placing a wire-like brazing material between the base metals and melting it using light energy (laser) to achieve a joint. Since the base material barely melts, thermal deformation can be kept within ideal limits. This minimizes the product's appearance and enables lightweight, highly rigid joints.

Previously, resistance spot welding was commonly used to join parts such as automotive roofs, side panels, and trunk lids. For example, when joining the roof to the body, a grooved roof connection was created and spot-welded. After joining, a molding was required to conceal the groove and weld marks.

However, Low Voltage Electrical Contacts maintains the aesthetics of the base material, eliminating the need for machining, molding, and other components and steps. Furthermore, its joint strength and joining speed are approximately twice that of resistance spot welding. Its use is growing, primarily in the automotive industry, both in Europe and Japan.

Braze and solder are categorized by the melting temperature of the brazing material. Brazing uses a brazing material with a melting temperature of 450°C or higher, while soldering uses a solder paste (soft solder) with a melting temperature below 450°C.

Braze welding: Brazing using a high-melting-point brazing material.

Based on the heat source, it can be categorized into "torch brazing," which uses a conventional gas torch, and "induction heating welding," which utilizes high-frequency induction heating. Furthermore, there are methods such as "Spot Welding Assembly," where the base metal and brazing material are heated and cooled in a furnace isolated from the atmosphere without using flux. These welding methods are used for non-oxidizing brazing of stainless steel and for automated joining of titanium, ceramics, and other materials.

Soldering: Brazing using a low-melting-point brazing material.

The most common method is "Projection Welding," which utilizes electrical heating, typically with a soldering iron. However, in the production of electronic components for factory automation (FA) applications, beam brazing is commonly used. Light from a high-power light source is focused on the welded part using a reflector, using the energy of the light to perform the welding. Using solder paste (soft solder) with a low melting point allows for precise robotic joining, making it ideal for automated assembly and mass production of products such as electronic components with low heat resistance.

Among the many brazing applications, Brazed Contact Assembly is a particularly representative area. This technology utilizes advanced brazing processes to precisely assemble high-quality contact materials, ensuring a reliable and stable electrical connection. By carefully selecting appropriate brazing materials and optimizing welding parameters, a brazed contact assembly can meet the requirements of a variety of high-precision and high-reliability electrical equipment. Whether in precision instruments, high-end electronic equipment, or industrial automation control systems, brazed contact assembly has demonstrated excellent performance and broad application prospects. With continuous technological advancement, brazed contact assembly will continue to leverage its unique advantages in the field of electrical connections, providing solid technical support for the development of modern industry.