Brazing is a welding method that uses a metal or alloy with a lower melting point than the base metal as a filler metal to join two or more workpieces without melting the base metal. Welding Button Contacts are a common application of this process in the machining of precision metal components.
Core Principles
Heating: Heating the workpieces and filler metal to a temperature above the filler metal's melting point but below the base metal's melting point provides the basic temperature conditions for the formation of the Welding Contacts.
Capillary Action: The molten filler metal wets the surface of the base metal through capillary action and fills the gap between the tightly fitting workpiece joints. This step is crucial for achieving a strong connection in Button Silver Contacts.
Metallurgical Bonding: The molten filler metal undergoes physicochemical reactions such as dissolution and diffusion with the base metal, forming a metallurgical bond at the interface, ensuring the structural stability of the Brazed Electrical Contacts.
Cooling and Solidification: After heating is stopped, the liquid solder solidifies, forming a strong joint to connect the workpieces, ultimately completing the machining of the Welding Electrical Contacts.
Main Classifications
Soft Soldering:
Solder melting point is below 450°C.
Common Solders: Tin-lead alloy, tin-silver alloy, tin-zinc alloy, etc.
The joint strength is relatively low. It is commonly used for electronic and electrical circuit connections, heat sinks, jewelry, food utensils, etc., and also has limited applications in the simple machining of small Electrical Contact Resistance Brazings.
Typical Processes: Soldering iron soldering, wave soldering, reflow soldering. Soldering iron soldering is suitable for localized soldering operations on miniature Welding Components.
Hard Soldering:
Solder melting point is above 450°C.
Common Solders: Copper-based alloys, silver-based alloys, aluminum-based alloys, nickel-based alloys, gold-based alloys, etc. Silver-based alloys are the preferred solder for precision machining of Resistance Welding Contacts.
This brazing method offers high joint strength, typically approaching or even reaching the strength of the base material, and has a wide range of applications, making it the mainstream brazing method for industrial-grade Welding Button Contacts.
Typical processes include flame brazing, furnace brazing, induction brazing, dip brazing, and resistance brazing. Furnace brazing ensures uniformity and consistency in the welding of Contact Tipselay Moving Springs.
Advantages
It can join high-melting-point metals or dissimilar materials at relatively low temperatures, such as steel-copper, aluminum-stainless steel, and ceramic-metal, adapting to the diverse material processing requirements of Welding Contacts.
It provides uniform heating of the entire workpiece, with a small heat-affected zone and minimal deformation, effectively ensuring the precision of the dimensions and shape of the Button Silver Contacts.
It can weld multiple joints or multiple workpieces simultaneously, suitable for mass industrial production of Brazed Electrical Contacts, improving processing efficiency.
It produces smooth, precise, and well-sealed joints, meeting the stringent requirements of Welding Electrical Contacts for surface quality and sealing performance.
Easily automatable production, automated brazing lines can significantly improve the processing consistency and production efficiency of Electrical Contact Resistance Brazings.
High and stable joint strength, especially in hard brazing, ensures the structural strength and service life of the Welding Components under operating conditions.
Disadvantages and Challenges
High precision is required for joint assembly gaps, and the miniaturized design of Resistance Welding Contacts further increases the difficulty of gap control.
Extremely stringent surface cleaning requirements are necessary; otherwise, joint quality will be affected. The tiny weld surfaces of Contact Tipselay Moving Springs are more prone to weld failure due to incomplete cleaning.
Some brazing filler metals and fluxes are expensive, such as silver brazing filler metal. Precision machining of Welding Contacts often requires the use of high-end brazing filler metals, increasing production costs.
Weld strength is generally lower than that of fusion welded joints, requiring process optimization to compensate for this deficiency and meet the mechanical performance requirements of Button Silver Contacts.
Some brazing filler metals may pose a risk of erosion to the base material; this issue must be carefully avoided in the machining of thin-film Brazed Electrical Contacts.
Some processes require significant investment in equipment, such as vacuum furnace brazing. The processing of high-end Welding Electrical Contacts often necessitates such high-precision equipment, raising the entry barrier.
Application Areas
Brazing applications are extremely broad, covering industries such as aerospace, automotive, electronics, refrigeration and air conditioning, power, instrumentation, piping engineering, home appliances, and jewelry. As core precision components, Electrical Contact Resistance Brazings are crucially used in high-end equipment across various fields.
Aerospace: Engine parts, heat exchangers, structural components. Welding Components in aerospace-grade switching components require high-level brazing processes to ensure reliability.
Automotive: Radiators, air conditioning condensers/evaporators, turbochargers, etc. New energy vehicle electronic control systems extensively use brazed Resistance Welding Contacts.
Electronics and Electrical: Circuit board components, lead connections, radiator substrates, etc. Contact Tipselay Moving Springs in relays and contactors are typical applications of brazing in this field.
our Product
As a core application of brazing technology in the field of precision metal components, Welding Button Contacts are our flagship product. Based on a mature hard brazing process system, we select high-purity silver-based brazing filler metal and match it with high-quality copper-based and silver-based base materials. From precise control of joint gaps and oxidation-free surface cleaning to brazing in a vacuum furnace and multi-dimensional quality inspection, the entire process adheres to precision brazing standards. The resulting silver brazed contacts possess excellent conductivity, strong metallurgical bond strength, and precise dimensional accuracy, perfectly meeting the stringent requirements of high-end applications such as relays, contactors, circuit breakers, and new energy vehicle electronic control systems.
our Product
In conclusion, we have been deeply involved in the R&D and production of silver brazed contacts for decades and can provide customized solutions based on your process requirements. Welcome to contact us anytime to discuss and customize precision silver brazed contact products exclusively for you!
