Products Description
Copper Tungsten Contacts are a specialized functional material produced through a powder metallurgy process, combining high-melting-point tungsten with highly conductive copper. They are typically utilized in the form of contacts or contact pads within switching applications characterized by high electrical loads and frequent operation. In automotive horns, these contacts are specifically engineered to withstand the shock of high inrush currents, frequent mechanical vibrations, and arc erosion in harsh environments. They serve as the core actuating components that ensure the horn's sound-generating unit (electromagnet) can execute high-speed, reliable switching-occurring dozens of times per second-thereby directly influencing the horn's acoustic performance, service life, and overall vehicle safety.
Application Fields
| Automotive Electronics | Tungsten Copper Solid Rivet Contacts serve as the core contact components in various automotive horns and anti-theft alarm systems, capable of withstanding extreme temperature fluctuations and high-frequency vibrations. |
| High-Voltage Electrical Switches | Electric Horn Tungsten Contacts are employed in molded-case circuit breakers, load switches, and transformer tap changers to ensure the safety and stability of power grids. |
| Industrial Resistance Welding Equipment | Half Hollow Tungsten Contact Rivets are utilized as electrodes in spot welding and butt welding machines, leveraging their high hardness and anti-adhesion properties to extend mold lifespan. |
| Electrical Discharge Machining (EDM) | Applied in the electrical erosion processing of ultra-hard alloy molds-such as those made from tungsten carbide-delivering minimal material loss and high machining precision. |
Technical Features
Tungsten Sheet Mirror Polishing
The working surface of the Tungsten Contact Point Rivet undergoes a mirror-polishing treatment (Ra ≤ 0.2 μm). This process reduces the initial contact resistance by approximately 30% while simultaneously lowering the wear rate of the mating contacts. Furthermore, the polished surface facilitates the formation of a dense oxide film, which further inhibits arc erosion.
Layered Substrate Design
Tungsten Copper Electrical Contacts (catering to the mid-to-low-end market) are cost-efficiency-oriented; featuring high tensile strength, they are suitable for high-volume, economical horn applications. Copper-based rivets (catering to the mid-to-high-end market) offer excellent electrical conductivity and heat dissipation capabilities, making them ideal for high-performance applications or scenarios involving continuous horn usage.
Brazing Process Window Control
The brazing process is conducted within a temperature range of 1000–1100°C, with a holding time of 5–60 seconds, under a protective hydrogen atmosphere. If the temperature is too low, the brazing filler metal will not fully melt, resulting in a "cold joint" (incomplete bond); conversely, if the temperature is too high, brittle intermetallic compounds will form at the tungsten-copper interface. Metallographic inspection is required for every production batch of Copper Tungsten Electrical Contacts to verify process integrity.
Detailed Features
Mirror-Finish Pure Tungsten Contact Surface
The surface of the Tungsten Copper Solid Rivet Contacts undergoes high-precision surface grinding and finishing, resulting in an extremely low microscopic roughness (Ra). This highly planar pure tungsten contact surface ensures that the maximum effective electrical contact area is achieved immediately upon initial contact, thereby significantly reducing the initial power consumption of the entire circuit assembly.
Fully Encapsulating, Void-Free Braze Fillet
Metallographic analysis of the Electric Horn Tungsten Contacts's cross-section reveals an exceptionally uniform distribution of metallic material within the braze joint. At the interface edges, a minute, smooth, and convex fillet is evident-devoid of any concavities or slag inclusions-serving as the tangible physical manifestation of a brazing process executed to its absolute optimal limit.
contact us
If you require consultation regarding product specifications for Copper Tungsten Contacts, application solutions for automotive horn contacts, sample validation, or bulk pricing-or if you wish to discuss your automotive electrical designs-we invite you to contact our professional team. We will provide technical support and tailored solutions based on your specific application requirements.
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