Difference between revisions of "Manufacturing of Single Contact Parts"

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The group of single contacts includes contact rivets, contact tips, and formed
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The group of single contacts includes contact rivets, contact tips and formed parts such as weld buttons. Contact spheres (or balls) are today rarely used because of economical considerations.
parts such as weld buttons. Contact spheres (or balls) are today rarely used
 
because of economical considerations.
 
  
 
===Contact Rivets===
 
===Contact Rivets===
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====Solid Contact Rivets====
 
====Solid Contact Rivets====
  
Solid contact rivets are the oldest utilized contact parts. Their manufacturing
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Solid contact rivets are the oldest utilized contact parts. Their manufacturing requires a ductile contact material and is done without scrap on fully automated special cold heading machines. A wire slug is cut off and the rivet head is formed by pressing and hammering. This way contact rivets with various head configurations such as flat, domed, spherical or pointed can be manufactured, depending on the final application and switch or relay design.
requires a ductile contact material and is done without scrap on fully automated
 
special cold heading machines. A wire slug is cut off and the rivet head is
 
formed by pressing and hammering. This way contact rivets with various head
 
configurations such as flat, domed, spherical, or pointed can be manufactured
 
depending on the final application and switch or relay design.
 
[[File:Ty_pical_Contact_Shapes_of_Solid_Contact_Rivets.jpg|right|thumb|Typical Contact Shapes of Solid Contact Rivets]]
 
  
*Typical Contact Shapes of Solid Contact Rivets (s. Picture "Typical Contact Shapes of Solid Contact Rivets")
+
*Typical Contact Shapes of Solid Contact Rivets (<xr id="fig:Typical_Contact_Shapes_of_Solid_Contact_Rivets"/>)
  
*Contact Materials <br /> Au-, AgPd-, PdCu-Alloys, Ag, AgNi 0,15 (ARGODUR-Spezial), AgCu, AgCuNi (ARGODUR 27), Ag/Ni (SINIDUR), Ag/CdO (DODURIT CdO), Ag/SnO<sub>2</sub> SISTADOX), Ag/ZnO (DODURIT ZnO),Ag/C 97/3*, Cu<br /> <span class="small"><sup>*</sup> dimensionally very limited</span>  
+
*Contact Materials <br /> Au-, AgPd-, PdCu-Alloys, Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO<sub>2</sub>, Ag/ZnO,Ag/C 97/3*, Cu<br /> <span class="small"><sup>*</sup> dimensionally very limited</span>  
  
*Dimensional Ranges (s. Picture "Dimensional Ranges") <br /> The respective parameters cannot be chosen independently of each other. They mainly depend on the ductility of the required contact material. Before a final decision on the dimensions we recommend to consult with the contact manufacturer. <br />
+
*Dimensional Ranges (<xr id="fig:Dimensional_Ranges"/>) <br /> The respective parameters cannot be chosen independently of each other. They mainly depend on the ductility of the required contact material. Before a final decision on the dimensions we recommend to consult with the contact manufacturer. <br />
[[File:Dimensional Ranges.jpg|right|thumb|Dimensional Ranges]]  
+
*Quality criteria and tolerances (<xr id="fig:Qualitaetsmerkmale_und_Toleranzen"/>)
 
+
<div class="multiple-images">
*Qualitätsmerkmale und Toleranzen (s. Picture "Qualitaetsmerkmale und Toleranzen")
+
<figure id="fig:Typical_Contact_Shapes_of_Solid_Contact_Rivets">
 
+
[[File:Ty_pical_Contact_Shapes_of_Solid_Contact_Rivets.jpg|right|thumb|Figure 1: Typical Contact Shapes of Solid Contact Rivets]]
[[File:Qualitaetsmerkmale und Toleranzen.jpg|right|thumb|Qualitaetsmerkmale und Toleranzen]]
+
</figure>
 +
<figure id="fig:Dimensional_Ranges">
 +
[[File:Dimensional Ranges.jpg|right|thumb|Figure 2: Dimensional Ranges]]  
 +
</figure>
 +
<figure id="fig:Qualitaetsmerkmale_und_Toleranzen">
 +
[[File:Qualitaetsmerkmale und Toleranzen.jpg|left|thumb|Figure 3: Quality criteria and tolerances]]
 +
</figure>
 +
</div>
 +
<div class="clear"></div>
  
 
<table class="twocolortable" border="1" cellspacing="0" style="border-collapse:collapse"><tr><th><p class="s13">Characteristics</p></th><th><p class="s13">Form A                  Form B                Form C</p><p class="s13">Rounded headf    Trapeziodal          Trapeziodal head, radiused    head,flat</p></th><th><p class="s13">Suggested test equipment</p></th></tr><tr><td><p class="s13">a) Head diameter d<sub>1</sub> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub></span><u>&lt;</u> 4  + 0,06        During optical measurement</p><p class="s13">d<span class="s14"><sub>1</sub></span>&gt; 4  - 0,06        disregard corner</p><p class="s13">radius R<span class="s14"><sub>3</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Measuring microscope</p></td></tr><tr><td><p class="s13">b) Head thickness</p><p class="s13">k [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub></span><u>&lt;</u> 4  + 0,03</p><p class="s13">d<span class="s14"><sub>1</sub></span>&gt; 4  + 0,08</p></td><td><p class="s13">Micrometer, Dial indicator</p></td></tr><tr><td><p class="s13">c) Shank diameter d<span class="s14"><sub>2</sub></span> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub></span><u>&lt;</u> 2  - 0,06</p><p class="s13">d<span class="s14"><sub>2</sub></span>&gt; 2  - 0,08</p></td><td><p class="s13">Micrometer</p></td></tr><tr><td><p class="s13">d) Shank length  [mm]</p></td><td><p class="s13">+ 0,15</p></td><td><p class="s13">Micrometer, Dial</p><p class="s13">indicator, Comparator</p></td></tr><tr><td><p class="s13">e) Radius at center</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>1</sub></span> [mm]</p></td><td><p class="s13">Form A und B:      Within the head thickness</p><p class="s13">tolerance</p><p class="s13">Form C:                Allowable deviation from flatness: convex: within head thickness tolerance</p><p class="s13">concave: 0.005 d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Comparator template, Radius gage</p></td></tr><tr><td><p class="s13">f) Radius at edge of contact surface R<span class="s14"><sub>2</sub></span> [mm]</p></td><td><p class="s13">Form A:                Smooth transition to R<span class="s14"><sub>1</sub></span></p><p class="s13">Form B:                1.5 R<span class="s14"><sub>2</sub></span> allowed</p><p class="s13">Form C:                <u>&lt;</u>0,1d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Profile template,</p><p class="s13">Comparator, Radius gage</p></td></tr><tr><td><p class="s13">g) Radii</p><p class="s13">R<span class="s14"><sub>3 </sub></span>and R<span class="s14"><sub>5</sub></span> [mm]</p></td><td><p class="s13">Sligth rounding allowed</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">h) Transition radius head underside to shank R<span class="s14"><sub>4</sub></span> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub> </span><u>&lt;</u> 2  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0,08  if covered  by DIN 46240 pg.1 d<span class="s14"><sub>2</sub> </span>&gt; 2 R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0,1</p><p class="s13">d<span class="s14"><sub>2</sub> </span>&gt; 3  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0,2</p></td><td><p class="s13">Comparator if in doubt: microsection</p></td></tr><tr><td><p class="s13">i) Allowed deviation</p><p class="s13">from cylindrical shape</p></td><td><p class="s13">max. 7°  30’:        or d<span class="s14"><sub>2</sub> </span> <u>&lt;</u> l, l <u>&gt;</u> 0,7 mm and k <u>&lt;</u> 0,6 d<span class="s14"><sub>1</sub></span>.</p><p class="s13">max. 15°:            for all other rivets</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">k) Concentricity between head and shank center line [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub> </span><u>&lt;</u> 4  0,15</p><p class="s13">d<span class="s14"><sub>1</sub> </span>&gt; 4  0,2</p><p class="s13">in general: approx. 70% of allowable deviation</p><p class="s13">per DIN 46240</p></td><td><p class="s13">Comparator, Special</p><p class="s13">turn fixture</p></td></tr></table>
 
<table class="twocolortable" border="1" cellspacing="0" style="border-collapse:collapse"><tr><th><p class="s13">Characteristics</p></th><th><p class="s13">Form A                  Form B                Form C</p><p class="s13">Rounded headf    Trapeziodal          Trapeziodal head, radiused    head,flat</p></th><th><p class="s13">Suggested test equipment</p></th></tr><tr><td><p class="s13">a) Head diameter d<sub>1</sub> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub></span><u>&lt;</u> 4  + 0,06        During optical measurement</p><p class="s13">d<span class="s14"><sub>1</sub></span>&gt; 4  - 0,06        disregard corner</p><p class="s13">radius R<span class="s14"><sub>3</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Measuring microscope</p></td></tr><tr><td><p class="s13">b) Head thickness</p><p class="s13">k [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub></span><u>&lt;</u> 4  + 0,03</p><p class="s13">d<span class="s14"><sub>1</sub></span>&gt; 4  + 0,08</p></td><td><p class="s13">Micrometer, Dial indicator</p></td></tr><tr><td><p class="s13">c) Shank diameter d<span class="s14"><sub>2</sub></span> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub></span><u>&lt;</u> 2  - 0,06</p><p class="s13">d<span class="s14"><sub>2</sub></span>&gt; 2  - 0,08</p></td><td><p class="s13">Micrometer</p></td></tr><tr><td><p class="s13">d) Shank length  [mm]</p></td><td><p class="s13">+ 0,15</p></td><td><p class="s13">Micrometer, Dial</p><p class="s13">indicator, Comparator</p></td></tr><tr><td><p class="s13">e) Radius at center</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>1</sub></span> [mm]</p></td><td><p class="s13">Form A und B:      Within the head thickness</p><p class="s13">tolerance</p><p class="s13">Form C:                Allowable deviation from flatness: convex: within head thickness tolerance</p><p class="s13">concave: 0.005 d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Comparator template, Radius gage</p></td></tr><tr><td><p class="s13">f) Radius at edge of contact surface R<span class="s14"><sub>2</sub></span> [mm]</p></td><td><p class="s13">Form A:                Smooth transition to R<span class="s14"><sub>1</sub></span></p><p class="s13">Form B:                1.5 R<span class="s14"><sub>2</sub></span> allowed</p><p class="s13">Form C:                <u>&lt;</u>0,1d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Profile template,</p><p class="s13">Comparator, Radius gage</p></td></tr><tr><td><p class="s13">g) Radii</p><p class="s13">R<span class="s14"><sub>3 </sub></span>and R<span class="s14"><sub>5</sub></span> [mm]</p></td><td><p class="s13">Sligth rounding allowed</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">h) Transition radius head underside to shank R<span class="s14"><sub>4</sub></span> [mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub> </span><u>&lt;</u> 2  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0,08  if covered  by DIN 46240 pg.1 d<span class="s14"><sub>2</sub> </span>&gt; 2 R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0,1</p><p class="s13">d<span class="s14"><sub>2</sub> </span>&gt; 3  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0,2</p></td><td><p class="s13">Comparator if in doubt: microsection</p></td></tr><tr><td><p class="s13">i) Allowed deviation</p><p class="s13">from cylindrical shape</p></td><td><p class="s13">max. 7°  30’:        or d<span class="s14"><sub>2</sub> </span> <u>&lt;</u> l, l <u>&gt;</u> 0,7 mm and k <u>&lt;</u> 0,6 d<span class="s14"><sub>1</sub></span>.</p><p class="s13">max. 15°:            for all other rivets</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">k) Concentricity between head and shank center line [mm]</p></td><td><p class="s13">d<span class="s14"><sub>1</sub> </span><u>&lt;</u> 4  0,15</p><p class="s13">d<span class="s14"><sub>1</sub> </span>&gt; 4  0,2</p><p class="s13">in general: approx. 70% of allowable deviation</p><p class="s13">per DIN 46240</p></td><td><p class="s13">Comparator, Special</p><p class="s13">turn fixture</p></td></tr></table>
  
 
==== Composite Contact Rivets====
 
==== Composite Contact Rivets====
Clad rivets for which only a part of the head (composite or bimetal rivets) or also
+
Clad rivets, for which only a part of the head (composite or bimetal rivets) or also the shank end (tri-metal rivets) are composed of contact material – with the balance of the body mostly being copper – have replaced the solid rivet for many applications because of economical considerations. The cost savings depend on the contact material and its required volume for a specific application. These composite rivets are also produced scrap-less from wire material on special machinery with two process variations utilized.
the shank end (tri-metal rivets) are composed of contact material – with the
 
balance of the body mostly being copper – have replaced for many applications
 
solid rivet versions because of economical considerations. The cost savings
 
depend on the contact material and its required volume for a specific
 
application. These composite rivets are also produced scrap-less from wire
 
material on special machinery with two process variations utilized.
 
 
 
During ''cold bonding'' and heading the bond between the contact material and
 
the copper is achieved without external heat energy by high plastic deformation
 
at the face surfaces of the two wire segments ''(Picture Cold bonding of bimetall rivets)''. The bonding pressure
 
must be high enough to move the lattice components of the two metals within a
 
few atom radii so that the adhesion forces between atoms become effective.
 
Therefore the head to shank diameter ratio of 2:1 must be closely met for a
 
strong bond between the two metals. (s. Picture "Cold bonding of bimetall rivets")
 
 
 
[[File:Cold_bonding_of_bimetall_rivets.jpg|right|thumb|Cold bonding of bimetall rivets (schematic)]]
 
 
 
During ''hot bonding'' the required heat energy is applied by a short term electrical
 
current pulse ''(Picture Hot bonding of bimetall rivets)''. In the case of Ag and Cu a molten eutectic alloy of
 
silver and copper is formed in the constriction area between the two wire ends.
 
When using metal oxide containing contact materials the non-soluble oxide
 
particles tend to coagulate and the bonding strength between the component
 
materials is greatly reduced. Therefore the cold bonding technology is preferred
 
for these contact materials. The during cold bonding required high surface
 
deformation ratio can be reduced for the hot bonding process which allows the
 
head to shank diameter ratio to be reduced below 2:1.
 
  
For composite rivets with AgPd alloys as well as alloys on the basis of Au, Pd,
+
During ''cold bonding'' the process of heading the bond between the contact material and the copper is achieved without external heat energy by high plastic deformation at the face surfaces of the two wire segments (<xr id="fig:Cold_bonding_of_bimetall_rivets"/><!--(Fig. 3.1)-->).
and Pt the above methods cannot be used because of the very different work
+
The bonding pressure must be high enough to move the lattice components of the two metals within a few atom radii, so that the adhesion forces between atoms become effective.
hardening of these materials compared to the base material copper. The
+
Therefore the head to shank diameter ratio of 2:1 must be closely met for a strong bond between the two metals.
starting material for such composite rivets is clad strip material from which the
 
contact rivets are formed in multiple steps of press-forming and stamping.
 
Similar processes are used for larger contact rivets with head diameters > 8 mm
 
and Ag-based contact materials. (s. Picture "Hot bonding of bimetall rivets")
 
  
[[File:Hot_bonding_of_bimetal_rivets.jpg|right|thumb|Hot bonding of bimetall rivets (schematic)]]
+
During ''hot bonding'' the required heat energy is applied by a short term electrical current pulse (<xr id="fig:Hot_bonding_of_bimetal_rivets"/><!--(Fig. 3.2)-->).
 +
In the case of Ag and Cu a molten eutectic alloy of silver and copper is formed in the constriction area between the two wire ends. When using metal oxide containing contact materials, the non-soluble oxide particles tend to coagulate and the bonding strength between the component materials is greatly reduced. Therefore the cold bonding technology is preferred for these contact materials. During cold bonding, the required high surface deformation ratio can be reduced for the hot bonding process which allows the head to shank diameter ratio to be reduced below 2:1.
  
*Typical contact shapes for composite rivets (s. Picture "Typical contact shapes for composite rivets")
+
For composite rivets with AgPd alloys, as well as alloys on the basis of Au, Pd and Pt, the methods named above cannot be used because of the very different work hardening of these materials, compared to the base material copper. The starting material for such composite rivets is clad strip material, from which the contact rivets are formed in multiple steps of press-forming and stamping. Similar processes are used for larger contact rivets with head diameters > 8 mm and Ag-based contact materials.
  
[[File:Typical_contact_shapes_for_composite_rivets.jpg|right|thumb|Typical contact shapes for composite rivets]]
+
*Typical contact shapes for composite rivets (<xr id="fig:Typical_contact_shapes_for_composite_rivets"/>)
  
*Contact materials <br /> Ag, AgNi 0,15 (ARGODUR), AgCu, AgCuNi (ARGODUR 27), Ag/Ni (SINIDUR), Ag/CdO (DODURIT CDO), Ag/SnO<sub>2</sub> (SISTADOX), Ag/ZnO (DODURIT ZNO)<br />
+
*Contact materials <br /> Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO<sub>2</sub>, Ag/ZnO <br />
  
 
*Base materials <br /> Cu <br />
 
*Base materials <br /> Cu <br />
  
*Dimensional ranges (s. Picture "Dimensional ranges") <br />These parameters cannot be chosen independently of each other. They depend mainly on the mechanical properties of the contact material. Before specifying the final dimensions we recommend to consult with the contact manufacturer. <br />
+
*Dimensional ranges (<xr id="fig:Dimensional_ranges"/>) <br />These parameters cannot be chosen independently of each other. They depend mainly on the mechanical properties of the contact material. Before specifying the final dimensions we recommend to consult with the contact manufacturer. <br />
 
 
[[File:Dimensional_ranges.jpg|right|thumb|Dimensional ranges]]
 
  
*Quality criteria and tolerances (s. Picture "Quality criteria and tolerances")
+
*Quality criteria and tolerances (<xr id="fig:Quality_criteria_and_tolerances"/>)
  
[[File:Quality_criteria_and_tolerances.jpg|right|thumb|Quality criteria and tolerances]]
+
<div class="multiple-images">
 +
<figure id="fig:Cold_bonding_of_bimetall_rivets">
 +
[[File:Cold_bonding_of_bimetall_rivets.jpg|left|thumb|Figure 4: Cold bonding of bimetall rivets (schematic)]]
 +
</figure>
 +
<figure id="fig:Hot_bonding_of_bimetal_rivets">
 +
[[File:Hot_bonding_of_bimetal_rivets.jpg|left|thumb|Figure 5: Hot bonding of bimetall rivets (schematic)]]
 +
</figure>
 +
<figure id="fig:Typical_contact_shapes_for_composite_rivets">
 +
[[File:Typical_contact_shapes_for_composite_rivets.jpg|left|thumb|Figure 6: Typical contact shapes for composite rivets]]
 +
</figure>
 +
<figure id="fig:Dimensional_ranges">
 +
[[File:Dimensional_ranges.jpg|left|thumb|Figure 7: Dimensional ranges]]
 +
</figure>
 +
<figure id="fig:Quality_criteria_and_tolerances">
 +
[[File:Quality_criteria_and_tolerances.jpg|left|thumb|Figure 8: Quality criteria and tolerances]]
 +
</figure>
 +
</div>
 +
<div class="clear"></div>
  
 
<table class="twocolortable">
 
<table class="twocolortable">
 
<tr><th><p class="s13">Criteria</p></th><th><p class="s13">Form B                          Form C</p><p class="s13">Trapezoidal head,        Trapezoidal head radiused                        flat</p></th><th><p class="s13">Suggested test</p><p class="s13">equipment</p></th></tr><tr><td><p class="s13">a)  Head diameter</p><p class="s13">d<span class="s14"><sub>1 </sub> </span>[mm]</p></td><td><p class="s13">During optical measurement disregard corner radius R<span class="s14"><sub>3</sub> </span><u>+</u> 0.1</p></td><td><p class="s13">Comparator, measu-</p><p class="s13">ring microscpope</p></td></tr><tr><td><p class="s13">b)  Head thickness</p><p class="s13">k [mm]</p></td><td><p class="s13">+ 0.1</p></td><td><p class="s13">Micrometer,</p><p class="s13">Dial indicator</p></td></tr><tr><td><p class="s13">c)  Shank diameter</p><p class="s13">d<span class="s14"><sub>2</sub> </span>[mm]</p></td><td><p class="s13">Deviation from roundness and conical shape of</p><p class="s13">shank only within allowed diameter tolerance d<span class="s14"><sub>2</sub> </span> <u>&lt;</u> 1.5  - 0.08</p><p class="s13">d<span class="s14"><sub>2</sub> </span>&gt; 1.5  - 0.1</p></td><td><p class="s13">Micrometer</p></td></tr><tr><td><p class="s13">d)  Shank length l</p><p class="s13">[mm]</p></td><td><p class="s13">+ 0.15</p></td><td><p class="s13">Micrometer, Dial indicator, Comparator</p></td></tr><tr><td><p class="s13">e)  Radius at center</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>1</sub> </span>[mm]</p></td><td><p class="s13">Form B:            <u>+</u> 10%, but not below</p><p class="s15">+<span class="s13"> 0.5 mm</span></p><p class="s13">Form C:            Allowable deviation from flatness: convex: within head thickness tolerance concave: 0.005 d<span class="s14">1</span></p></td><td><p class="s13">Comparator, Comparator template, Radius gage, Profile template</p></td></tr><tr><td><p class="s13">f)    Radius at edge</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>2</sub> </span>[mm]</p></td><td><p class="s13">per DIN 46240: Form B and C max. 0.5 without DIN:max. 1</p></td><td><p class="s13">Profile template,</p><p class="s13">Comparator, Radius gage</p></td></tr><tr><td><p class="s13">g)  Radii</p><p class="s13">R<span class="s14"><sub>3</sub> </span>and R<span class="s14"><sub>5</sub> </span>[mm]</p></td><td><p class="s13">Sligth rounding allowed</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">h)  Transition radius</p><p class="s13">head underside to shank R<span class="s14"><sub>4</sub> </span>[mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub> </span><u>&lt;</u> 2  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0.08 d<span class="s14"><sub>2</sub> </span>&gt; 2  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0.1 d<span class="s14"><sub>2</sub> </span>&gt; 3  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0.2</p></td><td><p class="s13">Comparator, if in doubt: micro-section</p></td></tr><tr><td><p class="s13">i)      Allowed deviation from cylindrical shape</p></td><td><p class="s13">d<span class="s14"><sub>1</sub> </span> <u>&lt;</u> 4  up to 7°30’ + 2°30’</p><p class="s13">d<span class="s14"><sub>1</sub> </span>&gt; 4  up to 10°    + 5°</p></td><td><p class="s13">Comparator, Measu- ring microscope, if in doubt: microsection</p></td></tr><tr><td><p class="s13">k)  Concentricity bet-</p><p class="s13">ween head and shank center line [mm]</p></td><td><p class="s13">5% of d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Measuring microscope, Special turn fixture</p></td></tr><tr><td><p class="s13">l)    Contact  layer</p><p class="s13">thickness [mm]</p></td><td><p class="s13">In center area of 0.5 d<span class="s14"><sub>1</sub> </span>s<u>&gt;</u> nominal thickness</p><p class="s13">Remaining head area must be covered</p></td><td><p class="s13">Measuring micros- cope, Microsection</p></td></tr></table>
 
<tr><th><p class="s13">Criteria</p></th><th><p class="s13">Form B                          Form C</p><p class="s13">Trapezoidal head,        Trapezoidal head radiused                        flat</p></th><th><p class="s13">Suggested test</p><p class="s13">equipment</p></th></tr><tr><td><p class="s13">a)  Head diameter</p><p class="s13">d<span class="s14"><sub>1 </sub> </span>[mm]</p></td><td><p class="s13">During optical measurement disregard corner radius R<span class="s14"><sub>3</sub> </span><u>+</u> 0.1</p></td><td><p class="s13">Comparator, measu-</p><p class="s13">ring microscpope</p></td></tr><tr><td><p class="s13">b)  Head thickness</p><p class="s13">k [mm]</p></td><td><p class="s13">+ 0.1</p></td><td><p class="s13">Micrometer,</p><p class="s13">Dial indicator</p></td></tr><tr><td><p class="s13">c)  Shank diameter</p><p class="s13">d<span class="s14"><sub>2</sub> </span>[mm]</p></td><td><p class="s13">Deviation from roundness and conical shape of</p><p class="s13">shank only within allowed diameter tolerance d<span class="s14"><sub>2</sub> </span> <u>&lt;</u> 1.5  - 0.08</p><p class="s13">d<span class="s14"><sub>2</sub> </span>&gt; 1.5  - 0.1</p></td><td><p class="s13">Micrometer</p></td></tr><tr><td><p class="s13">d)  Shank length l</p><p class="s13">[mm]</p></td><td><p class="s13">+ 0.15</p></td><td><p class="s13">Micrometer, Dial indicator, Comparator</p></td></tr><tr><td><p class="s13">e)  Radius at center</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>1</sub> </span>[mm]</p></td><td><p class="s13">Form B:            <u>+</u> 10%, but not below</p><p class="s15">+<span class="s13"> 0.5 mm</span></p><p class="s13">Form C:            Allowable deviation from flatness: convex: within head thickness tolerance concave: 0.005 d<span class="s14">1</span></p></td><td><p class="s13">Comparator, Comparator template, Radius gage, Profile template</p></td></tr><tr><td><p class="s13">f)    Radius at edge</p><p class="s13">of contact surface</p><p class="s13">R<span class="s14"><sub>2</sub> </span>[mm]</p></td><td><p class="s13">per DIN 46240: Form B and C max. 0.5 without DIN:max. 1</p></td><td><p class="s13">Profile template,</p><p class="s13">Comparator, Radius gage</p></td></tr><tr><td><p class="s13">g)  Radii</p><p class="s13">R<span class="s14"><sub>3</sub> </span>and R<span class="s14"><sub>5</sub> </span>[mm]</p></td><td><p class="s13">Sligth rounding allowed</p></td><td><p class="s13">Comparator</p></td></tr><tr><td><p class="s13">h)  Transition radius</p><p class="s13">head underside to shank R<span class="s14"><sub>4</sub> </span>[mm]</p></td><td><p class="s13">d<span class="s14"><sub>2</sub> </span><u>&lt;</u> 2  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0.08 d<span class="s14"><sub>2</sub> </span>&gt; 2  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0.1 d<span class="s14"><sub>2</sub> </span>&gt; 3  R<span class="s14"><sub>4</sub> </span><u>&lt;</u> 0.2</p></td><td><p class="s13">Comparator, if in doubt: micro-section</p></td></tr><tr><td><p class="s13">i)      Allowed deviation from cylindrical shape</p></td><td><p class="s13">d<span class="s14"><sub>1</sub> </span> <u>&lt;</u> 4  up to 7°30’ + 2°30’</p><p class="s13">d<span class="s14"><sub>1</sub> </span>&gt; 4  up to 10°    + 5°</p></td><td><p class="s13">Comparator, Measu- ring microscope, if in doubt: microsection</p></td></tr><tr><td><p class="s13">k)  Concentricity bet-</p><p class="s13">ween head and shank center line [mm]</p></td><td><p class="s13">5% of d<span class="s14"><sub>1</sub></span></p></td><td><p class="s13">Comparator,</p><p class="s13">Measuring microscope, Special turn fixture</p></td></tr><tr><td><p class="s13">l)    Contact  layer</p><p class="s13">thickness [mm]</p></td><td><p class="s13">In center area of 0.5 d<span class="s14"><sub>1</sub> </span>s<u>&gt;</u> nominal thickness</p><p class="s13">Remaining head area must be covered</p></td><td><p class="s13">Measuring micros- cope, Microsection</p></td></tr></table>
  
*Typical contact shapes of tri-metal rivets (s. Picture "Typical contact shapes of tri-metal rivets")
+
*Typical contact shapes of tri-metal rivets (<xr id="fig:Typical_contact_shapes_of_tri-metal_rivets"/>)
 
 
[[File:Typical_contact_shapes_of_tri-metal_rivets.jpg|right|thumb|Typical contact shapes of tri-metal rivets]]
 
  
*Contact materials <br /> Ag, AgNi 0,15 (ARGODUR), AgCu, AgCuNi (ARGODUR 27), Ag/Ni (SINIDUR), Ag/CdO (DODURIT CDO), Ag/SnO (SISTADOX), Ag/ZnO (DODURIT ZNO)<br />  
+
*Contact materials <br /> Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/CdO, Ag/SnO<sub>2</sub> , Ag/ZnO<br />  
  
 
*Base materials <br /> Cu <br />
 
*Base materials <br /> Cu <br />
  
*Dimensional ranges (s. Picture "Dimensional ranges")
+
*Dimensional ranges (<xr id="fig:Dimensional_ranges2"/>)
  
[[File:Dimensional_ranges2.jpg|right|thumb|Dimensional ranges]]
+
<div class="multiple-images">
 +
<figure id="fig:Typical_contact_shapes_of_tri-metal_rivets">
 +
[[File:Typical_contact_shapes_of_tri-metal_rivets.jpg|left|thumb|Figure 9: Typical contact shapes of tri-metal rivets]]
 +
</figure>
 +
<figure id="fig:Dimensional_ranges2">
 +
[[File:Dimensional_ranges2.jpg|right|thumb|Figure 10: Dimensional ranges]]
 +
</figure>
 +
</div>
 +
<div class="clear"></div>
  
*Standard values for rivet dimension
+
===Standard values for rivet dimension===
 
+
<table class="twocolortable" style="width:75%">
<table border="1" cellspacing="0" style="border-collapse:collapse"><tr><td>d<sub>1</sub></td><td><p class="s13">k</p></td><td><p class="s13">1</p></td><td><p class="s13">d<sub>2</sub></p></td><td><p class="s13">&alpha;</p></td><td><p class="s13">r<sub>1</sub></p></td><td><p class="s13">s<sub>1</sub></p></td><td><p class="s13">s<sub>2</sub></p></td></tr><tr><td><p class="s13">3.0</p></td><td><p class="s13">0.8</p></td><td><p class="s13">2.0</p></td><td><p class="s13">1.5</p></td><td><p class="s13">7.5°</p></td><td><p class="s13">4.0</p></td><td><p class="s13">0.4</p></td><td><p class="s13">1.0</p></td></tr><tr><td><p class="s13">4.0</p></td><td><p class="s13">1.0</p></td><td><p class="s13">2.5</p></td><td><p class="s13">2.0</p></td><td><p class="s13">7.5°</p></td><td><p class="s13">8.0</p></td><td><p class="s13">0.5</p></td><td><p class="s13">1.2</p></td></tr><tr><td><p class="s13">5.0</p></td><td><p class="s13">1.2</p></td><td><p class="s13">3.0</p></td><td><p class="s13">2.5</p></td><td><p class="s13">10°</p></td><td><p class="s13">12.0</p></td><td><p class="s13">0.6</p></td><td><p class="s13">1.4</p></td></tr></table>
+
<tr><th>d<sub>1</sub></th><th><p class="s13">k</p></th><th><p class="s13">1</p></th><th><p class="s13">d<sub>2</sub></p></th><th><p class="s13">&alpha;</p></th><th><p class="s13">r<sub>1</sub></p></th><th><p class="s13">s<sub>1</sub></p></th><th><p class="s13">s<sub>2</sub></p></th></tr><tr><td><p class="s13">3.0</p></td><td><p class="s13">0.8</p></td><td><p class="s13">2.0</p></td><td><p class="s13">1.5</p></td><td><p class="s13">7.5°</p></td><td><p class="s13">4.0</p></td><td><p class="s13">0.4</p></td><td><p class="s13">1.0</p></td></tr><tr><td><p class="s13">4.0</p></td><td><p class="s13">1.0</p></td><td><p class="s13">2.5</p></td><td><p class="s13">2.0</p></td><td><p class="s13">7.5°</p></td><td><p class="s13">8.0</p></td><td><p class="s13">0.5</p></td><td><p class="s13">1.2</p></td></tr><tr><td><p class="s13">5.0</p></td><td><p class="s13">1.2</p></td><td><p class="s13">3.0</p></td><td><p class="s13">2.5</p></td><td><p class="s13">10°</p></td><td><p class="s13">12.0</p></td><td><p class="s13">0.6</p></td><td><p class="s13">1.4</p></td></tr></table>
  
 
==== Braze Alloy Clad Contact Rivets====
 
==== Braze Alloy Clad Contact Rivets====
For special cases, especially high surrounding temperatures with high thermal
+
For special cases, especially high surrounding temperatures with high thermal and mechanical stresses during switching operations, a full metallurgical bond between the contact rivet and the contact carrier may be required to prevent a loosening of the connection and early failures of the device. To accomplish this superior bond, a thin layer of brazing alloy is added to the underside of the head and the rivet shank. During assembly, a thermal treatment is added after the mechanical staking.
and mechanical stresses during switching operations, a full metallurgical bond
 
between the contact rivet and the contact carrier may be required to prevent a
 
loosening of the connection and early failures of the device. To accomplish this
 
superior bond a thin layer of brazing alloy is added to the underside of the head
 
and the rivet shank. During assembly a thermal treatment is added after the
 
mechanical staking.
 
  
 
====Contact Rivets with Brazed Contact Material Layers====
 
====Contact Rivets with Brazed Contact Material Layers====
For certain applications contact rivets with non-ductile or brittle materials such
+
For certain applications, contact rivets with non-ductile or brittle materials such as tungsten, silver–tungsten or silver–graphite are required. Rivets with these contact materials can only be fabricated by brazing. Small round tips are brazed to pre-fabricated copper or steel bases using special brazing alloys in a reducing atmosphere.
as tungsten, silver–tungsten, or silver–graphite are required. Rivets with these
 
contact materials can only be fabricated by brazing. Small round tips are brazed
 
to pre-fabricated copper or steel bases using special brazing alloys in a
 
reducing atmosphere.
 
  
 
=== Contact Tips===
 
=== Contact Tips===
Flat or formed contact tips, welded or brazed to contact carriers, are frequently
+
Flat or formed contact tips, welded or brazed to contact carriers, are frequently used in switching devices for higher power technology. Depending on the contact material and specified shapes, these tips are produced by various manufacturing processes. The most frequently used ones are:
used in switching devices for higher power technology. Depending on the
 
contact material and specified shapes these tips are produced by various
 
manufacturing processes. The most frequently used ones are:
 
  
 
*Stamping from strips and profiles
 
*Stamping from strips and profiles
 
*Cutting from extruded rods
 
*Cutting from extruded rods
*Pressing, Sintering, and Infiltrating
+
*Pressing, Sintering and Infiltrating
*Pressing, Sintering, and Re-Pressing
+
*Pressing, Sintering and Re-Pressing
 
*Pressing and Sintering
 
*Pressing and Sintering
  
For stamping sufficiently ductile semi-finished materials are needed. These are
+
For stamping, sufficiently ductile semi-finished materials are needed. These are mainly silver, silver–alloys, silver–nickel, silver–metal oxide and silver–graphite (with graphite particle orientation parallel to the switching surface). Silver–metal oxides and silver–graphite needs an additional well brazable or weldable silver layer on the underside which can be bonded to the bulk of the contact material by various processes. To further facilitate the final attachment process strips and profiles are often coated on the brazing underside with an additional thin layer of brazing alloy such as L-Ag 15P (CP 102 or BCuP-5).
mainly silver, silver–alloys, silver–nickel, silver–metal oxide, and silver–graphite
+
For Ag/C with the graphite orientation perpendicular to the switching surface, the brazable underside is produced by cutting tips from extruded rods and burning out graphite in a defined thickness.
(with graphite particle orientation parallel to the switching surface). silver–metal
 
oxides and silver–graphite need an additional well brazable or weldable silver
 
layer on the underside which can be bonded to the bulk of the contact material
 
by various processes. To further facilitate the final attachment process strips and
 
profiles are often coated on the brazing underside with an additional thin layer of
 
brazing alloy such as L-Ag 15P (CP 102 or BCuP-5).
 
For Ag/C with the graphite orientation perpendicular to the switching surface the
 
brazable underside is produced by cutting tips from extruded rods and burning
 
out graphite in a defined thickness.
 
  
The press-sinter-infiltrate process (PSI) is used mainly for Ag/W and Cu/W
+
The press-sinter-infiltrate process (PSI) is used mainly for Ag/W and Cu/W material tips with tungsten contents of > 50 wt%. A silver or copper surplus on the underside of the tip, later facilitates the brazing or welding during final assembly.
material tips with tungsten contents of > 50 wt%. A silver or copper surplus on
 
the underside of the tip later facilitates the brazing or welding during final
 
assembly.
 
  
The press–sinter–re-press method (PSR) allows the economic manufacturing of
+
The press–sinter–re-press method (PSR) allows the economic manufacturing of shaped contact parts with silver or copper contents > 70 wt%. This process also involves alloying the parts pressed in two layers, with the top being the contact material and the bottom being pure Ag or Cu for easy adhesion.
shaped contact parts with silver or copper contents > 70 wt%. This process also
 
alloys parts pressed in two layers, with the upper being the contact material and
 
the bottom side consisting of pure Ag or Cu to support easy attachment.
 
  
Press–sinter processes are limited to smaller Ag/W contact tips with a Ag
+
Press–sinter processes are limited to smaller Ag/W contact tips, with a Ag content of approximately 65 wt%.
content of approximately 65 wt%.
 
  
*Contact materials <br /> Ag, AgNi 0,15 (ARGODUR Spezial), AgCu, AgCuNi (ARGODUR 27), Ag/Ni (SINIDUR), Ag/CdO (DODURIT CdO), Ag/SnO<sub>2</sub> (SISTADOX), Ag/ZnO (DODURIT ZnO), Ag/C (GRAPHOR), Ag/W (SIWODUR), Ag/WC (SIWODUR C), Ag/WC/C (SIWODUR C/C), Ag/Mo (SILMODUR), Cu/W (CUWODUR)<br />
+
*Contact materials <br /> Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO<sub>2</sub>, Ag/ZnO, Ag/C, Ag/W, Ag/WC, Ag/WC/C, Ag/Mo, Cu/W<br />
  
*Typical contact shapes of tips and formed contact parts (s. Picture "Typical contact shapes of tips and formed contact parts")
+
*Typical contact shapes of tips and formed contact parts (<xr id="fig:Typical_contact_shapes_of_tips_and_formed_contact_parts"/>)
 +
<figure id="fig:Typical_contact_shapes_of_tips_and_formed_contact_parts">
 +
[[File:Typical_contact_shapes_of_tips_and_formed_contact_parts.jpg|left|thumb|Figure 11: Typical contact shapes of tips and formed contact parts]]
 +
</figure>
 +
<br style="clear:both;"/>
 +
*Dimensional ranges<br />Attachment Method: Welding <br />Bonding Area: approx. 5 – 25 mm<sup>2</sup><br />Attachment Method: Brazing <br />Bonding Area: > 25 mm<sup>2</sup> <br />
  
[[File:Typical_contact_shapes_of_tips_and_formed_contact_parts.jpg|right|thumb|Typical contact shapes of tips and formed contact parts]]
+
Because of the wide variety of shapes of contact tips and formed contact parts, the user and manufacturer usually develops special, part specific agreements on quality and tolerances.
 
 
*Dimensional ranges Attachment Method: <br /> Welding Bonding Area: approx. 5 – 25 mm<sup>2</sup> Attachment Method: Brazing Bonding Area: > 25 mm<sup>2</sup> <br />
 
 
 
Because of the wide variety of shapes of contact tips and formed contact parts
 
the user and manufacturer usually develop special parts specific agreements
 
on quality and tolerances.
 
  
 
===Weld Buttons===
 
===Weld Buttons===
  
For contacts used at higher temperatures, such as for example in controls for
+
For contacts used at higher temperatures, such as for example in controls for stove tops, the use of contact rivets or the direct welding of silver based contact materials on steel or thermo-bimetal carriers is usually not feasible. For such applications, weld buttons are suitable contact components.
stove tops, the use of contact rivets or the direct welding of silver based contact
 
materials on steel or thermo-bimetal carriers is usually not feasible. For such
 
applications weld buttons are suitable contact components.
 
 
 
Weld buttons are round or rectangular tips manufactured from clad contact bimetal
 
or in some cases tri-metal semi-finished materials. The surface layer is
 
produced from the specified contact material, the bottom weldable layer from a
 
material with higher electrical resistivity such as steel, nickel, or for example a
 
copper-nickel alloy. For precious metal savings a third high conductive layer of
 
copper may be inserted between the contact material and weld backing. To
 
improve the welding process the underside often has an embossed pattern with
 
one or more weld projections.
 
  
The manufacturing of weld buttons from bi– or tri–metal strip requires a ductile
+
Weld buttons are round or rectangular tips, manufactured from clad contact bimetal or in some cases tri-metal semi-finished materials. The surface layer is produced from the specified contact material, the bottom weldable layer from a material with higher electrical resistivity such as steel, nickel or for example a copper-nickel alloy. For precious metal savings, a third high conductive layer of copper may be inserted between the contact material and weld backing. To improve the welding process, the underside often has an embossed pattern with one or more weld projections.
contact material. Weld buttons with tungsten contact layers are therefore
 
produced by brazing of tungsten discs to a weldable pre-formed base.
 
  
*Typical contact forms of weld buttons (s. Picture "Typical contact forms of weld buttons")
+
The manufacturing of weld buttons from bi– or tri–metal strip requires a ductile contact material. Weld buttons with tungsten contact layers are therefore produced by brazing of tungsten discs to a weldable pre-formed base.
  
[[File:Typical_contact_forms_of_weld_buttons.jpg|right|thumb|Typical contact forms of weld buttons]]
+
*Typical contact forms of weld buttons (<xr id="fig:Typical_contact_forms_of_weld_buttons"/>)
  
*Contact materials <br /> Ag, AgNi 0,15 (ARGODUR-Spezial), AgCu, AgCuNi (ARGODUR 27), Ag/Ni (SINIDUR), Ag/CdO (DODURIT CdO), Ag/SnO<sub>2</sub> (SISTADOX), Ag/ZnO (DODURIT ZnO) <br />
+
*Contact materials <br /> Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO<sub>2</sub>, Ag/ZnO <br />
  
 
*Carrier materials <br />Ni, Fe, CuNi, CuNiZn et.al.<br />
 
*Carrier materials <br />Ni, Fe, CuNi, CuNiZn et.al.<br />
  
*Dimensional Ranges (s. Picture "Dimensional Ranges")
+
*Dimensional Ranges (<xr id="fig:13neuDimensional -Ranges"/>)
  
[[File:13neuDimensional -Ranges.jpg|right|thumb|Dimensional Ranges]]
+
*Quality criteria of standard weld buttons (<xr id="fig:16Quality_criteria_-of_standard_weld_-buttonsneu"/>)
 
+
<div class="multiple-images">
*Quality criteria of standard weld buttons (s. Picture "Quality criteria of standard weld buttons")
+
<figure id="fig:Typical_contact_forms_of_weld_buttons">
 
+
[[File:Typical_contact_forms_of_weld_buttons.jpg|left|thumb|Figure 12: Typical contact forms of weld buttons]]
[[File:16Quality_criteria_-of_standard_weld_-buttonsneu.jpg|right|thumb|Quality criteria of standard weld buttons]]
+
</figure>
 
+
<figure id="fig:13neuDimensional -Ranges">
[[Category:Manufacturing Technologies for Contact Parts|Category]]
+
[[File:13neuDimensional -Ranges.jpg|left|thumb|Figure 13: Dimensional Ranges]]
 +
</figure>
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<figure id="fig:16Quality_criteria_-of_standard_weld_-buttonsneu">
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[[File:16Quality_criteria_-of_standard_weld_-buttonsneu.jpg|left|thumb|Figure 14: Quality criteria of standard weld buttons]]
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</figure>
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==References==
 
==References==
 
[[:Manufacturing Technologies for Contact Parts#References|Manufacturing Technologies for Contact Parts]]
 
[[:Manufacturing Technologies for Contact Parts#References|Manufacturing Technologies for Contact Parts]]
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[[de:Herstellung_von_Einzelkontakten]]

Latest revision as of 12:49, 26 January 2023

The group of single contacts includes contact rivets, contact tips and formed parts such as weld buttons. Contact spheres (or balls) are today rarely used because of economical considerations.

Contact Rivets

Solid Contact Rivets

Solid contact rivets are the oldest utilized contact parts. Their manufacturing requires a ductile contact material and is done without scrap on fully automated special cold heading machines. A wire slug is cut off and the rivet head is formed by pressing and hammering. This way contact rivets with various head configurations such as flat, domed, spherical or pointed can be manufactured, depending on the final application and switch or relay design.

  • Typical Contact Shapes of Solid Contact Rivets (Figure 1)
  • Contact Materials
    Au-, AgPd-, PdCu-Alloys, Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO2, Ag/ZnO,Ag/C 97/3*, Cu
    * dimensionally very limited
  • Dimensional Ranges (Figure 2)
    The respective parameters cannot be chosen independently of each other. They mainly depend on the ductility of the required contact material. Before a final decision on the dimensions we recommend to consult with the contact manufacturer.
  • Quality criteria and tolerances (Figure 3)
Figure 1: Typical Contact Shapes of Solid Contact Rivets
Figure 2: Dimensional Ranges
Figure 3: Quality criteria and tolerances

Characteristics

Form A Form B Form C

Rounded headf Trapeziodal Trapeziodal head, radiused head,flat

Suggested test equipment

a) Head diameter d1 [mm]

d1< 4 + 0,06 During optical measurement

d1> 4 - 0,06 disregard corner

radius R3

Comparator,

Measuring microscope

b) Head thickness

k [mm]

d1< 4 + 0,03

d1> 4 + 0,08

Micrometer, Dial indicator

c) Shank diameter d2 [mm]

d2< 2 - 0,06

d2> 2 - 0,08

Micrometer

d) Shank length [mm]

+ 0,15

Micrometer, Dial

indicator, Comparator

e) Radius at center

of contact surface

R1 [mm]

Form A und B: Within the head thickness

tolerance

Form C: Allowable deviation from flatness: convex: within head thickness tolerance

concave: 0.005 d1

Comparator,

Comparator template, Radius gage

f) Radius at edge of contact surface R2 [mm]

Form A: Smooth transition to R1

Form B: 1.5 R2 allowed

Form C: <0,1d1

Profile template,

Comparator, Radius gage

g) Radii

R3 and R5 [mm]

Sligth rounding allowed

Comparator

h) Transition radius head underside to shank R4 [mm]

d2 < 2 R4 < 0,08 if covered by DIN 46240 pg.1 d2 > 2 R4 < 0,1

d2 > 3 R4 < 0,2

Comparator if in doubt: microsection

i) Allowed deviation

from cylindrical shape

max. 7° 30’: or d2 < l, l > 0,7 mm and k < 0,6 d1.

max. 15°: for all other rivets

Comparator

k) Concentricity between head and shank center line [mm]

d1 < 4 0,15

d1 > 4 0,2

in general: approx. 70% of allowable deviation

per DIN 46240

Comparator, Special

turn fixture

Composite Contact Rivets

Clad rivets, for which only a part of the head (composite or bimetal rivets) or also the shank end (tri-metal rivets) are composed of contact material – with the balance of the body mostly being copper – have replaced the solid rivet for many applications because of economical considerations. The cost savings depend on the contact material and its required volume for a specific application. These composite rivets are also produced scrap-less from wire material on special machinery with two process variations utilized.

During cold bonding the process of heading the bond between the contact material and the copper is achieved without external heat energy by high plastic deformation at the face surfaces of the two wire segments (Figure 4). The bonding pressure must be high enough to move the lattice components of the two metals within a few atom radii, so that the adhesion forces between atoms become effective. Therefore the head to shank diameter ratio of 2:1 must be closely met for a strong bond between the two metals.

During hot bonding the required heat energy is applied by a short term electrical current pulse (Figure 5). In the case of Ag and Cu a molten eutectic alloy of silver and copper is formed in the constriction area between the two wire ends. When using metal oxide containing contact materials, the non-soluble oxide particles tend to coagulate and the bonding strength between the component materials is greatly reduced. Therefore the cold bonding technology is preferred for these contact materials. During cold bonding, the required high surface deformation ratio can be reduced for the hot bonding process which allows the head to shank diameter ratio to be reduced below 2:1.

For composite rivets with AgPd alloys, as well as alloys on the basis of Au, Pd and Pt, the methods named above cannot be used because of the very different work hardening of these materials, compared to the base material copper. The starting material for such composite rivets is clad strip material, from which the contact rivets are formed in multiple steps of press-forming and stamping. Similar processes are used for larger contact rivets with head diameters > 8 mm and Ag-based contact materials.

  • Typical contact shapes for composite rivets (Figure 6)
  • Contact materials
    Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO2, Ag/ZnO
  • Base materials
    Cu
  • Dimensional ranges (Figure 7)
    These parameters cannot be chosen independently of each other. They depend mainly on the mechanical properties of the contact material. Before specifying the final dimensions we recommend to consult with the contact manufacturer.
  • Quality criteria and tolerances (Figure 8)
Figure 4: Cold bonding of bimetall rivets (schematic)
Figure 5: Hot bonding of bimetall rivets (schematic)
Figure 6: Typical contact shapes for composite rivets
Figure 7: Dimensional ranges
Figure 8: Quality criteria and tolerances

Criteria

Form B Form C

Trapezoidal head, Trapezoidal head radiused flat

Suggested test

equipment

a) Head diameter

d1 [mm]

During optical measurement disregard corner radius R3 + 0.1

Comparator, measu-

ring microscpope

b) Head thickness

k [mm]

+ 0.1

Micrometer,

Dial indicator

c) Shank diameter

d2 [mm]

Deviation from roundness and conical shape of

shank only within allowed diameter tolerance d2 < 1.5 - 0.08

d2 > 1.5 - 0.1

Micrometer

d) Shank length l

[mm]

+ 0.15

Micrometer, Dial indicator, Comparator

e) Radius at center

of contact surface

R1 [mm]

Form B: + 10%, but not below

+ 0.5 mm

Form C: Allowable deviation from flatness: convex: within head thickness tolerance concave: 0.005 d1

Comparator, Comparator template, Radius gage, Profile template

f) Radius at edge

of contact surface

R2 [mm]

per DIN 46240: Form B and C max. 0.5 without DIN:max. 1

Profile template,

Comparator, Radius gage

g) Radii

R3 and R5 [mm]

Sligth rounding allowed

Comparator

h) Transition radius

head underside to shank R4 [mm]

d2 < 2 R4 < 0.08 d2 > 2 R4 < 0.1 d2 > 3 R4 < 0.2

Comparator, if in doubt: micro-section

i) Allowed deviation from cylindrical shape

d1 < 4 up to 7°30’ + 2°30’

d1 > 4 up to 10° + 5°

Comparator, Measu- ring microscope, if in doubt: microsection

k) Concentricity bet-

ween head and shank center line [mm]

5% of d1

Comparator,

Measuring microscope, Special turn fixture

l) Contact layer

thickness [mm]

In center area of 0.5 d1 s> nominal thickness

Remaining head area must be covered

Measuring micros- cope, Microsection

  • Typical contact shapes of tri-metal rivets (Figure 9)
  • Contact materials
    Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/CdO, Ag/SnO2 , Ag/ZnO
  • Base materials
    Cu
  • Dimensional ranges (Figure 10)
Figure 9: Typical contact shapes of tri-metal rivets
Figure 10: Dimensional ranges

Standard values for rivet dimension

d1

k

1

d2

α

r1

s1

s2

3.0

0.8

2.0

1.5

7.5°

4.0

0.4

1.0

4.0

1.0

2.5

2.0

7.5°

8.0

0.5

1.2

5.0

1.2

3.0

2.5

10°

12.0

0.6

1.4

Braze Alloy Clad Contact Rivets

For special cases, especially high surrounding temperatures with high thermal and mechanical stresses during switching operations, a full metallurgical bond between the contact rivet and the contact carrier may be required to prevent a loosening of the connection and early failures of the device. To accomplish this superior bond, a thin layer of brazing alloy is added to the underside of the head and the rivet shank. During assembly, a thermal treatment is added after the mechanical staking.

Contact Rivets with Brazed Contact Material Layers

For certain applications, contact rivets with non-ductile or brittle materials such as tungsten, silver–tungsten or silver–graphite are required. Rivets with these contact materials can only be fabricated by brazing. Small round tips are brazed to pre-fabricated copper or steel bases using special brazing alloys in a reducing atmosphere.

Contact Tips

Flat or formed contact tips, welded or brazed to contact carriers, are frequently used in switching devices for higher power technology. Depending on the contact material and specified shapes, these tips are produced by various manufacturing processes. The most frequently used ones are:

  • Stamping from strips and profiles
  • Cutting from extruded rods
  • Pressing, Sintering and Infiltrating
  • Pressing, Sintering and Re-Pressing
  • Pressing and Sintering

For stamping, sufficiently ductile semi-finished materials are needed. These are mainly silver, silver–alloys, silver–nickel, silver–metal oxide and silver–graphite (with graphite particle orientation parallel to the switching surface). Silver–metal oxides and silver–graphite needs an additional well brazable or weldable silver layer on the underside which can be bonded to the bulk of the contact material by various processes. To further facilitate the final attachment process strips and profiles are often coated on the brazing underside with an additional thin layer of brazing alloy such as L-Ag 15P (CP 102 or BCuP-5). For Ag/C with the graphite orientation perpendicular to the switching surface, the brazable underside is produced by cutting tips from extruded rods and burning out graphite in a defined thickness.

The press-sinter-infiltrate process (PSI) is used mainly for Ag/W and Cu/W material tips with tungsten contents of > 50 wt%. A silver or copper surplus on the underside of the tip, later facilitates the brazing or welding during final assembly.

The press–sinter–re-press method (PSR) allows the economic manufacturing of shaped contact parts with silver or copper contents > 70 wt%. This process also involves alloying the parts pressed in two layers, with the top being the contact material and the bottom being pure Ag or Cu for easy adhesion.

Press–sinter processes are limited to smaller Ag/W contact tips, with a Ag content of approximately 65 wt%.

  • Contact materials
    Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO2, Ag/ZnO, Ag/C, Ag/W, Ag/WC, Ag/WC/C, Ag/Mo, Cu/W
  • Typical contact shapes of tips and formed contact parts (Figure 11)
Figure 11: Typical contact shapes of tips and formed contact parts


  • Dimensional ranges
    Attachment Method: Welding
    Bonding Area: approx. 5 – 25 mm2
    Attachment Method: Brazing
    Bonding Area: > 25 mm2

Because of the wide variety of shapes of contact tips and formed contact parts, the user and manufacturer usually develops special, part specific agreements on quality and tolerances.

Weld Buttons

For contacts used at higher temperatures, such as for example in controls for stove tops, the use of contact rivets or the direct welding of silver based contact materials on steel or thermo-bimetal carriers is usually not feasible. For such applications, weld buttons are suitable contact components.

Weld buttons are round or rectangular tips, manufactured from clad contact bimetal or in some cases tri-metal semi-finished materials. The surface layer is produced from the specified contact material, the bottom weldable layer from a material with higher electrical resistivity such as steel, nickel or for example a copper-nickel alloy. For precious metal savings, a third high conductive layer of copper may be inserted between the contact material and weld backing. To improve the welding process, the underside often has an embossed pattern with one or more weld projections.

The manufacturing of weld buttons from bi– or tri–metal strip requires a ductile contact material. Weld buttons with tungsten contact layers are therefore produced by brazing of tungsten discs to a weldable pre-formed base.

  • Typical contact forms of weld buttons (Figure 12)
  • Contact materials
    Ag, AgNi 0,15, AgCu, AgCuNi (ARGODUR 27), Ag/Ni, Ag/SnO2, Ag/ZnO
  • Carrier materials
    Ni, Fe, CuNi, CuNiZn et.al.
  • Dimensional Ranges (Figure 13)
  • Quality criteria of standard weld buttons (Figure 14)
Figure 12: Typical contact forms of weld buttons
Figure 13: Dimensional Ranges
Figure 14: Quality criteria of standard weld buttons

References

Manufacturing Technologies for Contact Parts