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→Silver–Graphite (GRAPHOR)-Materials
manufacturing process of single pressed tips by pressing - sintering - repressing (PSR) has been replaced in Europe for quite some time by extrusion. In North America and some other regions however the PSR process is still used to some extend mainly for cost reasons.
The extrusion of sintered billets is now the dominant manufacturing method for semi-finished AgC materials ''(Figs. 2.126 – 2.129)''. The hot extrusion process results in a high density material with graphite particles stretched and oriented in the extrusion direction ''(Figs. 2.130 – 2.133)''. Depending on the extrusion method in either rod or strip form the graphite particles can be oriented in the finished contact tips perpendicular (GRAPHOR) or parallel (GRAPHOR D) to the switching contact surface ''<xr id="fig:fig2.131"/> (FigsFig. 2.131 ) and <xr id="fig:fig2.132"/> (Fig. 2.132)''.
Since the graphite particles in the Ag matrix of Ag/C materials prevent contact tips from directly being welded or brazed, a graphite free bottom layer is required. This is achieved by either burning out (de-graphitizing) the graphite selectively on one side of the tips or by compound extrusion of a Ag/C billet covered with a fine silver shell.
is especially high for materials with the graphite particle orientation parallel to the arcing contact surface. Since the contact surface after arcing consists of pure silver the contact resistance stays consistently low during the electrical life of the contact parts.
A disadvantage of the Ag/C materials is their rather high erosion rate. In materials with parallel graphite orientation this can be improved if part of the graphite is incorporated into the material in the form of fibers (GRAPHOR DF), ''<xr id="fig:fig2.133"/> (Fig. 2.133)''. The weld resistance is determined by the total content of graphite particles.
Ag/C tips with vertical graphite particle orientation are produced in a specific sequence: Extrusion to rods, cutting of double thickness tips, burning out of graphite to a controlled layer thickness, and a second cutting to single tips. Such contact tips are especially well suited for applications which require both, a high weld resistance and a sufficiently high arc erosion resistance ''<xr id="tab:tab2.33"/> (Table 2.33)''. For attachment of Ag/C tips welding and brazing techniques are applied.
welding the actual process depends on the material's graphite orientation. For Ag/C tips with vertical graphite orientation the contacts are assembled with single tips. For parallel orientation a more economical attachment starting with contact material in strip or profile tape form is used in integrated stamping and welding operations with the tape fed into the weld station, cut off to tip form and then welded to the carrier material before forming the final contact assembly part. For special low energy welding the Ag/C profile tapes GRAPHOR D and DF can be pre-coated with a thin layer of high temperature brazing alloys such as CuAgP.
In a rather limited way, Ag/C with 2 – 3 wt% graphite can be produced in wire form and headed into contact rivet shape with low head deformation ratios.
The main applications for Ag/C materials are protective switching devices such as miniature molded case circuit breakers, motor-protective circuit breakers, and fault current circuit breakers, where during short circuit failures highest resistance against welding is required ''<xr id="tab:tab2.34"/> (Table 2.34)''. For higher currents the low arc erosion resistance of Ag/C is compensated by asymmetrical pairing with more erosion resistant materials such as Ag/Ni and Ag/W.
Fig. 2.126: Strain hardening of Ag/C 96/4 D by cold working
