Changes

===3.5 Stamped Contact Parts===Stamped electrical contact parts typically consist of a base carrier material towhich a contact material is attached by various methods ''<xr id="fig:Plated_and_contact_containing_pre_stamped_strips_and_stamped_parts"/><!--(Fig. 3.17)''-->. <figure id="fig:Plated_and_contact_containing_pre_stamped_strips_and_stamped_parts">[[File:Plated and contact containing pre-stamped strips and stamped parts.jpg|right|thumb|Plated and contact containing pre-stamped strips and stamped parts for different applications]]</figure>They serveas the important functional components in many switching andelectromechanical devices for a broad range of electrical and electronicapplications. On the one hand they perform the mostly loss-free electricalcurrent transfer and the closing and opening of electrical circuits. In addition thecontact carriers are important mechanical design components selected to meetthe requirements on electrical, thermal, mechanical and magnetic properties.

The increasing miniaturization of electromechanical components requires eversmaller stamped parts with low dimensional tolerances. Such precisionstamped parts are needed in the automotive technology for highly reliableswitching and connector performance. In the information and data processingtechnology they transfer signals and control impulses with high reliability andserve as the interface between electronic and electrical components.

 ===3.5.1 Types of Stamped Parts===Stamped parts are produced as single pieces, in pre-stamped strip and combconfigurations. Depending on the requirements and application the contact andbase material as well as the coating and attachment technology is carefullyselected.

Stamped parts can be selectively or completely coated with precious metalcontaining materials based on gold, palladium, and silver as well asnon-precious materials such as tin, nickel and copper ''<xr id="fig:Plated and contact containing pre-stamped strips and stamped parts"/><!--(Fig. 3.17)''-->. <figure id="fig:Plated and contact containing pre-stamped strips and stamped parts">[[File:Plated and contact containing pre-stamped strips and stamped parts.jpg|right|thumb|Plated and contact containing pre-stamped strips and stamped parts for different applications]]</figure>For stampedparts in high volumes like those used as electrical components in automobilesthe carrier material is mostly coated in a reel-to-reel process starting with eithersolid or pre-stamped strips (see also chapter 7.1.1.3[[Electroplating (or Galvanic Deposition)#Electroplating of Semi-finished Materials| Electroplating of Semi-finished Materials]]). Frequently the prestampedstrip will be used directly in further automated assembly of the finishedfunctional component. As an alternative finished stamped parts can beelectroplated using barrel and rack plating methods.

Very thin coating layers with tight tolerances are deposited by electroplating. Formany applications the high mechanical wear resistance is advantageous. Sinceeven very thin layers are mostly pore-free, these coatings also act as aneffective corrosion inhibitor. The type of coatings, the sequence of multiplelayers, and the coating thickness, for example for connectors, are chosenaccording to the requirements for the end application.

For many applications thicker precious metal surfaces or AlSi layers arenecessary. These cannot be deposited by electroplating. Besides meltmetallurgicallyproduced materials on the basis of gold, palladium and silver,also powder-metallurgical materials are required frequently. The metallurgicalbond between these contact materials and the mostly copper based substratesis achieved through various mechanical cladding methods (see also chapter3.2.1[[Manufacturing of Semi-Finished Materials#Clad Semi-Finished Pre-Materials (Contact-Bimetals)| Clad Semi-Finished Pre-Materials (Contact-Bimetals)]]). In this way also aluminum clad strips are manufactured in which thealuminum layer serves as the bondable surface in the interface betweenelectromechanical connections and electronic circuits. These clad semifinishedmaterials can be further fabricated into pre-stamped strips, in combform, or single stamped parts ''<xr id="fig:Examples of clad stamped parts"/><!--(Fig. 3.18)''-->.

Fig. 3.18<figure id="fig:Examples of clad stamped parts">[[File:Examples of clad stamped parts.jpg|right|thumb|Examples of clad stamped parts]]</figure>

Welded stamped parts can be fabricated by various methods (see also Chapter3.3.3chapter [[Attachment of Single Contact Parts#Welding Processes| Welding Processes]]). Single contact pieces can be attached to pre-stamped or finishedstamped strips as weld buttons and wire or profile segments by electricalresistance welding. Contact parts can also be stamped from seam-weldedsemi-finished strip. Fitting the end application contact materials based on gold,palladium and silver. Depending on the contact material and the design of thefinished contact component the contact bottom surface may be consist of aweldable backing material.

Brazed stamped contact assemblies are manufactured by two joining methods(see also chapter 3.3.2[[Attachment of Single Contact Parts#Brazing Processes| Brazing Processes]]). The contact material is either attached by resistanceor induction brazing to base metal carriers as prefabricated contact tip or theyare stamped from brazed semi-finished toplay strip. It is typical for brazedcontact parts that the contact material consists of silver based contact materialand a good conducting copper base material with larger cross-sectional areafor the usually higher current carrying capacity.

Riveted stamped contact parts are manufactured with the use of contact rivetswhich are transferred over suitable feed mechanisms correctly oriented intoholes punched into the carrier ''<xr id="fig:Examples of riveted stamped parts"/><!--(Fig. 3.19)''-->. Frequently also wire or wire segmentsresp. are used which are subsequently coined and formed into the desiredcontact shape (see also chapter 3.3.1[[Attachment of Single Contact Parts#Mechanical Attachment Processes| Mechanical Attachment Processes]]). Both attachment methods have theirdistinct advantages. Using composite or tri-metal rivets allows limiting the useof precious metal custom tailored to the volume needed for specific switchingrequirements. For wire staking the precious metal usage is usually higher butthe staking can be performed at significantly higher production ratesand the additional rivet making step is eliminated.<figure id="fig:Examples of riveted stamped parts">Fig. 3[[File:Examples of riveted stamped parts.19:jpg|right|thumb|Examples of riveted stamped parts]]</figure>

Components stamped parts consist of a minimum of two carrier parts whichdiffer in their material composition and geometrical form and the contactmaterial''<xr id="fig:Examples of pre-mounted stamped component parts"/><!--(Fig. 3.2120?)''-->. The assembly of these components as single pieces or stampingprogressions is performed in a stamping die by riveting or coining. To increasethe current carrying capacity at the joining area an additional welding step canbe added. Depending on the requirements the different properties of the twocarrier components can be combined. As an example: the high electricalconductivity of a contact carrier blade is joined with the thermal or mechanicalspring properties of a second material to form a functional component. For thisprocess both carrier base materials can also be coated with additionallayers of other functional materials.<figure id="fig:Examples of pre-mounted stamped component parts">[[File:Examples of pre-mounted stamped component parts.jpg|right|thumb|Examples of pre-mounted stamped component parts]]</figure>

Fig. 3Stamped parts which are insert molded into or combined with plastic parts are used in electromechanical components (see Chapter [[Electromechanical Components | Electromechanical Components ]]).20:Examples of pre-mounted stampedcomponent parts

Stamped parts which === Stamping Tools===For the design of stamping tools the latest CAD software systems are insert molded into or combined used.Modern stamping tools usually employ a modular design with plastic integrated dimensional and functional controls <xr id="fig:Progressive die for stamped contact parts"/><!--(Fig. 3.21)-->. <figure id="fig:Progressive die for stamped contact parts ">[[File:Progressive die for stamped contact parts.jpg|right|thumb|Progressive die for stamped contact parts]]</figure>Depending on the requirements on the parts and the volumes they areused in electromechanical components built with steel or carbide (see Chapter 10-steel)inserts which are coated with a wear resistant material such as for example TiN for longer life.

===3A special stamping process is precision stamping for contact parts made from thin strip materials with thicknesses in the range of 0.05 – 2.5mm. With high capacity stamping technology up to 1400 strokes/min can be reached for high volume parts.2 Stamping Tools===For During the design actual stamping operation frequently other processes such as thread-forming, welding of stamping tools the latest CAD software systems contact segments and insertion and forming of contacts from wire segments are used.Modern stamping tools usually employ a modular design with integrateddimensional and functional controls ''(Fig. 3.21)''. Depending on the requirementson the parts and the production volumes they are built with steel or carbide (-steel) insertswhich are coated with a wear resistant material such as for example TiN forlonger lifethese operations can also be performed in multiples.

A special The quality of the tools used for stamping process , like progressive dies and stamp-forming tools is precision stamping important for contact parts made fromthin strip materials with thicknesses in the range final precision and consistency of 0the parts.05 – 2.5 mm. With During highcapacity speed stamping technology up the tools are exposed to 1400 strokes/min can extreme mechanical stresses which must be reached compensated for to ensure the highest precision over long production runs. With such highvolume quality progressive dies partsof high precision with a cutting width of less than the material thickness and with strict quality requirements for the cutting surfaces can be manufactured. During To ensure the highest demands on the actual stamping operation frequently other processessuch as thread-forming, welding surface quality of precision contact segments parts quite often vanishing oils are used as tool lubricants. Cleaning and insertion degreasing operations can also be integrated into the stamping process. Additionally most stamping lines are also equipped with test stations for a 100% dimensional and formingsurface quality control.During the design of stamping tools for electrical contacts from wire segments are integrated. Depending on minimizing of process scrap and the possibility to separate the productionvolumes these operations can also precious metal containing scrap must be performed in multiplesconsidered.

The quality of the tools used for stamping, like progressive dies and stamp-formingtools is important for the final precision and consistency of the parts. During highspeed stamping the tools are exposed to extreme mechanical stresses which mustbe compensated for to ensure the highest precision over long production runs. Withsuch high quality progressive dies parts of high precision with a cutting width of lessthan the material thickness and with strict quality requirements for the cutting surfacescan be manufactured.==References==To ensure the highest demands on the surface quality of precision contact parts quiteoften vanishing oils are used as tool lubricants. Cleaning and degreasing operationscan also be integrated into the stamping process. Additionally most stamping linesare also equipped with test stations [[:Manufacturing Technologies for a 100% dimensional and surface qualitycontrol.During the design of stamping tools for electrical contacts minimizing of processscrap and the possibility to separate the precious metal containing scrap must beconsidered.Contact Parts#References|References]]

Fig. 3.21:Progressive die for stamped contact parts[[Categoryde:Manufacturing Technologies for Contact Parts|CategoryStanzteile]]