Difference between revisions of "Stamped Contact Parts"

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Stamped electrical contact parts typically consist of a base carrier material to
+
==Stamped Contact Parts==
which a contact material is attached by various methods ''(Fig. 3.17)''. They serve
+
Stamped electrical contact parts typically consist of a base carrier material to which a contact material is attached by various methods <xr id="fig:Plated_and_contact_containing_pre_stamped_strips_and_stamped_parts"/><!--(Fig. 3.17)-->.  
as the important functional components in many switching and
+
<figure id="fig:Plated_and_contact_containing_pre_stamped_strips_and_stamped_parts">
electromechanical devices for a broad range of electrical and electronic
+
[[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]]
applications. On the one hand they perform the mostly loss-free electrical
+
</figure>
current transfer and the closing and opening of electrical circuits. In addition the
+
They serve as the important functional components in many switching and electromechanical devices for a broad range of electrical and electronic
contact carriers are important mechanical design components selected to meet
+
applications. On the one hand they perform the mostly loss-free electrical current transfer and the closing and opening of electrical circuits. In addition the contact carriers are important mechanical design components selected to meet the requirements on electrical, thermal, mechanical and magnetic properties.
the requirements on electrical, thermal, mechanical and magnetic properties.
 
  
The increasing miniaturization of electromechanical components requires ever
+
The increasing miniaturization of electromechanical components requires ever smaller stamped parts with low dimensional tolerances. Such precision
smaller stamped parts with low dimensional tolerances. Such precision
+
stamped parts are needed in the automotive technology for highly reliable switching and connector performance. In the information and data processing
stamped parts are needed in the automotive technology for highly reliable
+
technology they transfer signals and control impulses with high reliability and serve as the interface between electronic and electrical components.
switching and connector performance. In the information and data processing
 
technology they transfer signals and control impulses with high reliability and
 
serve as the interface between electronic and electrical components.
 
  
Fig. 3.17:
 
Plated and contact
 
containing pre-stamped strips and
 
stamped parts for different
 
applications
 
  
 
+
=== Types of Stamped Parts===
== Types of Stamped Parts==
+
Stamped parts are produced as single pieces, in pre-stamped strip and comb configurations. Depending on the requirements and application the contact and base material as well as the coating and attachment technology is carefully selected.
Stamped parts are produced as single pieces, in pre-stamped strip and comb
 
configurations. Depending on the requirements and application the contact and
 
base material as well as the coating and attachment technology is carefully
 
selected.
 
  
 
*Coated stamped parts
 
*Coated stamped parts
Stamped parts can be selectively or completely coated with precious metal
+
Stamped parts can be selectively or completely coated with precious metal containing materials based on gold, palladium, and silver as well as
containing materials based on gold, palladium, and silver as well as
+
non-precious materials such as tin, nickel and copper <xr id="fig:Plated and contact containing pre-stamped strips and stamped parts"/><!--(Fig. 3.17)-->.
non-precious materials such as tin, nickel and copper ''(Fig. 3.17)''. For stamped
+
<figure id="fig:Plated and contact containing pre-stamped strips and stamped parts">
parts in high volumes like those used as electrical components in automobiles
+
[[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]]
the carrier material is mostly coated in a reel-to-reel process starting with either
+
</figure>
solid or pre-stamped strips (see also chapter 7.1.1.3). Frequently the prestamped
+
For stamped parts in high volumes like those used as electrical components in automobiles the carrier material is mostly coated in a reel-to-reel process starting with either solid or pre-stamped strips (see also chapter [[Electroplating (or Galvanic Deposition)#Electroplating of Semi-finished Materials| Electroplating of Semi-finished Materials]]). Frequently the prestamped strip will be used directly in further automated assembly of the finished functional component. As an alternative finished stamped parts can be electroplated using barrel and rack plating methods.
strip will be used directly in further automated assembly of the finished
 
functional component. As an alternative finished stamped parts can be
 
electroplated using barrel and rack plating methods.
 
  
Very thin coating layers with tight tolerances are deposited by electroplating. For
+
Very thin coating layers with tight tolerances are deposited by electroplating. For many applications the high mechanical wear resistance is advantageous. Since even very thin layers are mostly pore-free, these coatings also act as an effective corrosion inhibitor. The type of coatings, the sequence of multiple layers, and the coating thickness, for example for connectors, are chosen according to the requirements for the end application.
many applications the high mechanical wear resistance is advantageous. Since
 
even very thin layers are mostly pore-free, these coatings also act as an
 
effective corrosion inhibitor. The type of coatings, the sequence of multiple
 
layers, and the coating thickness, for example for connectors, are chosen
 
according to the requirements for the end application.
 
  
 
*Clad stamped parts
 
*Clad stamped parts
  
For many applications thicker precious metal surfaces or AlSi layers are
+
For many applications thicker precious metal surfaces or AlSi layers are necessary. These cannot be deposited by electroplating. Besides meltmetallurgically produced materials on the basis of gold, palladium and silver, also powder-metallurgical materials are required frequently. The metallurgical bond between these contact materials and the mostly copper based substrates is achieved through various mechanical cladding methods (see also chapter [[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 the aluminum layer serves as the bondable surface in the interface between electromechanical connections and electronic circuits. These clad semifinished materials can be further fabricated into pre-stamped strips, in comb form, or single stamped parts <xr id="fig:Examples of clad stamped parts"/><!--(Fig. 3.18)-->.
necessary. These cannot be deposited by electroplating. Besides meltmetallurgically
 
produced materials on the basis of gold, palladium and silver,
 
also powder-metallurgical materials are required frequently. The metallurgical
 
bond between these contact materials and the mostly copper based substrates
 
is achieved through various mechanical cladding methods (see also chapter
 
3.2.1). In this way also aluminum clad strips are manufactured in which the
 
aluminum layer serves as the bondable surface in the interface between
 
electromechanical connections and electronic circuits. These clad semifinished
 
materials can be further fabricated into pre-stamped strips, in comb
 
form, or single stamped parts ''(Fig. 3.18)''.
 
  
Fig. 3.18:
+
<figure id="fig:Examples of clad stamped parts">
Examples of clad stamped parts
+
[[File:Examples of clad stamped parts.jpg|right|thumb|Examples of clad stamped parts]]
 +
</figure>
  
 
*Welded stamped parts
 
*Welded stamped parts
  
Welded stamped parts can be fabricated by various methods (see also Chapter
+
Welded stamped parts can be fabricated by various methods (see also chapter [[Attachment of Single Contact Parts#Welding Processes| Welding Processes]]). Single contact pieces can be attached to pre-stamped or finished stamped strips as weld buttons and wire or profile segments by electrical resistance welding. Contact parts can also be stamped from seam-welded semi-finished strip. Fitting the end application contact materials based on gold, palladium and silver. Depending on the contact material and the design of the finished contact component the contact bottom surface may be consist of a weldable backing material.
3.3.3). Single contact pieces can be attached to pre-stamped or finished
 
stamped strips as weld buttons and wire or profile segments by electrical
 
resistance welding. Contact parts can also be stamped from seam-welded
 
semi-finished strip. Fitting the end application contact materials based on gold,
 
palladium and silver. Depending on the contact material and the design of the
 
finished contact component the contact bottom surface may be consist of a
 
weldable backing material.
 
  
 
*Brazed stamped parts
 
*Brazed stamped parts
  
Brazed stamped contact assemblies are manufactured by two joining methods
+
Brazed stamped contact assemblies are manufactured by two joining methods (see also chapter [[Attachment of Single Contact Parts#Brazing Processes| Brazing Processes]]). The contact material is either attached by resistance or induction brazing to base metal carriers as prefabricated contact tip or they are stamped from brazed semi-finished toplay strip. It is typical for brazed contact parts that the contact material consists of silver based contact material and a good conducting copper base material with larger cross-sectional area for the usually higher current carrying capacity.
(see also chapter 3.3.2). The contact material is either attached by resistance
 
or induction brazing to base metal carriers as prefabricated contact tip or they
 
are stamped from brazed semi-finished toplay strip. It is typical for brazed
 
contact parts that the contact material consists of silver based contact material
 
and a good conducting copper base material with larger cross-sectional area
 
for the usually higher current carrying capacity.
 
  
 
*Stamped contact parts with rivets
 
*Stamped contact parts with rivets
  
Riveted stamped contact parts are manufactured with the use of contact rivets
+
Riveted stamped contact parts are manufactured with the use of contact rivets which are transferred over suitable feed mechanisms correctly oriented into holes punched into the carrier <xr id="fig:Examples of riveted stamped parts"/><!--(Fig. 3.19)-->. Frequently also wire or wire segments resp. are used which are subsequently coined and formed into the desired contact shape (see also chapter [[Attachment of Single Contact Parts#Mechanical Attachment Processes| Mechanical Attachment Processes]]). Both attachment methods have their distinct advantages. Using composite or tri-metal rivets allows limiting the use of precious metal custom tailored to the volume needed for specific switching requirements. For wire staking the precious metal usage is usually higher but the staking can be performed at significantly higher production rates and the additional rivet making step is eliminated.
which are transferred over suitable feed mechanisms correctly oriented into
+
<figure id="fig:Examples of riveted stamped parts">
holes punched into the carrier ''(Fig. 3.19)''. Frequently also wire or wire segments
+
[[File:Examples of riveted stamped parts.jpg|right|thumb|Examples of riveted stamped parts]]
resp. are used which are subsequently coined and formed into the desired
+
</figure>
contact shape (see also chapter 3.3.1). Both attachment methods have their
 
distinct advantages. Using composite or tri-metal rivets allows limiting the use
 
of precious metal custom tailored to the volume needed for specific switching
 
requirements. For wire staking the precious metal usage is usually higher but
 
the staking can be performed at significantly higher production rates
 
and the additional rivet making step is eliminated.
 
 
 
Fig. 3.19:
 
Examples of riveted stamped parts
 
  
 
*Pre-mounted component stamped parts
 
*Pre-mounted component stamped parts
  
Components stamped parts consist of a minimum of two carrier parts which
+
Components stamped parts consist of a minimum of two carrier parts which differ in their material composition and geometrical form and the contact
differ in their material composition and geometrical form and the contact
+
material <xr id="fig:Examples of pre-mounted stamped component parts"/><!--(Fig. 3.20?)-->. The assembly of these components as single pieces or stamping progressions is performed in a stamping die by riveting or coining. To increase the current carrying capacity at the joining area an additional welding step can be added. Depending on the requirements the different properties of the two carrier components can be combined. As an example: the high electrical conductivity of a contact carrier blade is joined with the thermal or mechanical spring properties of a second material to form a functional component. For this process both carrier base materials can also be coated with additional layers of other functional materials.
material
+
<figure id="fig:Examples of pre-mounted stamped component parts">
''(Fig. 3.21)''. The assembly of these components as single pieces or stamping
+
[[File:Examples of pre-mounted stamped component parts.jpg|right|thumb|Examples of pre-mounted stamped component parts]]
progressions is performed in a stamping die by riveting or coining. To increase
+
</figure>
the current carrying capacity at the joining area an additional welding step can
 
be added. Depending on the requirements the different properties of the two
 
carrier components can be combined. As an example: the high electrical
 
conductivity of a contact carrier blade is joined with the thermal or mechanical
 
spring properties of a second material to form a functional component. For this
 
process both carrier base materials can also be coated with additional
 
layers of other functional materials.
 
  
Fig. 3.20:
+
Stamped parts which are insert molded into or combined with plastic parts are used in electromechanical components (see Chapter [[Electromechanical Components | Electromechanical Components ]]).
Examples of pre-mounted stamped
 
component parts
 
  
Stamped parts which are insert molded into or combined with plastic parts are
+
=== Stamping Tools===
used in electromechanical components (see Chapter 10).
 
 
 
== Stamping Tools==
 
 
For the design of stamping tools the latest CAD software systems are used.
 
For the design of stamping tools the latest CAD software systems are used.
Modern stamping tools usually employ a modular design with integrated
+
Modern stamping tools usually employ a modular design with integrated dimensional and functional controls <xr id="fig:Progressive die for stamped contact parts"/><!--(Fig. 3.21)-->.  
dimensional and functional controls ''(Fig. 3.21)''. Depending on the requirements
+
<figure id="fig:Progressive die for stamped contact parts">
on the parts and the volumes they are built with steel or carbide (-steel) inserts
+
[[File:Progressive die for stamped contact parts.jpg|right|thumb|Progressive die for stamped contact parts]]
which are coated with a wear resistant material such as for example TiN for
+
</figure>
longer life.
+
Depending on the requirements on the parts and the volumes they are built with steel or carbide (-steel) inserts which are coated with a wear resistant material such as for example TiN for longer life.
  
A special stamping process is precision stamping for contact parts made from
+
A special stamping process is precision stamping for contact parts made from thin strip materials with thicknesses in the range of 0.05 – 2.5 mm. With high capacity stamping technology up to 1400 strokes/min can be reached for high volume parts. During the actual stamping operation frequently other processes such as thread-forming, welding of contact segments and insertion and forming of contacts from wire segments are integrated. Depending on the production volumes these operations can also be performed in multiples.
thin strip materials with thicknesses in the range of 0.05 – 2.5 mm. With high
 
capacity stamping technology up to 1400 strokes/min can be reached for high
 
volume parts. During the actual stamping operation frequently other processes
 
such as thread-forming, welding of contact segments and insertion and forming
 
of contacts from wire segments are integrated. Depending on the production
 
volumes these operations can also be performed in multiples.
 
  
The quality of the tools used for stamping, like progressive dies and stamp-forming
+
The quality of the tools used for stamping, like progressive dies and stamp-forming tools is important for the final precision and consistency of the parts. During high speed stamping the tools are exposed to extreme mechanical stresses which must be compensated for to ensure the highest precision over long production runs. With such high quality progressive dies parts of high precision with a cutting width of less than the material thickness and with strict quality requirements for the cutting surfaces can be manufactured.  
tools is important for the final precision and consistency of the parts. During high
+
To ensure the highest demands on the surface quality of precision contact parts quite often vanishing oils are used as tool lubricants. Cleaning and 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 surface quality control.
speed stamping the tools are exposed to extreme mechanical stresses which must
+
During the design of stamping tools for electrical contacts minimizing of process scrap and the possibility to separate the precious metal containing scrap must be considered.
be compensated for to ensure the highest precision over long production runs. With
 
such high quality progressive dies parts of high precision with a cutting width of less
 
than the material thickness and with strict quality requirements for the cutting surfaces
 
can be manufactured.
 
To ensure the highest demands on the surface quality of precision contact parts quite
 
often vanishing oils are used as tool lubricants. Cleaning and 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 surface quality
 
control.
 
During the design of stamping tools for electrical contacts minimizing of process
 
scrap and the possibility to separate the precious metal containing scrap must be
 
considered.
 
 
 
Fig. 3.21:
 
Progressive die for stamped contact parts
 
[[Category:Manufacturing Technologies for Contact Parts|Category]]
 
  
 
==References==
 
==References==
 
[[:Manufacturing Technologies for Contact Parts#References|References]]
 
[[:Manufacturing Technologies for Contact Parts#References|References]]
 +
 +
[[de:Stanzteile]]

Revision as of 12:09, 21 September 2014

Stamped Contact Parts

Stamped electrical contact parts typically consist of a base carrier material to which a contact material is attached by various methods Figure 1.

Plated and contact containing pre-stamped strips and stamped parts for different applications

They serve as the important functional components in many switching and electromechanical devices for a broad range of electrical and electronic applications. On the one hand they perform the mostly loss-free electrical current transfer and the closing and opening of electrical circuits. In addition the contact carriers are important mechanical design components selected to meet the requirements on electrical, thermal, mechanical and magnetic properties.

The increasing miniaturization of electromechanical components requires ever smaller stamped parts with low dimensional tolerances. Such precision stamped parts are needed in the automotive technology for highly reliable switching and connector performance. In the information and data processing technology they transfer signals and control impulses with high reliability and serve as the interface between electronic and electrical components.


Types of Stamped Parts

Stamped parts are produced as single pieces, in pre-stamped strip and comb configurations. Depending on the requirements and application the contact and base material as well as the coating and attachment technology is carefully selected.

  • Coated stamped parts

Stamped parts can be selectively or completely coated with precious metal containing materials based on gold, palladium, and silver as well as non-precious materials such as tin, nickel and copper Figure 2.

Plated and contact containing pre-stamped strips and stamped parts for different applications

For stamped parts in high volumes like those used as electrical components in automobiles the carrier material is mostly coated in a reel-to-reel process starting with either solid or pre-stamped strips (see also chapter Electroplating of Semi-finished Materials). Frequently the prestamped strip will be used directly in further automated assembly of the finished functional component. As an alternative finished stamped parts can be electroplated using barrel and rack plating methods.

Very thin coating layers with tight tolerances are deposited by electroplating. For many applications the high mechanical wear resistance is advantageous. Since even very thin layers are mostly pore-free, these coatings also act as an effective corrosion inhibitor. The type of coatings, the sequence of multiple layers, and the coating thickness, for example for connectors, are chosen according to the requirements for the end application.

  • Clad stamped parts

For many applications thicker precious metal surfaces or AlSi layers are necessary. These cannot be deposited by electroplating. Besides meltmetallurgically produced materials on the basis of gold, palladium and silver, also powder-metallurgical materials are required frequently. The metallurgical bond between these contact materials and the mostly copper based substrates is achieved through various mechanical cladding methods (see also chapter Clad Semi-Finished Pre-Materials (Contact-Bimetals)). In this way also aluminum clad strips are manufactured in which the aluminum layer serves as the bondable surface in the interface between electromechanical connections and electronic circuits. These clad semifinished materials can be further fabricated into pre-stamped strips, in comb form, or single stamped parts Figure 3.

Examples of clad stamped parts
  • Welded stamped parts

Welded stamped parts can be fabricated by various methods (see also chapter Welding Processes). Single contact pieces can be attached to pre-stamped or finished stamped strips as weld buttons and wire or profile segments by electrical resistance welding. Contact parts can also be stamped from seam-welded semi-finished strip. Fitting the end application contact materials based on gold, palladium and silver. Depending on the contact material and the design of the finished contact component the contact bottom surface may be consist of a weldable backing material.

  • Brazed stamped parts

Brazed stamped contact assemblies are manufactured by two joining methods (see also chapter Brazing Processes). The contact material is either attached by resistance or induction brazing to base metal carriers as prefabricated contact tip or they are stamped from brazed semi-finished toplay strip. It is typical for brazed contact parts that the contact material consists of silver based contact material and a good conducting copper base material with larger cross-sectional area for the usually higher current carrying capacity.

  • Stamped contact parts with rivets

Riveted stamped contact parts are manufactured with the use of contact rivets which are transferred over suitable feed mechanisms correctly oriented into holes punched into the carrier Figure 4. Frequently also wire or wire segments resp. are used which are subsequently coined and formed into the desired contact shape (see also chapter Mechanical Attachment Processes). Both attachment methods have their distinct advantages. Using composite or tri-metal rivets allows limiting the use of precious metal custom tailored to the volume needed for specific switching requirements. For wire staking the precious metal usage is usually higher but the staking can be performed at significantly higher production rates and the additional rivet making step is eliminated.

Examples of riveted stamped parts
  • Pre-mounted component stamped parts

Components stamped parts consist of a minimum of two carrier parts which differ in their material composition and geometrical form and the contact material Figure 5. The assembly of these components as single pieces or stamping progressions is performed in a stamping die by riveting or coining. To increase the current carrying capacity at the joining area an additional welding step can be added. Depending on the requirements the different properties of the two carrier components can be combined. As an example: the high electrical conductivity of a contact carrier blade is joined with the thermal or mechanical spring properties of a second material to form a functional component. For this process both carrier base materials can also be coated with additional layers of other functional materials.

Examples of pre-mounted stamped component parts

Stamped parts which are insert molded into or combined with plastic parts are used in electromechanical components (see Chapter Electromechanical Components ).

Stamping Tools

For the design of stamping tools the latest CAD software systems are used. Modern stamping tools usually employ a modular design with integrated dimensional and functional controls Figure 6.

Progressive die for stamped contact parts

Depending on the requirements on the parts and the volumes they are built with steel or carbide (-steel) inserts which are coated with a wear resistant material such as for example TiN for longer life.

A special stamping process is precision stamping for contact parts made from thin strip materials with thicknesses in the range of 0.05 – 2.5 mm. With high capacity stamping technology up to 1400 strokes/min can be reached for high volume parts. During the actual stamping operation frequently other processes such as thread-forming, welding of contact segments and insertion and forming of contacts from wire segments are integrated. Depending on the production volumes these operations can also be performed in multiples.

The quality of the tools used for stamping, like progressive dies and stamp-forming tools is important for the final precision and consistency of the parts. During high speed stamping the tools are exposed to extreme mechanical stresses which must be compensated for to ensure the highest precision over long production runs. With such high quality progressive dies parts of high precision with a cutting width of less than the material thickness and with strict quality requirements for the cutting surfaces can be manufactured. To ensure the highest demands on the surface quality of precision contact parts quite often vanishing oils are used as tool lubricants. Cleaning and 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 surface quality control. During the design of stamping tools for electrical contacts minimizing of process scrap and the possibility to separate the precious metal containing scrap must be considered.

References

References