Changes

==Stamped Contact Parts==Stamped electrical contact parts typically consist of a base carrier material towhich a contact material is attached by various methods ''(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|Figure 1: 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 A great advantage ist that 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.

== Types of *'''Coated stamped parts'''Stamped Parts==parts can be selectively or completely coated with precious metal, containing materials based on gold, palladium, and silver as well asnon-precious materials such as tin, nickel and copper.Stamped For stamped parts are produced in high volumes like those used as single pieceselectrical components in automobiles, the carrier material is mostly coated in a reel-to-reel process, starting with either solid or pre-stamped strip and combconfigurationsstrips (see also chapter [[Electroplating (or Galvanic Deposition)#Electroplating of Semi-finished Materials| Electroplating of Semi-finished Materials]]). Depending on Frequently the requirements and application prestamped strip will be used directly in further automated assembly of the contact andbase material as well as the coating finished functional component (<xr id="fig:Plated_and_contact_containing_pre_stamped_strips_and_stamped_parts"/>). As an alternative, finished stamped parts can be electroplated using barrel and attachment technology is carefullyselectedrack plating methods.

*Coated stamped partsStamped parts can be selectively or completely coated Very thin coating layers with precious metalcontaining materials based on gold, palladium, and silver as well asnon-precious materials such as tin, nickel and copper ''(Fig. 3.17)''tight tolerances are deposited by electroplating. For stampedparts in many applications, the high volumes like those used as electrical components in automobilesthe carrier material mechanical wear resistance is advantageous. Since even, very thin layers are mostly coated in a reelpore-to-reel process starting with eithersolid or pre-stamped strips (see free. These coatings also chapter 7act as an effective corrosion inhibitor.1.1.3). Frequently The type of coatings, the prestampedstrip will be used directly in further automated assembly sequence of multiple layers and the finishedfunctional component. As an alternative finished stamped parts can beelectroplated using barrel and rack plating methodscoating thickness, for example for connectors, are chosen according to the requirements for the end application.

*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)-->).

For many applications thicker precious metal surfaces or AlSi layers arenecessary. These cannot be deposited by electroplating. Besides meltmetallurgically<figure id="fig:Examples of clad stamped parts">produced materials on the basis [[File:Examples 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 chapter3clad stamped parts.jpg|right|thumb|Figure 2.1). 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 : Examples of clad semifinishedmaterials can be further fabricated into pre-stamped strips, in combparts]]form, or single stamped parts ''(Fig. 3.18)''.</figure>

Fig. 3.18:Examples of clad *'''Welded stamped parts'''

*Welded stamped partscan 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.

Welded *'''Brazed stamped parts can be fabricated by various methods (see also Chapter3.3.3). 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 [[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 partsthat 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.

Brazed stamped contact assemblies are manufactured by two joining methods(see also chapter 3.3.2). 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 brazed*'''Stamped contact 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.rivets'''

*Stamped 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 rivetsallows 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.<figure id="fig:Examples of riveted stamped parts">[[File:Examples of riveted stamped parts.jpg|right|thumb|Figure 3: Examples of riveted stamped parts]]</figure>

Riveted *'''Pre-mounted component stamped contact parts are manufactured with the use of contact rivetswhich are transferred over suitable feed mechanisms correctly oriented intoholes punched into the carrier ''(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). 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.

Components stamped parts consist of a minimum of two carrier parts which differ in their material composition and geometrical form and the contactmaterial (<xr id="fig:Examples of pre-mounted stamped component parts"/><!--(Fig. 3.1920?)-->). 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.<figure id="fig:Examples of pre-mounted stamped component parts">[[File:Examples of riveted pre-mounted stamped component parts.jpg|right|thumb|Figure 4: Examples of pre-mounted stamped component parts]]</figure>

*Pre-mounted component stamped Stamped partswhich are insert molded into or combined with plastic parts are used in electromechanical components (see Chapter [[Electromechanical Components | Electromechanical Components ]]).

Components stamped parts consist === Stamping Tools===For the design of stamping tools the latest CAD software systems are used.Modern stamping tools usually employ a minimum of two carrier parts whichdiffer in their material composition modular design with integrated dimensional and geometrical form and the functional controls (<xr id="fig:Progressive die for stamped contactmaterial''parts"/><!--(Fig. 3.21)''-->). The assembly of these components as single pieces or stampingprogressions is performed in a stamping <figure id="fig:Progressive die for stamped contact parts">[[File:Progressive die by riveting or coiningfor stamped contact parts. To increasejpg|right|thumb|Figure 5: Progressive die for stamped contact parts]]the current carrying capacity at the joining area an additional welding step can</figure>be added. Depending on the part and volume requirements the different properties of the twocarrier components can be combined. As an example: the high electricalconductivity of a contact carrier blade is joined , they are built with the thermal steel or mechanicalspring properties of a second material to form a functional component. For thisprocess both carrier base materials can carbide inserts that are also be coated with additionallayers of other functional materials. Fig. 3.20:Examples of prea wear-mounted stampedcomponent parts Stamped parts which are insert molded into or combined with plastic parts areused in electromechanical components (see Chapter 10)resistant material such as TiN for longer life.

== Stamping Tools==For the design of A special stamping tools the latest CAD software systems are used.Modern process is precision stamping tools usually employ a modular design for contact parts, made from thin strip materials with integrateddimensional and functional controls ''(Figthicknesses in the range of 0. 305 – 2.21)''5 mm. Depending on the requirementson With the high capacity stamping technology, up to 1400 strokes/min can be reached for high volume parts and . During the volumes they are built with steel or carbide (actual stamping operation, frequently other processes such as thread-steel) insertswhich forming, welding of contact segments and insertion and forming of contacts from wire segments are coated with a wear resistant material such as for example TiN forlonger lifeintegrated. Depending on the production volume, these operations can also be performed several times.

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 mmDuring high speed stamping the tools are exposed to extreme mechanical stresses which must be compensated, to ensure the highest precision over long production runs. With such highcapacity stamping technology up to 1400 strokes/min 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 reached for highmanufactured. volume To ensure the highest demands on the surface quality of precision contact parts, quite often vanishing oils are used as tool lubricants. During Cleaning and degreasing operations can also be integrated into the actual stamping operation frequently other processessuch as thread-formingprocess. Additionally, welding of contact segments most stamping lines are also equipped with test stations for a 100% dimensional and insertion 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]]