DODUCO manufactures precision stamped parts incorporating electrical contact functions. These can be welded, brazed, riveted, electroplated, or produced from semi-finished contact materials. Depending on customer requirements we supply stampings as individual parts, in strip form, e.g. as punched strip. DODUCO has also comprehensive competence and facilities to design and build high value tooling. By combining all the above technologies and adding for example thread forming into progressive dies we can supply highest level economic and complex solutions to our customers.
Resistance welding is an economic joining process for contact materials to carrier substrates. Two basic processes are used in contact welding: individual contact pieces are welded onto solid or pre-stamped carrier strips or the stamped contact parts are manufactured from semi-finished strip with already pre-attached contact material. During welding of contact pieces the contact material is attached from either profiles (tapes), wire segments or in tip form.
Depending on the application different contact materials are used which base on silver. To utilize the most reliable and economical manufacturing process the contact materials usually have an easily weldable backing. This can be nickel, cupper-nickel or a thin brazing alloy coating of L-Ag15P for example. Besides this the backing side is frequently designed with a profile-rolled pattern in the form of weld rails or pyramidal.
The use of contact rivets as well as the insertion of wire segments with subsequent coining into rivet configurations – wire staking – are mechanical contact attachment processes. Both methods have their own specific advantages. Using composite or trimetal contact rivets allows limiting the precious metal usage according to the requirements of the switching function. In wire staking the usage of precious metal is higher while on the other hand the attachment process can be run at significantly higher manufacturing speeds.
One determining factor for selecting the most economical process is the requirement on contact material volume. From a functional viewpoint however, both processes are deemed equivalent. If the contact components are, for
example, to be used in hybrid electrical applications, i.e. for very low as well as higher electrical loads, contact rivets can additionally be electroplated with gold. Using gold electroplated solid or composite contact rivets is in this case the most advantageous process.
Stamped parts from semi-finished contact strip are economically produced from continuous strip. Contact material produced in our mill facilities are based most often on silver. Copper and copper alloys are usually used as base carrier materials.
Many contact applications require thicker precious metal layers. These cannot be applied to the substrates economically by electroplating processes. In addition contact materials with very specific physical and mechanical properties are often required. These silver-based materials are made by either alloy melting or powder metallurgy. The combination of contact and base material is achieved by cladding technology.
DODUCO Contacts and Refining GmbH
Im Altgefäll 12
75181 Pforzheim
Germany
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