Manufacturing Example: Copper Sliding Contacts
Copper sliding contacts are an essential component of many electrical and electronic systems. They play a critical role in the transmission of electrical power and signals, especially in applications where a moving connection is required.
Properties of copper sliding contacts:
Copper is an excellent electrical conductor, making it an ideal material for sliding contacts. Copper's high electrical conductivity enables efficient transmission of electricity, while its good thermal conductivity helps to dissipate the heat generated by the electrical current. Copper is also relatively resistant to corrosion.
Another important consideration is the mechanical strength of copper. Sliding contacts must be able to withstand repeated movement and mechanical stress without significant premature wear. Copper meets these requirements well, especially when combined with suitable alloys or surface treatments that increase wear resistance.
Preferred Use of Copper Sliding Contacts:
First, they provide a reliable electrical connection in applications where fixed connections are impractical. This is particularly important in automation, robotics and electric drives, where movement and rotation are common. Second, copper sliding contacts help reduce contact resistance, resulting in higher efficiency and lower power loss at a moderate material cost. This is particularly beneficial in high-current applications, where even small resistances can result in significant losses.
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When producing contact designs that are sometimes delicate and sometimes solid, the powder pressing technique can fully exploit its advantages: the greatest possible alloying options through particle mixing. Without special measures, mixing of alloys is only possible at similar liquidus temperatures. This is associated with contour designs that are sometimes impossible or uneconomical to produce otherwise. This is especially true for large-scale production with thousands of contacts per year, where the cost of the pressing tool and sintering are quickly amortized.
Innovating Production:
The Strength of KOMAGE
A leading manufacturer of sliding copper contacts wanted to improve its production in terms of quality and pIn response to a request for assistance from a customer who is a leader in the production of these critical components, the production of copper sliding contacts has seen significant advancements through the use of powder metallurgy and KOMAGE's powder pressing expertise and technology.
With KOMAGE's support, it has been possible to use the power of powder metallurgy to create electrical contacts from two different materials, fusing them into a single piece for optimum performance. This process maximizes the potential for alloy mixing, providing greater flexibility in material properties and design.
This project enabled the customer to produce contact designs that were otherwise difficult or expensive to achieve. The ability to mix and press with high-precision alloy particles ensured a wide range of possibilities, enabling the creation of custom contacts tailored to specific needs. In addition, the customer found that the cost of the press tool and sintering process could be quickly recouped in high-volume production, making this method particularly advantageous for manufacturers producing thousands of contacts every yea