Sulfamate Nickel Plating

Sulfamate nickel plating is a fairly versatile coating often used for electrical contacts. Part of its popularity is due to the fact it’s relatively less expensive when compared to other common coating processes. For sulfamate nickel coating, a 99.9% pure nickel deposit is used, as opposed to the more traditional nickel sulfate that’s found in electroless nickel plating. This higher concentration of nickel tends to provide a number of advantages, especially when it comes to durability.

You can find sulfamate nickel plating in both matte and semi-bright. The matte is the option that retains the 99.9% purity and is thus more ductile. Semi-bright deposits contain organic brighteners. While high purity might not be as aesthetically appealing, it does deliver temperature resistance up to nearly 1,400 degrees Celsius or 2,550 degrees Fahrenheit, which is the melting point of nickel. With a slight yellow or golden cast, the matte plating isn’t popular when it comes to decorative purposes. However, the low stress and high ductility allow for elongation and machinability that tends to be far superior to other nickel deposits. If brightness is a concern, a semi-bright bath is recommended.

Usage and Applications

Sulfamate nickel is typically used for repairing worn components. This is primarily due to being highly machinable when compared to other products. It’s also commonly used as a build-up coating when resurfacing worn parts. Sulfamate nickel plating is a great choice for joining applications, such as brazing, over molding, soldering, or epoxy welding and bonding. A lack of co-deposited organics and the high purity allow for excellent wetting for soldering. Additionally, it makes a preferred underplate for a diffusion barrier or when required for brazing.

You may have already noticed that sulfamate nickel plating is used in telecommunications, for power transmission, and in both the medical and defense industries. There are many common applications, including electrical equipment, molds and dies, food service equipment, and in the aerospace industry. Sulfamate nickel plating is quite popular whenever high solderability is necessary.

Advantages

When it comes to putting together a design, sulfamate nickel plating delivers several advantages. As already mentioned, it’s stable at higher temperatures, and the high ductility allows the coating to be brazed or welded more easily. If you’re worried about corrosion resistance for a substrate, nickel is a great undercoat for silver or gold plating.

Even by itself, sulfamate nickel is an ideal choice for components that need to be resistant to corrosion or to operate at higher temperatures. The thickness of nickel also tends to be quite consistent. It’s a great choice for restoration processes. Nickel is also known to have high tensile strength and may be elongated or machined without stress cracking or showing any sort of deformation.

When you’re looking at electrical contact tapes, buttons, devices, or assemblies, it’s worth remembering the benefits and functional advantages delivered by sulfamate nickel plating. Contact Checon Corporation at 1-508-809-5112 if you have any questions or if you would like to learn more.

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• In-Press Welding –   This fabrication method welds in place precious metal tape to base metal strip which is then stamped into parts in one operation.  In-press welding is a highly reliable fabrication method with in-line shear testing.  It is ideal for high volume applications.
• Wire Welding –  Wire welding is a  low-cost option for a variety of contact applications including  sliding electrical contact devices or logic level loads. The wire is welded and then coined or pressed into the final shape.
• Seam Welding – This is a great choice for electrical contacts when the contact needs to be bonded to an especially thin material or a material that cannot handle the high heat of traditional welding techniques. This technique restricts the heat to the area right around the contact and minimizes the chance of heat damage elsewhere.

These are only a few of the electrical contact fabrication options available for your needs.  Checon can help you determine the best electrical contact and fabrication design for optimum device performance that will also meet price and delivery objectives.

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Properties of Silver

Silver-metal oxide materials, such as silver-cadmium oxide (Ag-CdO) and silver-tin oxide (Ag-SnO₂), have very good contact and switching properties—they’re highly resistant to welding, low contact, and high arc erosion. For this reason, silver-metal oxide materials are widely used for various applications, including relays, appliances, protective devices, sliding electrical contact devices, and silver contact tips. Each silver-metal oxide material has its own distinct advantage over the other.

Traditionally, Ag-CdO has been the go-to silver electrical contact for a multitude of applications. As stated earlier, it has great contact and switching properties and is very often used for sliding electrical contact devices and silver contact tips. Indeed, the process in creating larger silver contact tips from Ag-CdO presents substantial economic advantages over using Ag-SnO₂. Ag-CdO’s contact properties can be influenced by using different silver powders and additives—it is this versatility that has made Ag-CdO one of the most widely-used silver electrical contacts.

Latest Developments

Recently, however, Ag-SnO₂ has begun replacing Ag-CdO. Ag-SnO₂ has been shown to have less toxicity than Ag-CdO. Additionally, Ag-SnO₂ often shows improved contact and switching properties over those of Ag-CdO. Ag-SnO₂’s contact properties can also be influenced during the manufacturing process, so it can also be quite versatile; however, the process of making complex forms of electrical contacts—such as silver contact tips—is more economically efficient with Ag-Cd alloy versus Ag-SnO₂.

Each silver-based contact material has its advantages, and knowing the intended application for the silver-based contact material is crucial.

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Electrical contacts are an important part of any electrical device. They’re especially important for switching devices as they must remain in good physical and electrical shape for the life of the product. If they wear out too quickly, the product’s useful life will be shortened. Contact materials must exhibit a number of properties to work well and withstand the process of completing and breaking the electrical circuit. Some of those properties include high arc erosion resistance, high resistance against welding, and good arc extinguishing capability. Let’s look at a few excellent choices for electrical contact materials.

Alloys

An alloy is a combination of two or more metals that is better than each individual metal on its own. Electrical contact manufacturers can mix metals in such a way to take advantage of the properties for both, while minimizing the negative properties of each individual metal. The result is an alloy that can be customized for your specific needs, ensuring that it will last for as long as necessary.

Composite materials

Composite materials are similar to alloys but typically use materials other than metals as part of the blend. Composites are particularly valuable for situations that utilize higher electrical current. Composites can be made to better resist and withstand the tendency of high electric current to arc and weld contact surfaces together. Composites are typically made through a sintering process to ensure that the materials are evenly distributed throughout the contacts.

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Silver Tungsten

Also known as AgW, silver tungsten is a popular material for use in both large air and oil circuit breakers. It’s known for having a high resistance to arc erosion. It’s also a common choice for re-closures, line disconnects, and both high current contactors and switches. Thanks to its resistance to welding, it can also serve as a good shorting contact. Composites of silver tungsten that contain more silver are used quite often in circuit breakers and in high current contactors.

Copper Tungsten

Commonly known as CuW, copper tungsten is also a very popular contact material. It’s known for being heat-resistant, ablation-resistant, easy to machine, and it’s both highly thermally conductive and electrically conductive. Copper tungsten can serve as an excellent material for switches and contacts for oil-filled devices. Thus, copper tungsten is a material commonly found used in the fossil fuel industry, as well as related industrial and commercial fields. You may also find it used in some oil, gas, or even air circuit breakers.

Silver Graphite

Sometimes shown as AgC, silver graphite is popular for many electrically conductive applications. It’s also known for having the best anti-welding properties of all contact materials. Because it has the best protection against contact welding, it’s an excellent choice for closed contacts under short circuit conditions. It’s also known for having low contact resistance and low erosion. For industrial purposes, silver graphite is excellent for circuit breakers, but it’s also effective for residential circuit breakers.

This is by no means an exhaustive list. Putting together the best electrical contact assemblies always necessities identifying the appropriate materials, so it’s always recommended that you discuss your application requirements at length before making a final decision.

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Rivet Production and Assembly

Checon manufactures highly ductile silver based contact rivets in a variety of silver and and silver alloy combinations including fine silver, AgNi, AgCdO, and AgSnO for higher performance applications; and with copper as the base shank material.  Rivets made with composite bi-metals can also be used to save on precious metal content and expense depending upon the material system and end device requirements.   Rivets are produced in range of  contact shapes, the most common being round with a spherical radius.

Checon maintains automated rivet production and insertion capabilities in both the U.S. and at our India based affiliate operation.   Staking is carefully monitored and repeatable to ensure proper seating of the rivet with the required twist-out torque requirements.

Alternative to Rivets

Checon’s in-press wire and tape welding technologies offer a low-cost alternative to many riveted designs. High speed, one operation, in-press welding is a core competency at Checon allowing us to develop the most consistent, high quality welded contact assemblies in the industry.  By connecting our weld head design to a large bed, high-speed vertical press via an innovative actuator design, we can dramatically increase production speeds to up to 400 assemblies per minute. Both electronic & mechanical shear testing is conducted on each contact before each welded contact moves into a Checon designed Class A progressive stamping die for coining of contact shape and stamping into a final contact assembly.

Checon has assisted numerous customers in their design and cost out processes to help them better understand these options and appropriate application. For more information on how Checon can help you maximize your contact and contact assembly performance while minimizing your costs, contact Steve Carter at 508-809-5112.    Checon also offers an on-line live chat via our website at www.checon.com.

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Contact tapes are overlaid and welded onto electrical equipment to ensure the effectiveness of electrical flow. These tapes contain a cap of precious material, which is needed for the electrical device to function. Also, they have a base of non-precious metal which works to support the cap and facilitate attachment. By precisely controlling the thickness of the tape, the conductivity of the equipment can be maximized, while providing protection during the welding process. Electrical contacts provide many benefits during the welding process, and there are several companies that produce these materials.

Manufacturers

Producers of electrical contact tapes sell to both individuals, as well as businesses that require this tape for their operations. Many electrical contact manufacturers also specialize in producing metal and plastic parts that can be used in electrical manufacturing. On the other hand, a company like the Checon Corporation specializes exclusively in electrical contact materials, working to create the most high-performing materials possible.

Checon offers a wide variety of contact materials. They also offer to fabricate and customize contact materials, depending on your specific needs. This guarantees the contacts you order will be the most effective for your specific application. Finally, Checon uses in-house development programs and electrical tests, which allows them to offer the highest performing contacts possible.

Benefits

Welded electrical contact tapes provide several key benefits in the operation of electronic equipment. Contact materials make sure that electricity flows correctly and does not cause short-circuits or overloads. Finally, these materials also maximize electrical equipment’s conductivity, thereby ensuring that they operate correctly. If you or your business needs electrical contact materials, consider visiting checon.com to view their wide selection of materials.

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Refractory Contacts

Refractory contacts are important in helping conduct electrical current through strategic placement in devices. The necessary conductivity and resistance help determine just what materials should be chosen for your product. The following are materials used to create refractory electrical contacts:

• Silver tungsten
• Silver Tungsten Carbide
• Silver Graphite
• Silver Tungsten Graphite Carbide
• Copper Tungsten

Buttons

In successful electrical contacts manufacturing, buttons help your finished product be as effective as possible. The following are alloys used in the composition of creating both single buttons and multi-layer buttons:

• Silver Cadmium Oxide
• Silver Tin Oxide
• Silver Nickel
• Silver Alloy
• Copper and Copper Alloy
• Steel and Nickel Monel
• Braze Alloy

Rivets

Rivets are created with the distinct purpose of extending that conductivity. The materials used and how they are constructed need to target the specific construction needs of the end-result product. The following are types of rivets that are manufactured to serve electrical contacts:

• Construction
  • Solid
  • Multi-Layer
  • Head and Shank
    • Straight Side
    • Chamfer Side
    • Step Side
    • Indent
    • Chamfer
    • Riveted Assemblies

Surface Features and Shapes

Varied shapes serve distinct purposes for the benefit of your products. The following alloy distinctions can help make a more intuitive design that enables a more efficiency and resiliency. Here are some characteristics that can be expected:

• Knurl and Score Lines
  • For Backing Designations
  • Projections
    • For Welding
    • Nibs
      • For Locating on the Substrate
      • Serrations
        • For Desired Performance
        • Shapes
          • • Square
            • Rectangular
            • Circular
            • Washer
            • Cylindrical
            • Spherical

          There are a wide range of metals that are used in making electrical contacts. In order to create a manufacturing plan best suited to your product, it doesn’t hurt to consult with an electrical contacts manufacturer to learn more.

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The Basics of Electrical Contacts

An electrical contact is a component found in an electrical circuit that helps to complete it and allow for electrical current to successfully flow from one point to another. These electrical contact components occur in switches, connectors, circuit breakers, and relays, and they can be formed out of a range of materials depending on how well those materials both successfully conduct electricity and resist corrosion over time. The materials used in electrical contacts are also often chosen related to how affordable they are and how cost effective they are over time.

Electrical Contact Assemblies

Creating these small parts and components is just one phase of the process. Some companies also offer to help assemble these parts into a specific device, taking a set design, interpreting it, and putting into action the needs of a design plan according to what electrical contacts are needed and where. These assembly services can also involve a company partnering with an assembly group in order to have them manufacture electrical contacts that meet certain custom specifications.

Types of Electrical Contacts

These conductive parts can get pretty specialized. Buttons, rivets, various conductive surface features, and an array of refractory contacts are used to make up electrical contacts. They can be made from silver tin oxide, copper tungsten, silver graphite, and a wide range of other alloys that can accommodate different needs.

Electrical contact assemblies are incredibly important in the design and manufacturing of a wide range of electronics. These tiny conductive parts make the most everyday tools we use possible, from a television remote to a light switch to our cell phones. The next time you flip that switch or turn that knob, think about the tiny parts that are all working together to connect that circuit and make it work for you.

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Pure Silver

This is also sometimes referred to as fine silver. Of all types of silver, pure silver is the most conductive—meaning it conveys electrical current the easiest. It also resists oxidation better than other silvers. On the flip side, it gets softer at lower temperatures than other silvers and, therefore, doesn’t stand up as well to mechanical wear. It also attracts sulfur, which means that sulfur can easily tarnish the exterior look of pure silver over time.

Silver Alloys

In order to take advantage of the strengths of pure silver, while minimizing the negative properties, silver alloys are created by combining a variety of other metals with pure silver in varying degrees. The goal in doing so is to strengthen the hardness of the silver and make it more resistant to wear. In some cases, it’s also to diminish its ability to conduct electricity so well.

Fine-Grain Silver

Nickel is the added ingredient that makes for fine-grain silver. As a result of the properties of liquid silver and nickel, only a small amount of nickel can be merged to form fine-grain silver. This material maintains its resistance to chemical corrosion while upping its hardness and overall strength as a metal. The nickel also slightly diminishes the conductivity.

Hard-Silver Alloys

Copper is the extra ingredient added in hard-silver alloys that greatly increases their mechanical stability. This is also referred to as hard-silver in Europe, and its mechanical stability and greater resistance to erosion make it a highly reliable material.

Silver tin oxide is just one of several different forms that silver can be used in. The varied uses of silver and its different variants make it highly useful in a wide range of industries.

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