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Overview of Commonly Used Copper Alloys for Connectors

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    There are numerous copper alloy grades used in connectors. Below, we have organized the commonly used copper alloy grades for connectors based on processing methods. This will help everyone make preliminary design choices based on processing methods and conductivity.   

     

    The common processing methods for connector pins include cutting processing, cold heading processing, stamping processing, etc. Cutting processing is often used to produce solid round pins, such as the solid pins used in D-sub connectors. These are usually formed in one step using Swiss-type lathes. Swiss-type lathes can perform various machining processes like turning, drilling, tapping, milling flats, and chamfering on copper bars. This allows for the quick processing of solid pins, characterized by the absence of mold opening and flexible machining, but the cost is relatively high.


    Solid pin of D-sub

    Solid pin of D-sub


    Machining pins using a Swiss-type lathe

    Machining pins using a Swiss-type lathe     


    Cold heading processing uses forming molds to directly physically extrude the copper bar into the desired shape in the mold cavity. For example, the pins used in many new energy charging guns are formed using cold heading techniques. This method has lower processing costs than machining, and the forming speed is faster, but it requires molding. It’s suitable for mass production.    


    Stamping processing is currently the most widely used method for connector terminals. It can stamp terminals in large quantities, and the processing cost is usually the lowest. However, it requires precision stamping molds, and the cost of these precision molds is not low.     


    Different types of connectors require different conductor materials and corresponding processing types. The table below roughly organizes commonly used copper alloy grades for connectors, sorted by conductivity and processing method. Use this as a reference when designing connectors.


    Commonly used copper alloy grades for turned pins

    Commonly used copper alloy grades for turned pins


    Commonly used copper alloy grades for stamped pins

    Commonly used copper alloy grades for stamped pins


    The selection of copper alloy for connectors is a multidimensional process. It usually involves choosing easily processed, readily available, and cost-effective materials according to the maximum operating temperature, current and voltage conditions, termination situation, and design factors of the connector.


    For connector copper alloy materials, especially for female terminal materials, several key parameters must be comprehensively compared, such as conductivity, thermal conductivity, modulus of elasticity, tensile strength, yield strength, stress relaxation data, hardness, and minimum bend R/T ratio. The actual material selection process is a compromise and balance between design and selection.

    References
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