WE KNOW HOW. Product Competency in Stamping Technology. The Complete

WE KNOW HOW Product Competency in Stamping Technology The Complete STAMPING TECHNOLOGY Availability of All Key Technologies Economic Solutions ...
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WE KNOW HOW

Product Competency in Stamping Technology

The Complete

STAMPING TECHNOLOGY

Availability of All Key Technologies

Economic Solutions Through The

Power Engineering

Information Engineering

Control Engineering

Automation Engineering

Automotive Engineering

Precision stamped parts from DODUCO are known throughout the world as important functional components for many applications in electrical engineering, power electronica, data and communications technology. As electrical contacts they provide reliable power transfer in low voltage switching devices. They serve as reliable switching and connector elements in the automotive technology. In measurement and controls they transfer signals with high reliability and provide the connection between electronic circuitry and electromechanical components. Precision stamped parts are also used as high reliability non-electrical functional components. DODUCO manufactures precision stamped parts which fulfill various electrical contact requirements. They may be produced as welded, brazed or rivet-staked assemblies, may be electroplated or made from clad materials, may have bondable surfaces, press-in areas or be pre-mounted. Depending on the customer's requirements they are supplied as individual pieces, in strip or comb form or pre-packed in bandolier blister strips. DODUCO has the underlying expertise and necessary equipment to design and build high value progressive dies.

DODUCO's global presence with manufacturing facilities in Europe and Asia and a worldwide sales organization provides our customers for localized personal support. A corporate wide global communication network provides customer access to all our know-how. Our experience in electrical contact parts, materials and processes based on many decades, makes us a leader in contact technology. DODUCO is pursuing long term partnerships with their customers. Tool dependent projects for precision stamped components are typical examples of projects that extend over multiple years. For the manufacture of high quality precision stampings DODUCO applies the most up-to-date stamping processes and the latest key technologies. Precision of the manufactured parts is the highest priority. Our goal is to offer the technically most advanced and economically optimized solutions to the customer.

Welded

Stamped Parts

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 The maximum contact area size for from either profiles (tapes), wire seghigh rate welding while maintaining ments or in tip form. close manufacturing tolerances is 5 x 5 mm².

STAMPING TECHNOLOGY

Depending on the application contact materials used are based on gold, palladium or silver. To utilize the most reliable and economical manufacturing process the contact materials usually have an easily weldable backing. This can be nickel, cupro-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.

Pre-assembled Stamped Parts

Pre-assembled – or pre-mounted – stamped parts consist of a minimum of two base materials. The attachment of the individual stamping grids is performed by riveting and coining in the stamping tool. In order to ensure a lasting high conductivity of the joint an additional welding step is often employed. Depending on the requirements for the pre-mounted parts different properties of the single components are combined. High electrical conductivity of one material, for example, is combined with the good elastic spring

Progressive die with assembling of springs

behavior of the second one. Stamping parts from step milled dual gage base materials can quite often not fulfill the diverging technical requirements. This is mostly the case if higher requirements on spring properties are specified.

Pre-mounted stamped parts can also be used as functional parts for nonelectrical applications. As a contact component however at least one of the base materials has either a electroplated functional coating or contact material is attached to one substrate material by cladding, welding or rivet-staking.

Electroplated Stamped Parts

Electroplating processes allow the selective deposition of very thin layers within tight manufacturing tolerances. The usually high internal hardness and mechanical wear resistance of electroplated layers is advantageous in many applications. Since even thin layers have mostly a low porosity, these deposits serve also as protection against corrosion. The type of deposit, its chemical and physical properties as well as layer

STAMPING TECHNOLOGY

copper, nickel and nickel-phosphorus. Tin and tin-lead can be applied in strip form also by hot-dipping.

sequences and thickness are defined by the application's mechanical and electrical requirements. Electroplated deposits consist mostly of pure gold, hard gold, silver, palladium-nickel,

Pre-stamped strips are selectively electro-plated using immersion, strip and spot-plating or by the process of brush-plating. Stamping combs or discrete stamped parts are coated completely or selectively by immersion electroplating or all-over in bulk by barrel plating.

Riveted

Stamped Parts

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. significantly higher manufacturing speeds. Using composite or trimetal contact rivets allows limiting the precious One determining factor for selecting metal usage according to the requithe most economical pro-cess is the rements of the switching function. requirement on contact material volume. From a functional viewpoint In wire staking the usage of precious however, both processes are deemed metal is higher while on the other hand equivalent. the attachment process can be run at 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.

Stamed Pars with

Semi-finished Contact Strips

Stamped parts from semi-finished contact strip are economically produced from continuous strip. Contact material produced in our mill facilities are based on gold, palladium and silver. Copper and copper alloys are used as base carrier materials. Clad Stampings 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 materials from goldpalladium alloys or based on silver are made by either alloy melting or powder metallurgy.

STAMPING TECHNOLOGY

The combination of contact and base material is achieved by cladding processes such as cold roll-cladding or hot roll-bonding. Stamped Parts from Toplay Profiles DODUCO manufactures contact bimetals in strip form by brazing of flat or shaped strips to carrier materials followed by profile rolling. These are the basis for customer specified contact parts with raised precious metal segments for highly demanding applications.

Stamped Parts from Seam-welded Strips The main advantage of seam-welded strip material for the production of contact stampings is the limited area of the weld zone. This results in softening of spring hard base materials only in the immediate weld effected area. The contact layers consist mainly of solid contact materials or composite contact profiles or weld tapes.

Stamped Parts with

Bondable Surfaces

DODUCO has for many years the inhouse capability for the manufacture of AlSi clad strip and its subsequent processing as stamped components.

For special stamping parts DODUCO has further developed surfaces for contacting semiconductors through wire bonding. For most customer applications the reliability of the bond

connections over extended periods of time and under demanding environmental conditions are of highest importance.

Stamped Parts with

Flexible Insertion Zones

For reliable connections in hybrid frames and printed circuit boards DODUCO manufactures stamped parts with flexible insertion zones according to DIN EN 60352-5. The Elo-Pin ® was developed in following the latest know-how of insertion technology. Based on high elasticity it exhibits low insertion forces and high holding power.

The stamped pins include the proven needle-eye design and precision formed zone edges resulting in a gastight connection without any shaving effects during the actual insertion process. These insertion zones have shown their superior function also for the high temperature engine room environment in automotive applications.

In most cases it is necessary to supply samples for testing to the customer even before the final series production tools are completed. This detail oriented sampling will also include necessary coatings and the attachment of the electrical contact components. For DODUCO the cooperation during the product development phase is always based on mutual trust, open communications and goal-oriented team work with its partners.

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Our many years of experience allow us to early on address questions regarding the design criteria, mechanical and electrical requirements and the selection of suitable materials. We also consider the influences of the applied processing technologies on the environment. Right from the start of the process they concentrate on the economical and organizational aspects of the cooperation.

Our project management teams are the interface between the customer and manufacturing, development, the various laboratories, quality assurance and suppliers. It coordinates the different technical options and openly monitors the time line, costs and subsequent steps for realization. The teams' focal points always remain the success of the customer product as well as total quality and shortest possible time-to-market.

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Our application engineers, process engineers and R&D experts advise our customers already early in the development phase. The consulting services are based upon how to best meet the requirements on a new product with regards to resources and economic value.

Product Delivery

STAMPING TECHNOLOGY

Cooperation

Partnership based already during the development phase

Measurement of contact resistance on electroplated surfaces for the information engineering

Product Development DODUCO strives for a partnership with it's customers in the early stages of product development as a means for lowering development costs and time. This cooperation makes full use of the know-how and capabilities of the DODUCO employees. Test laboratories with state-of-the-art equipment are used for our own development efforts as well as for finding solutions to questions arising from customer projects. The requirements of electromechanical components are quite different depending on the industry applications they are developed for. For the information and telecommunications technology as well as for measurement and controls most contact components are used in micro switches, connectors or sliding contact devices.

The main questions for these are related to contact resistance, frictional wear and environmental effects. The main components in the automotive industry are relays and miniature switching devices. The contact materials must reliably switch lamp, motor and resistive heater loads over a specified life span. Protective switches and contactors are key components in low voltage power engineering. Besides meeting standardized test criteria the required contact parts are optimized with regards to bounce behaviour, temperature rise and arc mobility characteristics.

We have many years of know-how in the calculation of contact springs for our customers using the latest modeling software. Focuses are the force-displacement curves as well as predictions of plastic deformation and mechanical fatigue life. In addition we advise about the optimum material for any specific application. Using these modeling techniques we can help to reduce optimizing cycles during sampling and save valuable time for the project realization.

STAMPING TECHNOLOGY

Tooling and Stamping technology

State of the art

Equipment for blister packaging of small contact parts

For the design of our high performance stamping tools we use 3D CAD (Creo) and employ modular concepts. Depending on the requirements, cutting inserts are constructed of carbide or special tool steels. Our modern and well equipped tool shop supports advanced technological standards. We integrate into our progressive dies additional functions such as multiple thread cutting, multiple in-die rivet staking and also pre-mounting of stamped parts in strip form. The flawless operation of our dies is monitored and controlled through optical and structure-born sound sensors. The range of our high capacity stamping presses allows the use of strip thicknesses from as low as 0.03 mm (.0012”) to about 3.0 mm (.118”) and with a width of up to 180 mm (about 7.0”). Our maximum stamping speed range up to 1,800 strokes/min. The carrier materials – usually Cubased or stainless steel materials – are processed from “master coils” in reelto-reel, or into combs or discrete stamping parts. To ensure the surface cleanliness of precision stamped parts we use vanishing oils for the tool lubrication or integrate cleaning and degreasing into the stamping operations.

STAMPING TECHNOLOGY

Integrated

Quality Management To ensure the high quality requirements for precision stamped components, DODUCO's quality management system is certified according to DIN EN ISO 9001, QS 9000 and VDA 6.1. Testing and inspection at receiving, prior to shipping and as part of in-process manufacturing steps are performed utilizing the most modern test equipment. For the analysis of raw materials, precious metal alloys and electroplating solutions we use for example: AAS – Atomic Absorption Spectroscopy , RFA (XRF) – X-ray Fluorescence Analysis, ICP – Inductively Coupled Plasma. Contact and base carrier materials are evaluated for their mechanical and physical properties: hardness,

tensile strength, electrical conductivity, statistical contact resistance measurements. We analyze and measure microstructure and coating thicknesses in metallographic mounts. To certify the purity and cleanliness of contact surfaces we use SEM – Scanning Electron Microscopy with X-ray spectrometer and for bondable surfaces we perform bonding and pull tests. Environmental testing is done in climate controlled test chambers, salt-spray equipment and in standardized corrosive gas test atmospheres. Design and process FMEA ensure the stability of reliably developed manufacturing processes. Computer controlled 2D and 3D measuring machines support the monitoring of mechanical manufacturing processes.

WE KNOW HOW

DODUCO GmbH Im Altgefäll 12 75181 Pforzheim Germany Phone +49 7231 602-0 Fax +49 7231 602-398

~ DODUCO ESPANA, S.L. Manises 1 28224 Pozuelo de Alarcón Spain Phone +34 91 799-4620 Fax +34 91 799-4655 DODUCO (Tianjin) Co., Ltd. 32,Jing Shui Road, Nankai District Tianjin, PC 300111 P.R. China Phone +86 22 2764-1538 Fax +86 22 2764-1609

http://www.doduco.net Mail: [email protected]

Printed in Germany by WA,SCHN . 11.2013. 0,5 engl.

DODUCO GmbH Breite Seite 1 74889 Sinsheim Germany Phone +49 7261 409-0 Fax +49 7261 409-288