Strip for connectors - Wieland Gruppe · PDF fileproduction process is Europe‘s biggest ... brass. They are standard materials for ... Coining in the stamping tool can

Strip for connectors

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Wieland-Werke AG, Villingen-Schwenningen,

Germany

Wieland-Werke AG, Velbert-Langenberg,

Germany

The Wieland Group, headquartered in the southern German city of Ulm, is one of the world‘s leading manufacturers of semi-finished and special products in copper and copper alloys: strip, sheet, tube, rod, wire and sections as well as slide bearings, finned tubes and heat exchangers.

Wieland’s roots go back almost 200 years. Its founder, Philipp Jakob Wieland, took over his uncle‘s fine art and bell foundry in Ulm in 1820, and by 1828 he was already fabricating sheet and wire from brass.

Today, Wieland‘s output reaches about 500,000 tonnes a year in copper alloy products. The starting point of the production process is Europe‘s biggest foundry for copper alloys at Wieland‘s Vöhringen/Iller location.

The Wieland Group has approximately 6,500 employees in its manufacturing companies, slitting centres and trading firms in several European countries as well as the USA, South Africa, Singapore, India and China.

Wieland-Werke AG, Vöhringen, Germany

Wieland supplies over 100 different copper alloys to customers in many different markets, first and foremost the electric and electronic sector, but other important consumers include the building trade, the automotive industry and air-conditioning and refrigeration engineering.

Wieland produces strip in all major economic regions of the world: in Germany in Vöhringen, Velbert-Langenberg and Villingen-Schwenningen. Further rolling mills are based in Great Britain, Singapore and the USA. A global network of slitting centres ensures swift and flexible product deliveries worldwide.

Wieland-Werke AG, Ulm, Germany

The Wieland Group

North America

USA

South America

Brazil

Colombia

Africa

South Africa

Asia

China

India

Japan

Singapore

South Korea

Australia

Australia

Europe

Austria

Belarus

Belgium

Croatia

Czech Republic

Denmark

Finland

France

Germany

Great Britain

Greece

Hungary

Italy

Poland

Portugal

Russia

Spain

Sweden

Switzerland

Turkey

Rolling mills and slitting centres

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B. Mason & Sons Ltd., Birmingham,

Great Britain

Wieland Metals Singapore Pte Ltd.,

Singapore

Wieland Metals, Inc. Wheeling, IL, USA

Sites of the Wieland Group and its trading agencies

North America

USA

South America

Brazil

Colombia

Africa

South Africa

Asia

China

India

Japan

Singapore

South Korea

Australia

Australia

Europe

Austria

Belarus

Belgium

Croatia

Czech Republic

Denmark

Finland

France

Germany

Great Britain

Greece

Hungary

Italy

Poland

Portugal

Russia

Spain

Sweden

Switzerland

Turkey

Rolling mills and slitting centres

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If connectors are exposed to high temperatures (e.g. in applications near the engine in cars), adequate stress relaxation resistance must be assured. Further details on this are given in the data sheets for the various materials.

Standard alloys

After silver, pure copper has the highest electrical conductivity. This material is therefore particularly suitable for non-elastic electrical conductors and components.

Brass is the alloy group most commonly used for electrical contacts. It is cost-effective and at room temperature mostly meets the requirements regarding elasticity and corrosion resistance.

Materials for connectors

Requirements

Connectors and other electromechanical components call for copper or a copper alloy as the starting material, for no other material so comprehensively meets the demands for

• strength and elasticity

• electrical and thermal conductivity

• formability and stamping properties

• temperature resistance under stress

• coating or surfacing with noble metals

• surfaces suitable for tinning

• tight dimensional tolerances

Most important materials

The chart below shows the most important materials for electromechanical components with their yield strength Rp0.2 and electrical conductivity.

For higher requirements phosphor bronzes are a common alternative to brass. They are standard materials for applications in telecommunications and data processing.

High-performance alloys

The trend to miniaturisation is leading to ever-smaller connectors. Wieland has developed new high-performance alloys for such applications, e.g. Wieland-K55 and Wieland-K57. With their good conductivity, strength and formability, they allow the use of thinner strip. So these high-performance alloys are ideally suited for the smallest connectors and as a substitute for beryllium copper.

Ele

ctri

cal c

ond

uctiv

ity (M

S/m

)

0

10

20

30

40

50

60

C18080 K88

CuCrSiTi K75

B18 SUPRALLOY

Bending 90° with r max. 0.5 x t

Bending edge perpendicular to direction of rollingmax. strip thickness 0.35 mm

300 350 400 450 500 550 650600 750700 800 9000

10

20

30

40

50

60

0

10

20

30

50

40

70

60

80

100

90

K57 C70350

K81 C14415 K88 C18080

K75 C18070

K55 C70250

K65 C19400

M30 C260

S23 C688

K76 C19010

B14 SUPRALLOY C511

Relaxation resistant up to 80 °C Relaxation resistant up to 120 °C

Relaxation resistant up to 175 °CRelaxation resistant up to 105 °C

B18 SUPRALLOY C521

B14 C511

50

Ele

ctri

cal c

ond

uctiv

ity (%

IAC

S)

Yield strength Rp0.2 (MPa)

K57 CuNi1Co1Si

K81 CuSn0.15K88 CuCrAgFeTiSi

K75 CuCrSiTi

K55 CuNi3SiMg

K65 CuFe2P

M30 CuZn30

S23 CuZn23Al3Co

K76 CuNiSi

B14 SUPRALLOY CuSn4

B18 SUPRALLOY CuSn8

B14 CuSn4S30 SUPRALLOY CuZn30Sn1Fe0.6

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Even higher electrical and thermal conductivity is available with the high-performance alloys Wieland-K75 and Wieland-K88.

Severe cost-cutting pressures are forcing manufacturers of contacts and busbars to seek cost-effective solutions. Here, the proven high copper materials Wieland-K65 and Wieland-K81 can be recommended as suitable alternatives. They provide satisfactory spring properties coupled with high to very high conductivity.

All of Wieland‘s high-performance alloys meet the RoHS mandatory requirements. Stamping waste and other scrap can be returned to Wieland for recycling.

SUPRALLOY® bronzes

Wieland helps the manufacturers of connectors and electromechanical components by optimising conventional copper alloys.

A current example of this are Wieland‘s SUPRALLOY bronzes. They have the same chemical composition as standard bronzes and are available as Wieland-B14, Wieland-B16 and Wieland-B18. A special thermo-mechanical treatment generates an extremely fine-grained microstructure. As a result, substantially higher mechanical strength is achieved in combination with very good bending properties.

The fine microstructure means that shaped contact zones (e.g. in spherical contacts) are significantly smoother, which is advantageous for subsequent electroplating with noble metals. Wieland SUPRALLOY bronzes are therefore outstandingly suitable for miniaturised connectors in electronic applications.

Automotive connectors stamped from tinned strip

SIM socket stamped from a high-performance alloy

Socket for microprocessor stamped from a high-performance alloy

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Wieland materials for connectors comply with established international standards such as EN, ASTM and JIS.

Besides the technical properties, price is of course an important criterion for the selection of a material. Here the value of the

Material designations

metal makes up a substantial part of the end price of the strip. Non-ferrous metals such as copper, zinc and tin are traded on commodity exchanges and are therefore subject to price fluctuations, which can be quite considerable. Details are available from your sales contact and at wieland.com.

Material designations Physical properties

Brand nameDesignationanalogous to ISO

ENnumber

UNSnumber D

ensi

ty

(g/c

m³)

Ele

ctric

al

cond

uctiv

ity

(MS

/m)

Ele

ctric

al

cond

uctiv

ity

(% IA

CS

)

Ther

mal

co

nduc

tivity

(W

/mK

)

Ther

mal

ex

pan

sion

(1

0-6/

K)

Mod

ulus

of

elas

ticity

(G

Pa)

Copper

Wieland-K09 Cu-OFE CW009A C10100 8.9 59 101 394 17.7 127

Wieland-K11 Cu-OF CW008A C10200 8.9 58 100 394 17.7 127

Wieland-K12 Cu-HCP CW021A C10300 8.9 57 98 385 17.7 127

Wieland-K14 Cu-PHC CW020A C10300 8.9 58 100 390 17.7 127

Wieland-K15 Cu-DLP CW023A C12000 8.9 52 90 350 17.7 132

Wieland-K19 Cu-DHP CW024A C12200 8.9 46 80 340 17.6 132

Wieland-K32 Cu-ETP CW004A C11000 8.9 58 100 390 17.7 127

Wieland-K42 CuZn0.5 CW119C − 8.9 48 83 350 17.7 127

High-performance copper alloys

Wieland-K55 CuNi3SiMg − C70250 8.8 25 43 190 17.6 130

Wieland-K57 CuNi1Co1Si − C70350 8.8 29 50 200 17.6 131

Wieland-K65 CuFe2P CW107C C19400 8.9 37 64 280 17.6 123

Wieland-K75 CuCrSiTi − C18070 8.9 45 78 310 18.0 138

Wieland-K76 CuNi1Si – C19010 8.9 29 50 260 16.8 135

Wieland-K80 CuFeP − C19210 8.9 53 91 350 17.0 130

Wieland-K81 CuSn0.15 CW117C C14415 8.9 51 88 350 18.0 130

Wieland-K88 CuCrAgFeTiSi − C18080 8.9 46 80 320 17.6 137

Brass

Wieland-M05 CuZn5 CW500L C21000 8.9 33 57 243 18.0 127









Special brass

Wieland-S12 CuZn9Sn3 CW454K C42500 8.8 16 28 120 18.4 126

Wieland-S23 CuZn23Al3Co CW703R C68800 8.2 10 17 78 18.2 116

Wieland-S30 SUPRALLOY CuZn30Sn1Fe0.6 – C44750 8.5 13 22 100 20,7 115

Phosphor bronze

Wieland-B14 CuSn4 CW450K C51100 8.6 13 22 100 18.0 120




Nickel silver

Wieland-N12 CuNi12Zn24 CW403J C75700 8.7 4 8 42 18.0 125



CuNi-alloy

Wieland-L49 CuNi9Sn2 CW351H C72500 8.9 6 11 48 17.6 140

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Wieland-ZZZIP®

Flexible, flat cables (FFC) are increasingly establishing themselves in information technology, but also in consumer products and in the automotive industry. FFC production costs can be cut by the use of Wieland ZZZIP strip:

Wieland ZZZIP strip is pre-notched longitudinally according to the customer layout and delivered in coil form. Wieland can supply a simple device for separating (unzipping) the coils into individual conductor strips which can then either be directly laminated or extruded with plastic, obviating the need to process a large number of individual strands.

Strip for busbars

The heart of the electrical system in cars consists of several control units. As the demand for comfort increases, so do both the power load and the complexity of the control units. This is why they are made of stamped conductors called busbars.

Wieland alloys can satisfy all the requirements for busbars. Top strip quality together with the proven hot-dip tinning can contribute in no small measure to the reliability of a car‘s electrical system.

Wieland can also supply complete busbars collaborating with its long-established partners.

Contour-milled strip

Strip with contour-milled sections open up new possibilities of producing electromechanical components. They no longer have to be joined from different stamped parts but can be stamped in one operation. Coining in the stamping tool can be dispensed with.

Special delivery formats

ZZZIP strip for FFC in automotive clocksprings

Strip and busbars for a fuse box in cars

Contour-milled strip

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Hot-dip tinned strip

Connectors must have low contact resistance permanently. Tin coatings are a proven means of achieving this with moderate mating and unmating forces.

When the molten tin is applied, an intermetallic reaction layer forms, which ensures excellent adhesion of the coating to the strip surface. The coating has extremely low residual stresses and is thus largely resistant to whisker growth.

Wieland-SnPUR®

Pure hot-dip tin coated Wieland strip is named SnPUR. Wieland-SnPUR characterised by low hardness, high ductility, and good corrosion resistance.

Wieland-SnTEM®

Intelligent aftertreatment of SnPUR yields the variant SnTEM which has a substantially higher surface hardness. This allows the mating and unmating forces of connectors to be considerably reduced and improves the wear resistance.

Wieland-SnTOP®

SnTOP is a lead-free hot-dip tin coating with minor additions of silver which has been specifically developed for connectors.

Compared with SnPUR, SnTOP provides higher temperature stability in combination with high hardness and improved fretting corrosion resistance. It is particularly suitable for applications under-the-hood and lends itself as low-priced alternative to silver coatings.

Electroplated strip

In addition to hot-dip tinned strip, Wieland offers electroplated strip with different layers. Electroplated strip meets both functional and high optical requirements. The two most commonly used variants are Wieland-SnEP and Wieland-SnEPR.

Wieland-SnEP (EP = electroplated) consists of matt tin, on request with an intermediate layer, for example, of nickel. Wieland-SnEPR is a matt tin coating which is molten during a thermal (reflow) treatment and whose surface consequently becomes bright (EPR = electroplated reflow).

Tinned strip

Electroplated strip

Hot-dip tinned strip

Connectors made of hot-dip tinned strip

Tinned busbar for an automotive control unit

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Tolerances

At Wieland‘s customers, the finished strip is processed using high-precision equipment which makes particular demands on the tolerances and the geometric properties of the strip.

Thickness and width tolerances can be restricted to the tightest of margins compared with the relevant standards. Special measures can likewise be taken during strip production in order to minimise shape deviations such as longitudinal camber, coil set or cross bow. With this, the particular requirements of the tool can be anticipated and account for.

Dimensions and tolerances

For strip thicknesses of up to 0.6 and strip widths of up to 100 mm, tolerances of half the values listed above can be supplied on request.

Strip thick-ness (mm)

Strip thickness tolerance (mm)

over up to

Precision level acc. to production costs

I II III

0.10 0.30 +/– 0.010 +/– 0.007 +/– 0.005

0.30 0.50 +/– 0.015 +/– 0.010 +/– 0.007

0.50 0.80 +/– 0.020 +/– 0.015 +/– 0.010

0.80 1.30 +/– 0.025 +/– 0.020 +/– 0.015

1.30 1.50 +/– 0.030 +/– 0.025 +/– 0.020

1.50 on request

Strip thickness tolerances


Width tolerance according to EN 1652 (mm)

over up to

Strip width (mm)

up to 50 over 50 up to 100 over 100 up to 200

0.10 1.0 +0.20 / –0 +0.30 / –0 +0.40 / –0

1.0 2.0 +0.30 / –0 +0.40 / –0 +0.50 / –0

2.0 2.5 +0.50 / –0 +0.60 / –0 +0.70 / –0

2.5 3.0 +1.0 / –0 +1.10 / –0 +1.20 / –0

3.0 4.0 +2.00 / –0 +2.30 / –0 +2.50 / –0

Strip width tolerances


Camber according to EN 1654(mm/m)

over up to

Strip width (mm)

> 3–6 > 6–10 > 10–20 > 20–350

0.10 0.50 12 8 4 2

0.50 1.0 – 10 6 3

Camber

Strip Thickness (mm)

Camber(mm)

over up to

Strip width (mm)

> 3–6 > 6–10 > 10–20 > 20–350

0.10 0.50 7 5 3 1.0

0.50 1.00 – 6 4 1.5

Increased work in manufacturing allows the camber of a strip to be reduced to the following tolerances:

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Strip in coils

Coils are the simplest and therefore the most economical delivery format for strip. They are packed horizontally on square or round pallets whose size is matched to the outer diameter of the coils.

Traverse wound strip

Traverse wound strip comes in coils which are welded together using the TIG process and then wound onto a drum. The resulting strands are considerably longer than with individual coils. The advantage is a reduction in the operator‘s changeover times. The welds are marked in colour.

Wieland-MULTICOIL®

Wieland-MULTICOIL is packed with all the coils in a stack joined with each other, to produce the longest possible strip length. With this method, a whole stack of coils can be processed in a single stamping run. Uncoiling can be done on existing horizontal decoilers, so no investment is needed in equipment.

The advantages:• stamping runs with less downtime• reduced risk of tool break at coil feedings• higher productivity

Sizes and weightsStrip thickness Strip width0.20–0.80 mm 10–60 mm0.81–1.20 mm 10–40 mmMaximum pallet weight 5 t

Wieland-FLEXIDRUM®

Drum logistics, too, can be improved even further. Wieland‘s latest contribution is called FLEXIDRUM. Removable and re-usable spool flanges are retained by the customer. The coils are delivered on cores without flanges, and so the flanges can be fitted very simply on the spot without having to lift the core. The cores can be supplied either as reusable or one-way cores.

Delivery formats and packaging

Drums with and without flanges

Strip in coils

Wieland-MULTICOIL

Wieland-FLEXIDRUM

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Wieland – what we stand for

The Wieland connector team

QualityFlexibility

Reliability

InnovationVariety

QualityFlexibility

ServiceServiceReliability

InnovationVariety

Maximum productivityfor the customer

Quick response to all questions

Delivery reliabilityeven in turbulent times

Customised solutionsfor all applications Forward-looking,

future-oriented solutions

Short delivery times –worldwide

Wieland-Werke AG www.wieland.com

Graf-Arco-Str. 36, 89079 Ulm, Germany, Phone +49 731 944 0, Fax +49 731 944 2772, [email protected]

This brochure is for your general information only and is not subject to revision. No claims can be derived from it unless there is evidence of intent or gross negligence. The data presented is not guaranteed and does not replace expert advice. 05

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Strip for connectors - Wieland Gruppe · PDF fileproduction process is Europe‘s biggest ... brass. They are standard materials for ... Coining in the stamping tool can