Manufacturers depend on electrical contacts for a variety of products. If your organization needs circuit breakers or other electrical contacts, you probably need to develop an understanding of contact manufacturing and assembly. While creating electrical contacts requires many different procedures, virtually all electrical contact manufacturers rely on welding to create their products. Here is a brief explanation of welding types and applications involved in the creation of electrical contacts.
In-press welding is a state-of-the-art procedure that only top-notch electrical contact makers utilize. With this method, manufacturers can rapidly create electrical assemblies. Thus, if you have a high-volume need, you likely want to work with a manufacturer capable of in-press welding. Similarly, since you likely prioritize quality products above virtually everything else, you likely want your electrical contact assembler to use in-press welding for the most consistent products possible.
Not every component requires high-end, in-press welding. For some lower cost contact materials, wire welding is sufficient. With this technique, manufacturers wire weld contacts before coining them into their final shapes. By working with an experienced electrical contact manufacturer, you can determine if wire welding is appropriate for your needs. If so, you might be able to avoid in-press welding. Since you probably don’t have the technical expertise to know which is right for you, don’t forget to contract with a firm that has the knowledge, skill, training, and experience to create top-quality electrical contacts for your manufacturing needs.
For limited production or low-quality products, electrical contact manufacturers often use manual welding. This technique is particularly valuable for research and development purposes or to create prototypes. As manufacturers innovate, they often want to see how combining two or more electrical contacts will change their products or processes. With a quick, manual weld, organizations can often analyze new products without committing to a total change of their welding procedures. Of course, after the research and development phase concludes, these organizations typically upgrade to in-press or wire welding to achieve the quality they demand in their electrical contacts.
Traditional welding and brazing generates a remarkable amount of heat. For electrical contacts that are sensitive to heat or those attached to heat treatable materials, manufacturers often need an alternative. To safeguard against the negative effects of excess heat, welders can opt for seam welding. With this technique, welders contain heat to the area immediately around the electrical contact. Thus, the remaining parts of the assembly remain strong and uncompromised. For larger assemblies where manufacturers need to increase heat conductivity in the electrical contact, welders can use an OMNI-weld. Either way, with seam welding, contact manufacturers can generally avoid needing to impart tamper with subsequent post-weld rolling procedures.
By understanding electrical contacts manufacture and assembly, you can better determine which products work best for your organization’s needs. While all electrical contact manufacturers create their products in unique ways, most rely on these types of welding to deliver top-quality contacts. For the right products, though, be certain to work with a skilled electrical contact manufacturer to get a design and assembly that will satisfy your industrial or manufacturing goals.