Determining the quality of connecting device materials requires a comprehensive evaluation from three aspects: the composition and performance testing of metallic and non-metallic materials, and industry standards. This ensures that key indicators such as mechanical strength, conductivity, and corrosion resistance meet standards.
Metallic Material Quality Assessment
Conductor Material Types and Characteristics
High-Quality Conductors: Phosphor bronze (C5191), beryllium copper (C17200), or copper alloy plated with gold/silver should be used, possessing high elasticity, fatigue resistance, and low contact resistance.
Plating Thickness: A gold plating layer ≥ 0.8μm is recommended, which can significantly reduce contact resistance (≤5mΩ) and improve corrosion resistance.
Prohibited Materials: Avoid using inferior metals such as iron and zinc, as they have poor conductivity and are prone to oxidation and rust.
Mechanical and Electrical Performance Testing
Tensile Strength and Yield Strength: If used in automotive connectors, they must comply with SAE/USCAR standards to ensure they do not break under vibration.
Contact resistance test: Should be ≤10mΩ (≤5mΩ recommended for precision equipment), using the four-wire method to eliminate wire error.
Salt spray corrosion test: Conduct a 96-hour salt spray test according to ISO 9227 standard; no substrate corrosion or functional failure is considered (qualified).
Material testing methods:
Spectroscopic analysis: Used to detect whether the chemical composition of alloy steel and copper materials meets design requirements.
Tensile and impact tests: Verify the mechanical properties of materials, such as tensile strength and toughness.