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HIGH PERFORMANCE ALLOYS FOR AUTOMOTIVE ELECTRICAL SYSTEMS

In recent years, vehicles have become more electrical than mechanical, utilizing an increasing number of electrical systems, sensors, and control units to oversee everything from engine ignition to navigation systems to speed control to turn signals and emergency flashers. All of these systems are linked together with electrical connectors. 

SPECIALTY ALLOYS FOR UNDER-THE-HOOD CONNECTORS

Our specialty alloys have been used by major auto manufacturers for more than 30 years for critical electrical systems. For under-the-hood connectors, copper beryllium is the material of choice because of its durability, reliability and performance under extreme conditions that include high temperatures, vibration and moisture. 

With their high strength, conductivity and stress relaxation resistance, copper beryllium alloys offer many advantages in automotive connector applications, including formability that allows for miniaturization and lightweighting, durability for increased lifetime of parts, as well as resistance to heat and corrosion. Recommended alloys include:

  • Alloy 25 – very high strength with good conductivity
  • Alloy 174 – strength with higher conductivity in higher temperature environments
  • Alloy 190 – for very high strength applications and higher temperature environments

ADVANCED MATERIAL PROCESS TECHNOLOGIES OPTIMIZE CONNECTOR ALLOYS 

Nearly all electrical connectors require some type of process technology to provide a specific range of properties required for optimized performance in under-the-hood environments. Using one or more of our advanced technologies can combine the best properties of multiple materials to create unique material systems.  
Our advanced process technologies include:

  • Dovetail cladding – enables problem-free joining of aluminum and copper
  • Electron beam welding – joins dissimilar metals to combine the benefits of both metals in one part
  • Electroplating – deposits materials only where needed on base metals or stamped parts
  • High Strength Aluminum (HSA) - enables a light weight, drop-in alternative to conventional copper-based electrical components
  • Metal cladding – provides high reliability surfaces capable of surviving higher temperatures than electroplating

These processes may be combined to further enhance capabilities and create customized solutions that meet specific application requirements.

EVOLVING TECHNOLOGIES OFFER NEXT-GENERATION SOLUTIONS

Our team of engineers and metallurgists work continuously to advance our alloying, rolling, and bonding techniques to meet the unique, evolving needs of our customers and their applications. Contact us today for more information.