Can die cast copper terminals support high thermal loads?
Can Die Cast Copper Terminals Support High Thermal Loads?
Thermal Load Capacity of Copper Die Cast Terminals
Yes, die cast copper terminals—especially those made from high-performance alloys like C18200 and C17500—are well-suited to support high thermal loads. These alloys provide an exceptional combination of thermal conductivity, mechanical strength, and resistance to softening, making them ideal for high-current or heat-intensive electrical environments.
Key Thermal Properties of Copper Alloys
C18200 (Chromium Copper)
Thermal conductivity: ~320 W/m·K
Softening resistance: Up to 400°C
Tensile strength: 415–485 MPa
Ideal for resistance welding electrodes and high-current connectors
C17500 (Beryllium Copper)
Thermal conductivity: ~130 W/m·K
Softening resistance: Up to 480°C
High fatigue strength and stability under cyclic thermal conditions
These alloys maintain structural integrity and contact pressure even under elevated continuous or pulsed thermal loading, preventing terminal deformation and performance degradation.
Design and Casting Considerations for Thermal Durability
To ensure thermal stability and conductivity in terminal applications, Neway applies the following practices:
Optimized Casting Geometry: Uniform wall thickness and thermal mass balancing reduce localized heat buildup.
Material Homogenization: Controlled die temperature and fill rate ensure minimal porosity and uniform grain structure.
Post-Machining for Heat-Critical Surfaces: Critical contact areas are processed with precision CNC machining to ensure clean surface interfaces, improving thermal transfer and current flow.
Industry Applications Requiring High Thermal Resistance
Die cast copper terminals capable of handling thermal loads are used in:
Industrial power connectors and busbars
Electric vehicle battery connectors
Circuit breakers and switchgear terminals
Welding and high-frequency induction systems
Standards and Thermal Compliance
Neway’s copper terminals comply with:
ASTM B124 – Copper and copper alloy forgings
ASTM B505 – Continuous cast copper alloy bar/rod
IEC 61238-1 – Thermal performance of electrical connectors under load
These standards validate the long-term thermal and electrical reliability of copper terminal components.
Customer-Oriented Copper Terminal Solutions
Neway Die Casting provides high-performance copper terminal solutions for demanding applications:
Copper Die Casting Services: High-conductivity castings optimized for heat and current management.
Post-Machining Services: CNC finishing for precision interfaces and thermal optimization.
Engineering Consultation: Material and geometry selection support for high-load thermal environments.
