Which copper alloy is best for high-conductivity die cast connectors?
Which Copper Alloy Is Best for High-Conductivity Die Cast Connectors?
Copper Alloys and Electrical Conductivity in Die Casting
For high-conductivity die cast connectors, the most suitable copper alloys are those with high electrical conductivity, excellent thermal stability, and castability. Among available options, C18200 Chromium Copper is the top choice for industrial-grade electrical connectors due to its superior conductivity-to-strength ratio and proven die casting performance.
Why C18200 Is Ideal for High-Conductivity Connectors
Electrical Conductivity: C18200 delivers electrical conductivity up to 80% IACS, making it suitable for power distribution components, grounding systems, and electrical bus connectors.
Mechanical Strength: With a tensile strength of 415–485 MPa, C18200 maintains structural integrity under mechanical stress and thermal cycling.
High-Temperature Resistance: Excellent resistance to softening up to 400°C ensures stable performance in continuous-duty electrical applications.
Wear and Arc Resistance: This alloy is commonly used in resistance welding electrodes due to its arc erosion resistance, making it well-suited for high-cycle electrical connectors.
Alternative Copper Alloys for Specialized Needs
Alloy Type | Key Feature | Typical Application |
|---|---|---|
C17500 (Beryllium Copper) | High strength with moderate conductivity (45% IACS) | Connector housings exposed to vibration |
CuNi10Fe1 (Copper-Nickel) | Corrosion-resistant, stable conductivity | Marine-grade or outdoor power terminals |
Good conductivity and machinability | Decorative terminals or consumer electronics |
Industry Standards and Compliance
Neway Die Casting ensures all copper connector alloys meet international standards, including:
ASTM B124 – Copper and copper alloy forging rod, bar, and shapes.
ASTM B505/B505M – Continuous cast copper alloy specifications.
RoHS Compliance – Restriction of hazardous substances for electrical components.
Customer-Oriented Copper Connector Casting Services
Neway Die Casting offers end-to-end support for high-conductivity connector applications, including:
Copper Die Casting Services: Precision castings using high-conductivity alloys like C18200 and C17500.
Post-Machining Services: Tight-tolerance machining to ensure connector fit and electrical contact integrity.
Custom Engineering Support: Expert consultation for material selection, thermal optimization, and design for manufacturability.
