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Spot Resistance Welding of Brass and Copper Terminals for the water and waste water industry

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Spot Resistance Welding of Brass and Copper Terminals
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The Brass and Copper Terminal parts which we performed spot resistance welding on

A client in the water treatment industry came to Norstan, Inc. in need of a specialty project which required the spot resistance welding and stamping of a brass and copper terminal. The terminals were to be used within a water flow sensing application, and had to meet strict quality specifications as outlined in the customer supplied 2D CAD drawing.

The manufacturing process included spot resistance welding, stamping, heading and assembly. The customer spec called for the use of beryllium copper and brass for the terminals, and silver and cadmium oxide, as well as gold plating, for the contact. The part weighed .006 lbs. It measured .842" long and .281" wide, and held tolerances of ±.003". Upon completion, we performed thorough testing, including a peel test, full dimensional test, and contact torque test.

At Norstan we strive to give our customers the highest level of quality and customer service available. We currently produce between 50,000 to 100,000 per order for this client. To learn more about this project, or for more information on our other products and services, please contact Norstan.

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Spot Resistance Welding of Brass and Copper Project Highlights

Product Description These brass and copper terminals are used within a water flow sensing application
Capabilities Applied/Processes
  • Spot Weld Contact Strip to Terminals
Progressive Die Metal Stamping
  • 2 Dies: Contact Strip and Terminal
Cold Heading
Equipment Used to Manufacture Part 45 Ton Punch Press
Cold Heading Toggle
Overall Part Dimensions Length: .842"
Width: .281"
Tightest Tolerances ±.003"
Material Used
Beryllium Copper
90% AG
Gold Plated
Max Material Finish 16 RMS
In process testing/inspection performed
Peel test
Full Dimensional
Contact Torque
Estimated Part Weight .006lb/Part
Industry for Use Water and Waste Water
Volume 50,000 to 100,000 Pieces
Delivery Location United States
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Brass and Beryllium Copper w/ Auto Contact Insertion Terminal Assembly

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