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Copper & Brass Wire Connect Weld Assembly

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Copper & Brass Wire Connect Weld Assembly

A client in the automotive industry commissioned Norstan, Inc. to manufacture a copper contact assembly, which was to be used within a fuse application. Using a 60 ton punch press and inline welding equipment, we manufactured this part using progressive die metal stamping and wire welding.

The finished assembly weighed .0097 lbs. It measured 1.255" long, .407" wide, and .032" thick. Materials used included pre-plate tin on CDA 110 copper and CDA 260 brass. Our skilled team and state of the art equipment were able to maintain tolerances of ±.0005".

Performing weld presence, shear strength, and full dimensional testing we were easily able to fulfill all of the customer quality requirements. The assembly was then quickly shipped to the client. Extremely satisfied with our work, they hired us to supply them with two to three million units of this contact assembly every year.

To learn more about this project, or for more information on our other products and services, please contact Norstan.

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Copper & Brass Wire Connect Weld Assembly Project Highlights

Product Description This copper contact assembly is used within a fuse application
Capabilities Applied/Processes Progressive Die Metal Stamping
Wire Welding
Equipment Used to Manufacture Part 60 Ton Punch Press
Inline Welding Equipment
Overall Part Dimensions
Length: 1.255"
Width: .407"
Thickness: .032"
Tightest Tolerances ±.0005"
Material Used Pre-Plate Tin on CDA 110 Copper
CDA 260 Brass
Max Material Finish 16 RMS
In process testing/inspection performed
Weld Presence
Shear Strength
Full Dimensional
Estimated Part Weight .0097 lb/Part
Industry for Use Automotive
Volume 2 to 3 Million per Year
Delivery Location United States
Standards Met Customer supplied print, 2D CAD Drawing
Product Name Wire Connect Weld Assembly

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