Micro-special-shaped electric contact composite material is along with relay and switch develop and the small special-shaped contact material of a kind of multilayer that occurs to miniaturization and and Highgrade integration direction.It is a kind of advanced composite material (ACM) that has just grown up.Micro-special-shaped contact is that a kind of small-sized (usually cross-sectional area is less than 1mm for width 0.2~4mm, thickness 0.1~2mm
2) the stratiform composite contact, be widely used in stored-program control exchange, computer and other automatic control equipment, become the important step that signal transmits, the quality of its quality directly has influence on the reliability of place system.Usually micro-special-shaped contact mainly is made up of gold-base alloy electric contacting layer, silver and silver alloy intermediate layer, copper alloy or Ni substrate layer, so the consumption of noble metal is very big.In order to save noble metal to greatest extent, reduce cost, and the reliability of assurance micro-special-shaped contact, various countries relevant department has dropped into great amount of manpower and fund studies how to reduce the ratio of noble metal contact layer in micro-special-shaped contact, especially when the thickness difference in electric contacting layer and intermediate layer is very big, how to realize the compound number of research projects of having carried out between the two.
At present, have for the technology that realizes micro-special-shaped contact composite molding and ultra-thinization of electric contacting layer thickness (less than 10 microns): galvanoplastic, vapour deposition process, rolling, roll welding method.
Galvanoplastic are to adopt the Continuous Selection plating, and noble metal is overlying on the matrix, make electric contacting layer thickness reach micron order.Shortcoming, there is hole in first coating, influences electrical contact performance; The bond strength of its two coating and base layer can not show a candle to roll welding, other method such as rolling, and therefore the live load that can bear is less relatively, and useful life is also shorter; It three is to have problem of environmental pollution; It four is that selectable coated metal kind is restricted.
Vapour deposition process comprises thermal vapor deposition (vacuum evaporation) and electric deposition (cathodic sputtering and ion sputtering) mutually, the surface ratio that is characterized in the multiple layer of vapour deposition adopts the clad surface of other technology acquisition purer, its shortcoming is that equipment investment is big, the material cost height.In the manufacturing of micro-special-shaped contact web, seldom use this method.
In order to realize compound between the band, when adopting room temperature solid phase rolling, primary working modulus generally is not less than 50%.This just requires milling train to have quite high rolling power.Therefore equipment investment is bigger; When if the thickness difference in the electric contacting layer of micro-special-shaped contact web and intermediate layer is very big, for example the ratio of the two is 1: 20 in addition, adopts compound and follow-up processing and forming technology between this method electric contacting layer and the intermediate layer too complexity that seems.
Though the hot rolling method does not have special requirement to the rolling power of milling train.But because this method is brought excessive thermal diffusion inevitably, this is totally unfavorable to the electric contacting layer performance.
Purpose of the present invention just is to work out a kind of manufacturing process of the micro-special-shaped contact web with super thin electric contacting layer newly, makes this technology overcome the shortcoming that above-mentioned existing technology exists.
In order to eliminate the existing many weak points of micro-special-shaped contact web manufacture method in the prior art, the present invention has adopted the specific process of " roll welding one is rolling " to make micro-special-shaped contact web.Said roll welding is a kind of form of electric resistance welding, utilizes roll welding two kinds of materials can be combined.Rolling is adopted in follow-up machine-shaping.But, in order to overcome the shortcoming of prior art room temperature solid phase rolling and hot rolling method, the present invention has studied the new technology of a kind of " same intermediate layer (can be unlike material) be repeatedly compound " on the basis of a large amount of tests, successfully solved the problem that ultra-thinization of electric contacting layer run into.Its method is when the thickness in electric contacting layer and intermediate layer in the design of micro-special-shaped contact finished product band structure differs greatly, same intermediate layer separated into two parts or more parts.The first step is at first compound with contact layer and intermediate layer 1 roll welding, and the system of rerolling processing is thinned to certain thickness with two-layer composite band; Second step was compound two-layer composite band and intermediate layer 2 roll weldings, rolling then processing, three layers of composite band are thinned to certain thickness, can carry out again and intermediate layer 3, intermediate layer 4 by above-mentioned operation ... roll welding is compound, the follow-up rolling certain thickness that is machined to, compound by above-mentioned operation composite band and base layer roll welding that intermediate layer roll welding for several times is compound at last, again through the follow-up rolling required micro-special-shaped contact web that produces
In actual production, can be according to the precision and the ability of equipment, determine the first step and the thickness ratio of roll welding before compound in second step, and the number of times that repeats of second step.
Manufacturing process with micro-special-shaped contact web of super thin electric contacting layer of the present invention, at first will be compound as the band roll welding in the band of electric contacting layer and intermediate layer 1, form the two-layer composite band in electric contacting layer and intermediate layer 1, with the rolling band that is processed as the square-section of above-mentioned two-layer composite band, its thickness is 0.1~2 millimeter, width is 0.3~4 millimeter, be processed into composite band as stated above with electric contacting layer and n intermediate layer, and the rolling band that is processed as the square-section, its thickness is 0.1~2 millimeter, and width is 0.3~4 millimeter; The rolling man-hour rolling pass working modulus of adding is controlled at 10~30%, when reaching 30~70%, total working modulus carries out intermediate annealing, to have an electric contacting layer and n intermediate layer and the rolling band that is processed as the square-section at last, its thickness is 0.1~2 millimeter, width be 0.3~4 millimeter and compound through the band roll welding of annealed composite band and base layer, be rolled processing, the rolling pass working modulus is controlled at 10-30%, carry out intermediate annealing when total working modulus reaches 30-70%, last machine-shaping is the micro-special-shaped contact finished product band with super thin electric contacting layer.
Said special-shaped contact web is to be the special-shaped contact web that is the circular contact web except its cross section, thus special-shaped contact web be exactly its cross section be the contact web of shapes such as triangle, semicircle, rectangle (rectangle) and complexity be trapezoidal.Add man-hour after compound, can be again be processed into above-mentioned various special-shaped contact web with special-shaped roll is rolling with the roll welding of base layer material band.
After will be in roll welding composite rolling process compound as the band roll welding in the band of electric contacting layer and intermediate layer 1, form two-layer composite band, with the rolling band that is processed as the square-section of above-mentioned two-layer composite band, its thickness is 0.1~2 millimeter, width is 0.3~4 millimeter, again will be through the rolling band that is processed as the square-section, its thickness is 0.1~2 millimeter, width be 0.3~4 millimeter and through annealing two-layer composite band be compounded to form three layers composite band again with the band roll welding in intermediate layer 2, with the rolling band that is processed as the square-section of three layers composite band, its thickness is 0.1~2 millimeter, and width is 0.3~4 millimeter, and compound with intermediate layer 4 roll weldings again through annealing.The roll welding of carrying out following intermediate layer as stated above successively is compound, rolling processing is until making the composite band with electric contacting layer and n intermediate layer, and make composite band be processed as the band of square-section with electric contacting layer and n intermediate layer, its thickness is 0.1~2 millimeter, and width is 0.3~4 millimeter and annealing.Said intermediate layer can be one deck, can be multilayer, and the multilayer intermediate layer can be the material of unlike material, but the n in n intermediate layer is with 2~8 for well, also be exactly its intermediate layer be 2~8 layers for good.
The band of said electric contacting layer is gold, gold-base alloy a kind of band of material wherein, and the band that the said band of making the gold-base alloy of electric contacting layer is AuAg8, AuAg10, AuNi5 a kind of material wherein is for well.The band in intermediate layer is wherein a kind of band of material of silver, silver-base alloy, nickel, said is that the band of the band base layer of AgPd40, AgPd60, AgNi10 a kind of material wherein is wherein a kind of band of material of copper, nickel, acid bronze alloy as the intermediate layer silver-base alloy strip material, and said band as the base layer acid bronze alloy is the band of CuNi30, CuNi44 a kind of material wherein.
The thickness of electric contacting layer band is 0.1~2 millimeter, and its width is 0.3~4 millimeter, and its length is 〉=30 meters, and generally between 500~1000 meters, length also can again; Intermediate layer 1,2 ... the n wherein thickness of the band in any one intermediate layer is 0.1~2 millimeter, and its width is 0.3~4 millimeter, and its length is 〉=30 meters, and is general all between 500~1000 meters, longly more also can; The thickness of the band of base layer is 0.1~2 millimeter, and its width is 0.3~4 millimeter, and its length is 〉=30 meters, and long 500~1000 meters usually, length also can again.
Said roll welding is a kind of form of electric resistance welding, and the contact-making surface heating with two kinds of processed bands is combined with each other two kinds of bands exactly.In the roll welding process, do not use any scolder, solder flux in this technology.Used roll welding welding current is 50~4500A (ampere), is good with 50~2000A (ampere) again; The weldingvoltage of roll welding is 1~60V (volt); The band of electric contacting layer and intermediate layer band roll welding compound tense during roll welding, composite strip and any one intermediate layer band roll welding compound tense with electric contacting layer, last and its speed of welding of base layer band roll welding compound tense is 0.7~26m (rice)/min (branch); The pressure that welds during roll welding is 0~2.7MPa, is good with 0.3~2.7MPa again.
Carry out above-mentioned said rolling processing with the method that the one of ordinary skill in the art all knows, the rolling pass working modulus is controlled at 10~30%, carry out intermediate annealing when total working modulus reaches 30~70%, annealing temperature is 150-800 ℃, and the time of annealing is 10~100 minutes.
The micro-special-shaped contact that adopts processing method of the present invention to make has electric contacting layer, intermediate layer, base layer, and described intermediate layer can intermediate layer 1, intermediate layer 2 ... intermediate layer n forms.The thickness of the electric contacting layer of product micro-special-shaped contact web is 2-10 μ m (micron), and the thickness in intermediate layer is 20~160 μ m (micron); The thickness of base layer is 80~1830 μ m (micron).
The laminar composite AuNi5-Ni-CuNi44 (golden nickel 5-nickel-copper nickel 44 is hereinafter to be referred as ANC) of the micro-special-shaped contact web made from technology of the present invention with super thin electric contacting layer, AuNi5 is an electric contacting layer, and Ni is the intermediate layer, and CuNi44 is a base layer.This composite strip combines excellent good corrosion resistance, the resistance to wear of electrical contact performance, chemical stability and CuNi44 (copper nickel 44) of AuNi5 (golden nickel 5), not only saved the consumption of noble metal greatly, improved current capacity, the ANC composite material is widely used in stored-program control exchange.The midget relay of computer etc. and the contact material on the microswitch, this material are heterotypic strip, and its cross section is 0.34mm
2(square millimeter).It is mainly used in the light current occasion, i.e. transmission current little [less than 3A (ampere)], contact pressure little (less than 100g).The cross section metallographic structure of ANC composite material shown in Figure 1 because sectional dimension is too little, and layers of material to a kind of chemical mordant reactions vary, thereby the difficulty of metallographic preparation is very big.Though only base layer is corroded out, however, obviously the cross section of ANC is divided into three layers as can be seen: ground floor is the AuNi5 contact layer; Its thickness is 4~5 μ m, and the second layer is the Ni intermediate layer, the about 30 μ m of its thickness, and the 3rd layer is the CuNi44 base layer, its thickness is about 330 μ m.The interface district is level and smooth, does not have layering and crack, and evenly because the ANC composite material is the processing attitude, as can be seen, its CuNi44 matrix is tiny and fine and close, and can see the plastic deformation rheological curve profile that is processed to form for multiple layer thickness.Contact layer still keeps smooth radian and homogeneous thickness, and certain supporting role has been played in the intermediate layer.
Combining case for clearer understanding ANC composite material has carried out analyzing as can be seen from Figure 2 to its fracture, because the ANC composite material is hard attitude, its fracture plastic deformation feature is not fairly obvious, but has any to affirm, fracture origin is not at boundary layer.This has just illustrated the bond strength height of ANC composite material.
The advantage of the manufacturing process of the micro-special-shaped contact web with super thin electric contacting layer of the present invention is:
1. process of the present invention is than the work simplification of room temperature solid phase rolling, and production efficiency increases, and is fit to the needs of current industrial production.
2. it is littler than the thermal diffusion degree of hot rolling method.
3. owing to adopted " roll welding-rolling, same intermediate layer is composite algorithm repeatedly " to realize ultra-thinization of electric contacting layer, saved noble metal significantly, the rate of finished products height in the technology of the present invention.Faying face between each layer is big, the bond strength height of multiple layer, and be easy to below reduced thickness to the 10 μ m with contact layer; Automated production, cost is low.Adopt the technology of the present invention can the very long panel composite material of production high accuracy.
4. adopt the contact web of explained hereafter of the present invention, can bear than electroplating the bigger live load in contact and having longer useful life.
5. adopted roll welding in the technology of the present invention, the roll welding method can be selected required noble metal electric contacting layer material, base layer material and intermediate layer material for use, realizes three's the optimal mechanical properties and the coupling combination of electrical contact performance, and this point is that galvanoplastic are not accomplished.
6. processes precision height of the present invention.
Among the figure, 1 is electric contacting layer, AuAg8, thickness 5.2 μ m; 2 is the intermediate layer, Ag, thickness 0.097mm; 3 is base layer, CuNi30, thickness 0.13mm.Its cross-sectional width 0.5mm, thickness 0.23mm.
The present invention is further illustrated with following embodiment, will help the understanding to the present invention and advantage thereof, and the present invention is not subjected to the qualification of these embodiment, and protection scope of the present invention is decided by claims.
Embodiment 1
The micro-special-shaped contact web that present embodiment is made with super thin electric contacting layer as shown in Figure 3,1 is electric contacting layer among Fig. 3, its material is AuAg8, thickness 5.2 μ m; 2 is the intermediate layer, and its material is Ag, and thickness is 0.097mm; 3 is base layer, and its material is CuNi30, and thickness is 0.13mm.The width of the cross section of this micro-special-shaped contact web is 0.5mm, and thickness is 0.23mm, and electric contacting layer is 1: 20 with the thickness ratio in intermediate layer.
The manufacture method of the micro-special-shaped contact web with super thin electric contacting layer of present embodiment, used seam welder FN11401, two-roller mill.Be 0.2mm at first with thickness, width is 0.5mm, long 500m's is 0.45mm as the AuAg8 band of electric contacting layer and the thickness in intermediate layer 1, width is the Ag band of 0.5mm, in roll welding welding current 1000A (ampere), the weldingvoltage of roll welding is 3V (volt), speed of welding during roll welding is 10m (rice)/min (branch), welding pressure during roll welding is under the condition of 0.5MPa, the compound back of roll welding forms has the two-layer composite band in electric contacting layer and intermediate layer 1, with the rolling original size that is machined to the cross section of electric contacting layer AuAg8 band of above-mentioned two-layer composite band, promptly being processed into thickness is 0.2mm, and width is two layers of composite band that 0.5mm has electric contacting layer and intermediate layer 1.In the rolling course of processing, the rolling pass working modulus is about 20%, when total working modulus reaches 50%, carries out intermediate annealing and handles, and annealing temperature is 300 ℃, and annealing time is 30 minutes.
To be 0.2mm through rolling processing and the thickness after annealing, width is the two layers of composite band with electric contacting layer and intermediate layer 1 (two layers of composite band of AuAg8/Ag) and thickness 0.45mm of 0.5mm, width is the Ag band as intermediate layer 2 of 0.5mm, in roll welding welding current 1000A (ampere), the weldingvoltage of roll welding is 3V (volt), speed of welding during roll welding is 10m (rice)/min (branch), welding pressure is under the condition of 0.5MPa during roll welding, roll welding is compounded to form has electric contacting layer, intermediate layer 1, three layers the composite band in intermediate layer 2, with the rolling original size that is worked into the cross section of electric contacting layer AuAg8 band of above-mentioned three layers composite band, promptly being processed into thickness is 0.2mm, and width is the electric contacting layer that has of 0.5mm, intermediate layer 1, three layers of composite band in intermediate layer 2.In the operation of rolling, the rolling pass working modulus is about 20%, when total working modulus reaches 50%, carries out intermediate annealing, and annealing temperature is 300 ℃, and annealing time is 30 minutes.
To be 0.2mm through rolling processing and the thickness after annealing, width is that 0.5mm has electric contacting layer and intermediate layer 1, three layers of composite band in intermediate layer 2 (three layers of composite band of AuAg8/Ag/Ag) and thickness 0.26mm, the CuNi30 band of width 0.5mm as base layer, in roll welding welding current 1000A (ampere), the weldingvoltage of roll welding is 3V (volt), speed of welding during roll welding is 10m (rice)/min (branch), welding pressure is under the condition of 0.5MPa during roll welding, and roll welding is compounded to form has electric contacting layer, intermediate layer 1, intermediate layer 2, four layers of composite band of base layer.With the rolling thickness that is worked into of above-mentioned four layers of composite band is 0.23mm, and width is 0.5mm (four layers of composite band with electric contacting layer, intermediate layer 1, intermediate layer 2, base layer of 0.23 * 0.5mm).In the operation of rolling, the rolling pass working modulus is about 20%, when total working modulus reaches 50%, carry out intermediate annealing, annealing temperature is 500 ℃, and annealing time is 40 minutes, makes electric contacting layer AuAg8 thickness 5.2 μ m, intermediate layer Ag thickness 0.097mm, the micro-special-shaped contact finished product band of base layer CuNi30 thickness 0.13mm with super thin electric contacting layer.