30 Sep Improving conductivity and reliability: The power of cold forming in electrical connectors
Electrical and electromechanical connectors’ performance is influenced by their conductivity, as well as their longevity, which determines how reliable they are. In order to supply connectors that combine a high level of conductivity with unparalleled durability, connector manufacturers have developed an innovative means of production. Cold forming technology is emerging as a key method for manufacturing the next generation of electrical connectors.
By shaping metal at room temperature, the cold forming process improves the durability and conductivity of connectors without the need for additional heating. This reduces material waste, energy consumption, and production costs. As well as being a cost-effective and reliable method for manufacturing electrical and electromechanical connectors for a variety of industries such as automotive, electric vehicles, aerospace, telecommunications, consumer electronics, and renewable energy, cold forming can produce high-volume products with tight tolerances. With cold forming, connector manufacturing can be revolutionised and end users can benefit from superior performance.
We are going to take a closer look at how cold forming improves conductivity and reliability of electrical and electromechanical connectors in this blog post.
Improving connector’s conductivity
With the use of a cold forming process, electrical connectors can be improved in terms of their mechanical structure and outer surface quality. It is possible to greatly improve the performance of electrical connectors through the grain structure created as a result of the cold forming process as well as the material characteristics. By reshaping a piece of metal at room temperature, the grain direction of the metal is realigned. The linked metal grains will form a grain flow and align themselves along the forming direction at the same time.
A major advantage of aligning the grains in the connector is that there are virtually no impediments to electrical flow along the forming direction, such as voids or cracks. Electrons flow smoothly through the connector without encountering many obstacles in its material, avoiding an unfavourable threading effect. Therefore, the conductor has a lower resistance to current flow and can carry a higher electrical load. As a result, the conductor is able to carry higher currents and therefore produce more power.
In addition, cold forming increases the density of the material and improves the smoothness of the connector’s surface. As a result, it also contributes to a better electrical performance.
In the high-pressure process, the metal is compressed, allowing microscopic gaps and impurities to be removed that may cause current resistance in the finished product. Generally, the more homogeneous and denser a material is, the freer the electrons will be to move. A cold formed surface is much smoother than a hot formed surface. For example, when the surface is brushed, there will be much less texture than if the surface were hot formed. The flow of electrons will not be hindered by such microscopic effects, nor will friction cause electrons to be removed and converted into heat as a result.
This leads directly to improved contact between the connectors, while still minimising losses associated with contact. As a result, cold forming improves conductivity and reduces energy losses, without compromising the mechanical integrity or strength of the component.
A further benefit of this technology is that it can significantly improve the conductivity of electrical connectors, making them ideal for high-performance electronic applications within the automotive, aerospace and telecommunications sectors.
Enhancing the reliability of connectors
The reliability of electrical connectors is one of the greatest advantages of cold forming technology. As a result of cold forming, the mechanical strength of a material increases directly. Cold-formed components, for instance, are more wear, deformation, and fatigue-resistant than hot-formed components. In addition to having the ability to retain their functionality even after repeated use, cold-formed connectors can withstand high levels of stress, pressure, cycling, or can be designed to operate well in harsh environments for a considerable amount of time. These cold-formed connectors are especially suitable for applications requiring high reliability, such as those in automotive, aerospace, and industrial industries.
Additionally, components made with cold forming are more accurate than those made with hot forming, often with surface-finish tolerances of ten parts per million, or even better. As a result, a higher level of reliability can be achieved in high-temperature, high-vibration, or other corrosive environments as well. The cold forming process enables connectors – and the entire electrical system – to perform more reliably and last longer because it eliminates variation and weaknesses.
Dawson Shanahan: Experts in cold forming for connectors
A cold-forming process does not only help create world-class connectors, but also reduces production times, lowers costs, and eliminates material waste, compared to traditional machining techniques such as milling, turning, and drilling. Explore connector manufacturing using machining processes and cold forming technology here – Connector manufacturing using machining processes and cold forming technology. The advantages of cold forming are that it produces connectors of excellent performance characteristics, having high quality and dependability, and providing seamless electrical connections as well as mechanical stability.
Known for its cold forming expertise, Dawson Shanahan, a group company of Luvata, designs, develops, manufactures and assembles electrical and electromechanical connectors with the utmost precision. Our team of experts provides design, prototyping and precision engineering services. Contact us so we can help you custom design connectors that perform exceptionally. We’re committed to providing you with a hassle-free project planning experience. Get in touch with us to find out more.