EuroWire March 2020

Manufacturing Technology

Copper-based alloy for fasteners

In addition to ultra- ne wires, cables and stranded wires made from ISA-CON 414, Isabellenhuette produces preliminary materials for fasteners made of ISA-CON 450, another version of the copper-based alloy. The alloy reduces electrical resistance and dissipates excess heat. Both types of material, ISA-CON 414 and ISA-CON 450, are characterised by a high strength (similar to that of stainless steel) and high conductivity (similar to that of copper). With ISA-CON 450, the tensile strength is between 450 and 550 megapascal and the conductivity is 80 per cent ACS, the international Annealed Copper Standard. This combination makes the material suitable as a conductive fastener, for example as a bolt, screw, spring contact, plug connector or bus bar.

The requirements for the bolt application were a signi cantly reduced electrical resistance and thus a signi cantly reduced heat development of the bolt itself. Direct use here means that the entire current is conducted directly via the ISA-CON 450 bolt, which connects a shunt resistor with a plug. Thanks to the high conductivity of the alloy, there is only low electrical resistance with correspondingly reduced heat development in the contact bolt. In addition, heat development, which usually occurs in the shunt resistor, is dissipated better and is reduced by 50 per cent compared to a component with a steel contact. Another plus: ISA-CON 450 – like ISA-CON 414 – is also heat-resistant, which means the bolt retains its mechanical strength in applications with higher ambient temperatures. Current-carrying steel components that are di cult to cool, or that have to be signi cantly oversized to ensure su cient conductivity, can be replaced with ISA-CON 450. Mechanically supportive fasteners made of copper are also often oversized to comply with mechanical loads. The increased strength of ISA-CON means cross-sections can be reduced while maintaining the same level of safety. This allows for a reduction in weight and space, highly relevant for the automotive sector. An indirect connection replaces a previously non-current- carrying component, such as a steel screw, which presses a contact onto a bus bar. The pressed contact surface here and thus the component surface can be reduced, since part of the current can ow through the screw. The screw o ers additional safety due to its high conductivity. The direct use of ISA-CON 450 bolts in particular has a good cost-bene t ratio. Mr Brockhaus, business development manager at Isabellenhuette, said: “If heat development, electric conductivity and contact resistances are insigni cant in application, steel or simple copper alloys, such as bronze or brass, may be su cient. However, if the aforementioned problems occur, ISA-CON 450 is an ideal problem-solving alloy.” The alloy is of interest for all types of mechanically stressed plug connectors, which require high conductivity and reliability. Isabellenhuette Website: www.isabellenhuette.de

▲ The alloy reduces electrical resistance and dissipates excess heat

The ENKOnail+ series of high-capacity nail manufacturing machines incorporates the Enkotec rotary forming principle and a user-friendly machine design. This makes its nail manufacturing machines e cient, while o ering the possibility of automated production and in-line manufacturing. A key factor in the e ciency of Enkotec rotary nail machines is the durable tooling integrated in the process line and guaranteeing smooth, non-stop operations. The ENKOnail+ machines feature a user-friendly PLC control system and touchscreen operator interface, which displays current status, time and nail count. The operator interface is easy to navigate and allows for quick setup of nail parameters. It can be password protected to prevent unauthorised personnel from accessing the setup screens. Enkotec A/S www.enkotec.com When problems occur by using fasteners made of steel, for example, due to excessively high performance loss and heat development, or due to space problems or too much weight, using the ISA-CON 450 alloy is an alternative. With current-carrying components, the electrical resistance, both in the material as well as at the contact transition, is reduced compared to steel. This reduces the loss in performance, and the weight and diameter of components can be reduced too. The direct connection, for example as a bridging of a distance between two bus bars with a supporting function instead of a steel bolt or pin for a plug contact, is a promising application. High cost-e ciency

The ENKOnail+ series from Enkotec

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EF 13/95

www.read-eurofasteners.com

March 2020