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As the metal with the highest conductivity among all non-precious metals, copper has high toughness, medium strength, and good corrosion resistance, making it the first choice for the manufacture of large conductors, such as cables, busbars, transformer windings, and motor stators and rotors. However, for connector components and commutators, the addition of appropriate alloying elements is required to improve performance 

At the same time, as the functional requirements of automobiles increase, the application of automotive connectors will become more and more extensive. The synthesis trend of automobiles makes connectors more and more integrated, and the requirements for their comprehensive performance are becoming more and more stringent. This also requires copper and copper alloy strips for automotive connectors to have excellent comprehensive performance. This paper discusses the performance requirements of copper strips for automotive connectors, introduces the performance of various high-performance copper alloy strips, and gives reference high-performance copper alloys suitable for various performance requirements of automotive connectors. 

Necessary properties of copper and copper alloy strips for automotive connectors 

The performance required for automotive connectors includes high contact force, small displacement and deformation (limited press stroke but high contact force), small bending angle (product miniaturization), no failure under alternating stress (high insertion and removal times), relatively Low contact resistance, good heat dissipation and low temperature rise, long-lasting high contact force/work in high temperature environment, in line with environmental protection standards. Therefore, this requires that copper and copper alloy strips must have high yield strength, high elastic modulus, high electrical conductivity, excellent bending properties (low r/t), excellent fatigue resistance, high thermal conductivity, and high resistance to stress relaxation. / High temperature softening resistance, no environmentally harmful substances / ROHS and other properties, as shown in Figure 1.

high performance copper alloy

Copper is easy to form copper alloys with other elements, and then the performance of copper can be improved by alloying to meet the performance requirements of copper alloy strips for automotive connectors, as shown in Figure 2.

Figure 2 Effects of addition of other elements on copper properties At present, according to the requirements of automotive connectors on the performance of copper alloys, multiple groups and various high-performance alloys have been developed for selection.

As shown in Figure 3, there are STOL@95 with medium strength and high conductivity, STOL@76M with medium strength and medium conductivity, STOL@94 with high strength and medium conductivity, and CuSn8 with medium strength and low conductivity.

Comparison of typical properties of high-performance copper and copper alloy strips

1. Bending properties

Bending properties refer to the mechanical properties of materials when subjected to bending loads. The bending properties of copper and copper alloys are positively correlated with the manufacturability and reliability of the connector.

In this article, the coefficient R/t (bending radius/strip thickness) is used to evaluate the bending performance of copper and copper alloy strips perpendicular to (good way) and parallel to (bad way) rolling directions, as shown in Figure 4.

It can be seen from Figure 4 that although the bending properties of C103 and STOL80 are better than other alloys, their strength is lower. STOL76M, STOL78, STOL95 and CuSn5 not only have high strength, but also have excellent bending properties, which meet the bending performance requirements of copper and copper alloy strips for automotive connectors.

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