Electrical Contacts and Contact Materials

Electrical contacts and contact materials are soft, high-conductivity, oxidation- resistant materials that are used in circuit breakers, relays, switches, and electrical discharge machining (EDM) applications.  They often have a second phase in order to provide anti-welding and/or arc resistance. Electrical contacts and contact materials are used in many different type of contacts. Battery contacts usually consist of a low-cost base metal that is plated with a layer of high-conductivity metal. Contact probes or spring contacts are brush assemblies with a plunger-style configuration and an internal helical spring. EDM electrodes are designed specifically for EDM applications. Electrical brushes are used in conjunction with slip rings and other contact surfaces to maintain an electrical connection in mobile or rotary applications. Furnace electrodes are used to heat and melt metals or ceramics in arc furnaces. Welding electrodes are designed for resistance, arc, or plasma welding. Specialty electrical contacts and contact materials are also commonly available. 

Electrical contacts and contact materials are available in many different forms. Examples include: contact tips or buttons, contact rivets, EDM drilling electrodes, electrode blocks or billets, pins or probes, solid rod stock, sockets or receptacles, small stampings, sheets or foils, strips or tapes, tamped connections, tapping electrodes, wires, and wheels. Contact tips and contact buttons consist of a shaped pad, often with nibs for welding or serrations fro brazing. EDM drilling electrodes are solid-rod or hollow-tube electrodes used in drilling and trepanning applications. Electrode blocks and electrode billets are raw stock forms that are used to produce EDM electrodes or arc furnace electrodes. Pins and probes are used for testing printed circuit boards (PCB) or electronic components. Custom, application-specific and assembled electrical contacts and contact materials are also available.   

Electrical contacts and contact materials differ in terms of electrode materials, contact probe or battery probe materials, and plating or coating material. Choices for electrode materials include: brass, copper, graphite, carbon graphite, copper graphite, copper tellurium, copper tungsten, copper zirconium diboride, electrographite, metal graphite, molybdenum, palladium, platinum, silver, silver copper, silver cadmium oxide, silver graphite, silver molybdenum, silver nickel, silver tin oxide, silver tungsten, silver tungsten carbide, tungsten, and tungsten carbide.  Contact probe materials and battery probe materials include: aluminum, copper beryllium, copper, gold, nickel, steel, and  stainless steel. Gold, nickel, silver, and tin are the most common plating or coating materials. Current, conductivity, resistivity, tensile strength, flexural strength, outer diameter (OD), length, width, and thickness are also important parameters to consider when selecting electrical contacts and contact materials.

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