Copper parts for conductive disc holders are prone to deformation and fracture?

In the fields of power equipment, new energy vehicle charging piles and industrial automation, conductive disc holders are the core carriers of current transmission, and their material stability directly affects the safety and life of equipment operation. However, traditional sand-cast or die-cast copper parts often suffer from internal pores, loose tissue and other problems, resulting in attenuation of conductive performance, insufficient mechanical strength, and even short-circuit accidents. With 20 years of precision casting experience, Dongguan Xingxin Machinery Hardware Fittings Co., Ltd. (WEINAN) launched Gravity Cast Copper Parts for Conductive Disc Holders, redefining the quality standards of copper parts with three major technological breakthroughs, helping customers achieve "zero failure, long life" conductive solutions.

Advantage 1: Gravity casting process to eliminate internal defects

Traditional sand-cast copper parts rely on natural solidification of molds, which are prone to defects such as shrinkage cavities and cracks, resulting in large fluctuations in conductivity (usually ≤85% IACS). WEINAN uses vertical parting gravity casting technology to achieve the following improvements by precisely controlling the copper liquid filling speed and solidification direction:

Increased density: The density of copper parts reaches 8.9g/cm³, which is 12% higher than that of sand castings, and the conductivity is stable at more than 92% IACS;

Defect rate reduction: Ultrasonic flaw detection shows that the internal porosity is ≤0.05%, which is far lower than the industry average of 0.3%;

High dimensional accuracy: The tolerance of key parts is controlled within ±0.05mm, reducing subsequent machining allowance and reducing material waste.

The measured data of a new energy vehicle charging pile manufacturer shows that after using WEINAN gravity casting copper parts, the contact resistance of its conductive disc bracket is reduced from 120μΩ to 45μΩ, the temperature rise is reduced by 60%, and the pass rate is increased to 99.9%.

Advantage 2: Copper-chromium-zirconium alloy formula, high temperature resistance and creep resistance

When the conductive disc bracket passes high current for a long time, the local temperature can reach more than 200℃, and ordinary copper (C1100) is prone to softening and deformation. WEINAN develops CuCrZr alloy materials, which significantly improve the high-temperature performance of copper parts by adding 0.8%-1.2% chromium and 0.1%-0.3% zirconium:

Improved hardness: After solid solution + aging treatment, the hardness reaches HRB 85-90, which is 1.8 times that of pure copper;

Strong creep resistance: After continuous work for 1000 hours at 200℃, the deformation is only 0.02mm, meeting the IEC 60269 standard;

Electrocorrosion resistance: The surface oxide layer is dense, and there is no rust in the salt spray test (NSS 500h), which extends the service life of outdoor equipment.

At present, the material has passed UL and CE certification and is widely used in high-end scenarios such as photovoltaic inverters and rail transit traction systems.

Advantage 3: Modular design, compatible with multiple specifications of conductive discs

To meet the customization needs of different customers, WEINAN provides standardization + flexibility dual services:

Standard parts library: covers conductive disc brackets with diameters of 50mm-300mm, and supports immediate delivery;

Quick mold opening: For non-standard sizes, 3D modeling and mold design are completed within 7 days, and the first batch of samples are delivered within 15 days;

Integrated solutions: copper busbar connectors, insulating sleeves and other accessories can be provided to reduce customer supply chain management costs.

A power equipment manufacturer reported that by adopting WEINAN's modular copper parts, its product development cycle was shortened from 3 months to 6 weeks, and its annual production capacity increased by 40%.

Cooperate now and enjoy WEINAN's full-link support

Dongguan Xingxin Machinery Hardware Fittings Co., Ltd. now provides the following services to global customers:

Free sample testing: customers send conductive disc drawings or physical objects, and WEINAN's technical team will provide feedback on the adaptation plan within 48 hours;

Bulk purchase discount: single orders of more than 5,000 pieces will enjoy a 10% discount and bear domestic logistics costs;

Quality traceability system: each product comes with a unique code, supporting full quality traceability from raw materials to finished products.

Contact information:

Tel: +86-13662765916

Email: dglxzz168@163.com

Official website: www.xingxinmachinery.com

Address: No. 385, Manfeng Group West Road, Dani Village, Shatian Town, Dongguan City, Guangdong Province, China