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Material Variations

When it comes to metal stamping, PEP Brainin manufacturing engineers know all about material variations that harmonize well with our customers’ manufacturing,

PEP Brainin's materials science expertise ensures  your electrical contacts, metal stampings and assemblies meet design specifications - for applications ranging from automotive air bag brackets, as shown above...

PEP Brainin’s materials science expertise ensures your electrical contacts, metal stampings and assemblies meet design specifications – for applications ranging from automotive air bag brackets, as shown above…

component performance and cost objectives. For example, last year, we stamped 1100 variations encompassing a broad range of material widths, thicknesses, compositions and properties.

Here is a closer look at some of the material variables we routinely deal with.

Materials

Base metals, particularly copper and copper alloys, are used extensively in

switches and electrical components. Stainless steel is very hard and durable and provides high corrosion resistance. Is very commonly used for medical components. Cold rolled steel is strong and relatively inexpensive. It is used to produce all sorts of bracketing and is a mainstay of the automotive industry.

Nickel-based alloys are used in applications that require corrosion resistance at high temperatures and thermal stability in the automotive industry for various air bag components.

... to terminals used in power distribution...

… to terminals used in power distribution…

Other alloys such as titanium and tantalum can be exceptionally difficult to stamp and require special attention to tooling design and maintenance (including the application of special coatings and lubricants) for long-term cost and performance.

Aluminum is a very soft material, which requires special attention to prevent galling.

Thermostat metals are utilized for parts designed to expand or contract precisely as heat is added or taken away.

Precious metals – including gold, silver, platinum, and palladium and their alloys – are primarily used for electrical contacts.

Clad metals* combine properties of dissimilar metals such as strength,

... to gun magazine boxes.

… to gun magazine boxes.

electrical/thermal conductivity, wear resistance, and hardness.  Those used in electrical contact applications are often a copper-based material with inlay, overlays or tri-metal layers that provide optimal precious metal placement and utilization.

Plated materials are stamped either before or after the plating process, which can enhance conductivity, corrosion resistance, or other improved properties.

Thicknesses and Widths

PEP Brainin works with materials as thin as one thousandth of an inch (.0254 mm)  – essentially, foil.  This presents many challenges with tool design and material handling. On the thicker end of things our 400-ton press can accommodate materials up to about a quarter of an inch (6.35 mm).

PEP Brainin engineers like to believe we can stamp almost anything. Please allow us to apply our broad materials experience to your challenging project.