Copper alloys are widely used in manufacturing terminals (also known as pins) for various electrical connectors due to their excellent electrical conductivity, thermal conductivity, and machinability.
Main Processing Methods for Connector Terminals
Selecting the appropriate material is closely tied to the corresponding manufacturing process. The following are the three most common processing methods for connector terminals:
| Processing Method | Description of Characteristics | Typical Application Scenarios |
|---|---|---|
| Machining/Turning | Uses automatic Swiss-type lathes to perform turning, drilling, milling, etc., on copper rods. Advantages: No mold required, highly flexible processing. Disadvantages: Relatively high cost, typically lower efficiency compared to other mass-production methods. | Commonly used for producing solid round pins in connectors such as D-sub. |
| Cold Heading/Forging | Forms the shape by physically extruding copper rod material with a die. Advantages: Lower processing cost than machining, fast forming speed. Disadvantages: Requires dedicated molds, suitable for mass production. | Often used for high-volume pin manufacturing in products like new energy vehicle charging guns. |
| Stamping/Pressing | Uses precision dies to stamp and form copper alloy strips. Advantages: Typically the lowest cost for mass production, extremely high efficiency. Disadvantages: High cost for the precision dies themselves. | This is currently the most widely used processing method for connector terminals, especially sheet-type terminals. |
Common Copper Alloys Sorted by Processing Method and Conductivity
Material selection is a multi-faceted compromise process that must consider factors such as maximum operating temperature, current load, termination method, and cost. The table below provides a preliminary classification and sorting of commonly used copper alloy grades based on processing method and conductivity for design reference:
| Processing Method | Common Copper Alloy Grades (Sorted by Conductivity, High to Low) | Key Properties and Selection Considerations |
|---|---|---|
| For Machined/Turned Pins | C11000 (ETP Copper), C14500 (Tellurium Copper), C36000 (Free-Cutting Brass) | Balances conductivity with machinability. C14500 offers excellent chip-breaking properties. |
| For Stamped Terminals | C11000 (ETP Copper), C10200 (Oxygen-Free Copper), C17200 (Beryllium Copper), C51900 (Phosphor Bronze) | Requires good formability, strength, and spring properties. C17200 offers high strength and fatigue resistance. |
Key Parameters for Comprehensive Material Comparison
For connector copper alloy materials, especially those used for female terminals/sockets, several key parameters must be compared comprehensively:
Electrical Conductivity
Thermal Conductivity
Modulus of Elasticity
Tensile Strength & Yield Strength
Stress Relaxation Data
Hardness
Minimum Bend Radius to Thickness (R/T) Ratio
Actual material selection is a process of mutual compromise and balance between design requirements and practical choices.
Our product range
| Product Category | Product Name | Common Standard Grades | Key Specifications (Typical) | |
|---|---|---|---|---|
| Copper Tubes / Pipes | • Straight & Coiled Tubes • Refrigeration Tubes • Capillary Tubes • Heat Exchanger Tubes |
C11000 (ETP Copper) C12200 (DHP Phosphorous Copper) C12000 (DLP Phosphorous Copper) EN 12735-1: CU-DHP JIS H3300: C1220, C1100 |
Standards: ASTM B75, B88, B280, EN 12735 OD: 3mm - 300mm Wall Thickness: 0.3mm - 10mm Condition: Annealed (O), Hard (H) |
|
| Copper Sheets / Plates | • Hot Rolled Plates • Cold Rolled Sheets • Cut-to-Size Blanks |
C11000 (ETP Copper) C10200 (Oxygen-Free Copper) C26000 (Cartridge Brass) C70600 (90-10 CuNi) |
Standards: ASTM B152, B465 Thickness: 0.5mm - 50mm (Plates: >3mm) Width: up to 1500mm Length: up to 4000mm or custom Condition: Rolled, annealed, mill finish |
|
| Copper Rods / Bars | • Round, Square, Hexagonal Rods • Copper Alloy Rods • Precision Ground Bars |
C11000 (ETP Copper) C36000 (Free-Cutting Brass) C26000 (Cartridge Brass) C10200 (Oxygen-Free Copper) C17200 (Beryllium Copper) |
Standards: ASTM B187, B301, EN 12163, 12164 Diameter: 2mm - 200mm Length: Straight bars up to 6m, coils available Condition: Drawn, extruded, annealed |
|
| Copper Wires | • Bare Copper Wire (Hard/Soft) • Enamelled (Magnet) Wire • Stranded & Bunched Wires • Braided Wires & Flexibles |
C11000 (ETP Copper) C10200 (Oxygen-Free Copper) C10100 (C-OF Copper) Grade: 1/2 Hard, 1/4 Hard, Soft |
Standards: ASTM B1, B2, B3, IEC 60228 Diameter: 0.05mm - 12mm (bare) Conductivity: 100% IACS min. Packaging: Spools, coils, drums |
|
| Copper Foils | • Rolled Strips (in Coils) • Thin Foils • Connector Alloy Strips |
C11000 (ETP Copper) C26000 (Cartridge Brass) C19210 (Phosphor Bronze, 1.0%) C26800 (Yellow Brass) |
Standards: ASTM B152, B465, EN 1652 Thickness: 0.05mm - 3.0mm (Strips), <0.05mm (Foil) Width: 10mm - 600mm (typical coil width) Condition: Hard (H), 1/2 Hard, Soft (O), rolled temper |
Our factory
We are a specialized manufacturing factory with integrated production capabilities for copper and copper alloy products, including tubes, rods, bars, plates, sheets, strips, and wires. Our facility is equipped with modern production lines featuring extrusion presses, continuous casting machines, precision rolling mills, drawing benches, and controlled annealing furnaces, enabling us to control the entire process from raw material to finished product. Supported by an in-house laboratory for quality assurance and compliant with international standards (ASTM, EN, JIS), we provide customized solutions, reliable packaging, and efficient export logistics to serve global clients in HVAC&R, electrical, automotive, and industrial sectors.
copper product packaging
We take great care in packaging to ensure our copper products arrive in perfect condition. Standard packaging includes moisture-resistant materials, sturdy wooden crates or pallets, and protective corner guards to prevent damage during transit. For products requiring enhanced protection against oxidation, such as high-purity copper tubes or finely finished surfaces, we also offer optional nitrogen-purged (inert gas) packaging upon request. This service effectively minimizes surface oxidation during long-distance shipping or storage, ensuring your products maintain their optimal quality upon arrival.
