Brass Wire Connect Weld Assembly

A client in the automotive industry commissioned Norstan, Inc. to manufacture a copper contact assembly, which was to be used within a fuse application. Using a 60 ton punch press and inline welding equipment, we manufactured this part using progressive die metal stamping and wire welding.
The finished assembly weighed .0097 lbs. It measured 1.255" long, .407" wide, and .032" thick. Materials used included pre-plate tin on CDA 110 copper and CDA 260 brass. Our skilled team and state of the art equipment were able to maintain tolerances of ±.0005".
Performing weld presence, shear strength, and full dimensional testing we were easily able to fulfill all of the customer quality requirements. The assembly was then quickly shipped to the client. Extremely satisfied with our work, they hired us to supply them with two to three million units of this contact assembly every year.