Norstan, Inc.

• Equipment Used to Manufacture PartBimetal Machine-Composite Contact 45 Ton Punch Press
• Product DescriptionThis brass staked assembly is used within a safety switch application
• In process testing/inspection performedFull Dimensional Contact Torque
• Overall Part DimensionsLength: .540” Width: .300” Thickness: .032”

A client in the appliance industry approached Norstan, Inc. for the manufacturing of a brass staked assembly. Using the customer supplied drawings we were to manufacture the assembly, which was to be used within an appliance safety switch. The manufacturing processes included auto staking, cold heading, and progressive die metal stamping. Equipment used in the process included a bimetal machine-composite contact and a 45 ton punch press. The assembly was made using CDA 260 brass, the contact was composed of; 90% silver and 10% cadmium oxide on copper. The finished product measured .540" long, .300" wide, .032" thick, and weighed .64 lbs. We worked within tolerances of +.000"-.004". Upon completion of manufacturing, we performed contact torque and full dimensional testing. The client was extremely satisfied with all aspects of service and production, and we were commissioned to supply them with 1 to 1.5 million units per order of this brass staked assembly. To learn more about this project, or for more information on our other products and services, please contact Norstan.

• FinishPlain, Brass, Nickel, Passivated, Zinc, Black Zinc, Yellow Zinc, Clear Zinc and Black Oxide.
• MaterialsStainless Steel, Copper, Beryllium Copper, Phosbronze, Brass, Cadmium*, Gold, Indium*, Nickel, Palladium, Platinum, Ruthenium*, Silver, Steel, Tungsten and Iridium*. *Denotes materials typically alloyed with other materials.
• Types AvailableHand staked In-die staked Progressive die type stamping Welded and brazed contacts applied to stamped contacts

• Why Choose A Composite Over A Solid?Composite contacts are chosen over solid to save money on the precious metal that is replaced with copper. Norstan can work with customers to predict if it is a good choice for their application.
• FinishPlain, Brass, Nickel, Passivated, Zinc, Black Zinc, Yellow Zinc, Clear Zinc and Black Oxide.
• MaterialsStainless Steel, Copper, Beryllium Copper, Phosbronze, Brass, Cadmium*, Gold, Indium*, Nickel, Palladium, Platinum, Ruthenium*, Silver, Steel, Tungsten and Iridium*. *Denotes materials typically alloyed with other materials.

Brazed composite heading marries two metals together by bonding them under controlled conditions in a furnace. The bonding material is called a brazing metal alloy, which is a low melting point metalalloy used to attach and metallurgically fuse two metals together after elevating the temperature beyond its melting point.

• MaterialsStainless Steel, Copper, Beryllium Copper, Phosbronze, Brass, Cadmium*, Gold, Indium*, Nickel, Palladium, Platinum, Ruthenium*, Silver, Steel, Tungsten and Iridium*. *Denotes materials typically alloyed with other materials.Stainless Steel, Copper,
• FinishPlain, Brass, Nickel, Passivated, Zinc, Black Zinc, Yellow Zinc, Clear Zinc and Black Oxide.
• Why Choose A Composite Over A Solid?Composite contacts are chosen over solid to save money on the precious metal that is replaced with copper. Norstan can work with customers to predict if it is a good choice for their application.

• FinishPlain, Brass, Nickel, Passivated, Zinc, Black Zinc, Yellow Zinc, Clear Zinc and Black Oxide.
• MaterialsStainless Steel, Copper, Beryllium Copper, Phosbronze, Brass, Cadmium*, Gold, Indium*, Nickel, Palladium, Platinum, Ruthenium*, Silver, Steel, Tungsten and Iridium*. *Denotes materials typically alloyed with other materials.
• Equipment ListOver 50 cold headers, more than a dozen stamping presses - 5 to 50 ton press capability, 5 production in line welders and 4 manual welders.

A solid state rivet contact is a part with a head larger than its body or shank. It is designed to be clinched (or staked) onto another part of an assembly. Solid heading utilizes one metal throughout the entire part - all copper, brass, all silver, or alloys. Our cold heading equipment forms your parts from wire.

• Equipment ListOver 50 cold headers, more than a dozen stamping presses - 5 to 50 ton press capability, 5 production in line welders and 4 manual welders.
• MaterialsStainless Steel, Copper, Beryllium Copper, Phosbronze, Brass, Cadmium*, Gold, Indium*, Nickel, Palladium, Platinum, Ruthenium*, Silver, Steel, Tungsten and Iridium*. *Denotes materials typically alloyed with other materials.
• What Makes Tungsten The Best Choice?Tungsten is very durable and has a melting temperature above 6,000ºF which is several times higher than silver and other metals.

Globally, there are only a few companies that braze contacts made of tungsten. Of these, only Norstan, Inc. is based in the United States. Some applications of tungsten contacts include solenoids and horns.

• Why Choose A Composite Over A Solid?Composite contacts are chosen over solid to save money on the precious metal that is replaced with copper. Norstan can work with customers to predict if it is a good choice for their application.
• Equipment ListOver 50 cold headers, more than a dozen stamping presses - 5 to 50 ton press capability, 5 production in line welders and 4 manual welders.
• MaterialsStainless Steel, Copper, Beryllium Copper, Phosbronze, Brass, Cadmium*, Gold, Indium*, Nickel, Palladium, Platinum, Ruthenium*, Silver, Steel, Tungsten and Iridium*. *Denotes materials typically alloyed with other materials.

• MaterialTerminal: Brass-CDA260 Rivet: 75% AG 24.5% Cu .5% Ni Gold Plated
• Overall Part DimensionsLength: .70" Width: .50" Height: .032"
• Product DescriptionThis brass contact assembly is used within a pressure switch application
• Estimated Part Weight.005lb/part

• MaterialTerminals: Beryllium Copper Brass Contact: 90% AG 10%CdO Gold Plated
• Max Material Finish16 RMS
• Equipment Used to Manufacture Part45 Ton Punch Press Cold Heading Toggle
• Product DescriptionThese brass and copper terminals are used within a water flow sensing application

A client in the water treatment industry came to Norstan, Inc. in need of a specialty project which required the spot resistance welding and stamping of a brass and copper terminal. The terminals were to be used within a water flow sensing application, and had to meet strict quality specifications as outlined in the customer supplied 2D CAD drawing. The manufacturing process included spot resistance welding, stamping, heading and assembly. The customer spec called for the use of beryllium copper and brass for the terminals, and silver and cadmium oxide, as well as gold plating, for the contact. The part weighed .006 lbs. It measured .842" long and .281" wide, and held tolerances of ±.003". Upon completion, we performed thorough testing, including a peel test, full dimensional test, and contact torque test. At Norstan we strive to give our customers the highest level of quality and customer service available. We currently produce between 50, 000 to 100, 000 per order for this client. To learn more about this project, or for more information on our other products and services, please contact Norstan.

• Overall Part DimensionsLength: 1.255" Width: .407" Thickness: .032"
• Max Material Finish16 RMS
• Volume2 to 3 Million per Year
• Product DescriptionThis copper contact assembly is used within a fuse application