1. Electrical Conductivity Classification‌

• ‌Premium Conductivity Group‌ (σ > 20 MS/m):

  • Gold-plated Beryllium Copper (C17200): Contact resistance <5mΩ, for precision instruments
  • Silver-Nickel Alloy (AgNi10): Current-carrying capacity up to 15A/mm²

• ‌Economy Conductivity Group‌ (σ 10-20 MS/m):

  • Phosphor Bronze (C51000): 15% IACS conductivity, 30% cost reduction
  • Tin-plated Brass (C26000): Non-corrosive environments only

‌2. Mechanical Properties Matrix‌

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3. Electrochemical Compatibility‌

• ‌Li-ion Batteries‌: Mandatory Ni/Au plating; prohibit direct copper exposure to electrolyte
• ‌Alkaline Batteries‌: 316L stainless steel recommended (KOH corrosion resistance)
• ‌Lead-Acid Batteries‌: Requires Pb-Sn alloy plating

‌4. Surface Treatment Solutions‌

• ‌Standard Treatments‌:

  • Nickel Plating (5-8μm): Salt spray resistance >96h
  • Gold Plating (0.5-1μm): 40% contact resistance reduction

• ‌Advanced Treatments‌:

  • PTFE Coating: Coefficient of friction <0.1 (sliding contacts)
  • Graphene Coating: 300% thermal dissipation improvement

‌5. Failure Mode Analysis‌

• ‌Stress Relaxation‌:

  • Phosphor bronze: 15% force loss after 1,000h @60℃
  • Beryllium copper: Only 3% force loss under same conditions

• ‌Fretting Wear‌:

  • Gold plating >0.8μm withstands 50,000 mating cycles

‌6. Cost Optimization Strategies‌

• ‌Bimaterial Design‌: 0.1mm Au layer on contact surface + phosphor bronze substrate
• ‌Selective Plating‌: Precious metal coating only on critical contact zones

‌Compliance & Validation‌

• Critical applications (aerospace/medical implants) require ‌DOE (Design of Experiments)‌ validation
• Accelerated aging tests:
  • 85℃/85% RH for 1,000h (JEDEC JESD22-A101)
  • Thermal shock (-55℃⇄125℃, 50 cycles) per MIL-STD-883