Progressive Stamping Nickel Plated Busbars for Electrical Power Equipment

Overview

Our progressive stamping nickel plated busbars are precision-engineered conductors for efficient power distribution in electrical equipment. Manufactured from high-conductivity copper alloys and finished with uniform nickel plating, they ensure optimal current carrying capacity, low resistance, and corrosion resistance. We provide full OEM services for custom shapes, sizes, and electrical specifications.

Features:

The Advantages of Our Busbars:

1. Exceptional Electrical Performance: We use high-purity, low-resistance copper alloys (e.g., C1100) and ensure precise plating thickness to guarantee excellent conductivity, minimal power loss, and stable performance under high current loads.

2. Precision Stamping for Perfect Fit: Our progressive dies, crafted with Wire EDM technology, produce complex shapes, precise holes (for bolts/screws), and bends with tight tolerances, ensuring seamless integration into assemblies without need for rework.

3. Superior Corrosion Resistance & Durability: The uniform, pore-free nickel plating provides a robust barrier against oxidation and corrosion in harsh environments, extending the service life and reliability of the electrical connection.

4. Burr-Free, Safe Edges: Advanced fine-blanking techniques and post-stamping deburring processes ensure all edges and holes are smooth, eliminating risks of short circuits, insulation damage, and injury during handling.

Production Process:

1. Material Selection & Slitting: Select high-conductivity copper coil (temper: H00, H01) based on current rating requirements. Precision slitting is performed to the required width.

2. Progressive Die Design & Fabrication: Custom multi-station progressive dies are designed for stamping the exact profile, holes, and bends. Dies are manufactured using precision CNC and Wire EDM.

3. High-Speed Progressive Stamping: The copper coil is fed through the progressive die in a single pass, undergoing sequential operations of piercing, blanking, forming, and coining to create the final busbar shape.

4. Secondary Forming & Heat Treatment: Additional bending or folding is performed if needed. For beryllium copper busbars requiring high strength, age hardening heat treatment is applied.

5. Surface Preparation & Nickel Plating: Stamped busbars undergo cleaning and activation. They are then electroplated with a specified thickness of nickel in a controlled plating line to ensure uniformity and adhesion.

6. Quality Control & Electrical Testing: 100% dimensional inspection. Sample testing includes plating thickness measurement (X-ray fluorescence), conductivity testing, and thermal cycling evaluation.

7. Anti-Tarnish Packaging & Shipping: Plated busbars are treated with anti-tarnish coating, packaged in moisture-barrier materials, and shipped in secure crates.

Our Factory:

We operate a fully integrated manufacturing facility for precision metal stamping and plating. Our plant houses high-tonnage progressive stamping presses (60T to 400T) and maintains an in-house tool & die shop equipped with CNC, Wire-EDM, and surface grinding. A dedicated, automated plating workshop handles cleaning, nickel electroplating, and quality inspection. Our comprehensive quality control includes CMM for dimensional checks, XRF for plating analysis, and micro-ohmmeters for resistance testing. This combination of advanced stamping, precision plating, and stringent QC enables us to deliver high-performance busbars that meet the rigorous standards of the electrical power industry.