Calculating Intermetallic Growth Rates to Set Stamping Tooling Replacement Intervals
Calculating dynamic intermetallic growth rates establishes press stroke limits that prevent tab burrs and optimize die replacement intervals.
Terminal Wear Threshold
Meaning
Maximum allowable physical erosion on contact surfaces defines the point at which a battery connection is no longer considered reliable. The terminal wear threshold is established by testing how much plating or base metal can be lost before contact resistance rises. This value is a primary factor in determining the service life of pluggable connectors.
Surface Analysis
Friction during mating and unmating cycles removes the thin layers of gold, silver, nickel or tin that protect the terminal from oxidation. Once the terminal wear threshold is crossed, the base copper or alloy is exposed to the atmosphere. Corrosion then forms quickly, leading to poor electrical performance.
Failure Mode
Intermittent connections occur when the contact force drops due to the loss of material at the interface. Exceeding the terminal wear threshold can result in arcing, which further damages the surface and creates a major fire hazard. Monitoring the number of cycles helps prevent these conditions.
Maintenance Schedule
Technicians use visual guides and precision gauges to check for signs of excessive thinning, pitting or discoloration. If a connection shows signs of reaching the terminal wear threshold, the component is replaced during the next service window. Proactive replacement ensures the continuous operation of critical power systems.