Is 0.3 µm Gold Enough? Fortuna Busbar Plating tells you the extreme

Busbars play a crucial role in various industrial applications, particularly in the automotive and electronics industries, where they facilitate the efficient transfer of electrical current. The plating of busbars is a critical process, as it ensures reliable and low-resistance connections. This article explores the use of 0.3 m gold plating in busbars, specifically examining why this thickness is effective and how Fortuna Stampings plating techniques achieve a contact resistance consistently below 0.3 milliohms.

Why 0.3 m Gold?

Definition and Significance of 0.3 m Gold Plating

For busbars, the choice of gold plating thickness is not arbitrary but rather determined by a combination of technical requirements and practical considerations. At 0.3 m, the gold layer provides optimal protection against corrosion and wear, ensuring long-term durability and reliable electrical performance. This thickness is widely recognized and endorsed in industry standards for busbar plating.

Benefits of Using 0.3 m Gold Plating

1. Corrosion Protection: Gold's natural resistance to oxidation and corrosion helps prevent degradation of the busbar, extending its operational life.
2. Low Contact Resistance: The thin layer of gold maintains a low contact resistance while minimizing the cost, making it an efficient solution.
3. Durability: Despite its thinness, 0.3 m gold plating offers sufficient protection and reliability, outperforming thicker plating in many applications.

Industry Standards and Recommendations

Industry standards such as those set by the IPC (Institute of Printed Circuits) and ASTM (American Society for Testing and Materials) recommend gold thicknesses that balance performance and cost-effectively. 0.3 m gold plating meets these standards while offering superior performance.

Process Overview

The gold plating process for busbars involves several key steps, each crucial for achieving the desired thickness and properties.

Pre-treatment Steps

1. Cleaning: The busbar surface is thoroughly cleaned to remove any contaminants, such as oils, dirt, and residual oxides.
   • Solution Used: Deionized water, detergent, and mild acid solutions.
2. Etching: The cleaned surface is etched to enhance adhesion and uniformity of the gold layer.
   • Solution Used: Aqua regia (a mixture of nitric acid and hydrochloric acid).

Electroplating Steps

1. Activation: The etched surface is activated with a thin layer of metal ions to improve conductivity.
   • Solution Used: Palladium chloride.
2. Coating: The activation layer is further coated with a thin layer of gold through electroplating.
   • Solution Used: Gold cyanide or gold phosphate solution.
3. Hardening: The gold layer is treated to harden it and enhance its durability.
   • Solution Used: Potassium fluoride or zinc sulfate solution.

Post-treatment Steps

1. Rinsing: The plated busbar is rinsed with deionized water to remove any residual solutions.
2. Drying: The busbar is dried to avoid any moisture contamination.
3. Quality Inspection: Visual and electrochemical tests are performed to ensure the gold layer meets the specified thickness and uniformity.

Contact Resistance Testing

Methodology for Measuring Contact Resistance

Contact resistance is a critical parameter for evaluating the effectiveness of busbar plating. The measurement is typically conducted using a four-wire Kelvin contact method, which allows for precise determination of the contact resistance between mating surfaces.

Fortuna Metals Stampings Technology

Fortuna Metals has extensively tested its busbar plating processes to ensure that the contact resistance remains consistently below 0.3 milliohms. 

Comparison to Other Plating Methods

Comparing the contact resistance of Fortuna Stampings busbar plating process with other methods reveals its superior performance. For instance, copper plating often achieves contact resistance around 0.35 m, while silver plating, though initially lower, can degrade over time due to tarnishing.

Advantages of Fortuna Stamping

Brands Background and Expertise

Fortuna Stamping is a leading manufacturer in the sheet metal fabrication industry, with a long-standing reputation for technical innovation and quality. Our expertise lies in developing innovative solutions for busbar plating, ensuring that our clients receive the highest standards in performance and reliability.

Unique Features and Techniques

1. Advanced Plating Solutions: Fortuna Stamping utilizes advanced plating solutions and techniques to achieve uniform gold deposition and consistent contact resistance.
2. Customizable Processes: We offer tailored solutions for different customers, ensuring that the plating process aligns with specific requirements and applications.

Customer Feedback and Testimonials

Customer feedback has consistently praised Fortuna Stampings plating processes for their reliability and durability. Our commitment to quality and innovation is reflected in the satisfaction of our clients across various industries.

Real-world Applications

Typical Applications in the Automotive Industry

In the automotive industry, busbars are essential for distributing electrical power to various components. Fortuna Stampings 0.3 m gold plating ensures reliable connections and long-term performance, contributing to enhanced vehicle performance and safety.

Applications in the Electronics Industry

Electronics applications require precise control over contact resistance to ensure optimal performance. Fortuna Stampings plating process guarantees low contact resistance and consistent accuracy, making it ideal for use in electronic circuits and devices.

Other Key Applications

In addition to automotive and electronics, Fortuna Stampings plating solutions are also widely used in renewable energy systems, industrial automation, and other power distribution applications. The consistent performance and reliability of our busbar plating make it a trusted choice for a wide range of industries.

Conclusion

In conclusion, 0.3 m gold plating is indeed sufficient for busbar applications, as it provides a balance of corrosion protection, low contact resistance, and cost-effectiveness. Fortuna Stampings plating techniques demonstrate this through consistent contact resistance below 0.3 milliohms, backed by rigorous testing and real-world application success. Our commitment to innovation and quality ensures that our clients receive the highest standards in busbar plating processes.