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Tin-Zinc plated steel as electrical connector?

Q. I wish to produce a compression electrical connector (about 1 Amp max current) and brass is not strong enough for the space I have available. I need to be able to solder to the connector as well. I am considering a heat treat-able steel, post plated with Tin-Zinc. For use with copper conductors, do you see any pitfalls?

David Makinson
Product Designer - South Carolina
July 28, 2009

A. Hi, David. I am not experienced in connector design, so I could be in error, but I would not use a sacrificial coating on a connector because such coatings are intended to corrode and produce corrosion products which I would expect to interfere with the conductivity. Electroless nickel is a very popular plating for contacts. How does it sound?

Regards,

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
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July 29, 2009

A. Steel is a poor conductor, but may be adequate for your purpose. Electroless nickel can be soldered, but is not as easy as tin or silver which are the usual finishes on solderable connectors. It is not necessary to reinvent the wheel.

Jeffrey Holmes, CEF
Spartanburg, South Carolina
July 31, 2009

Q. We have used tin over steel, but, of course, it does not have the corrosion resistance of other platings, hence the thought of Tin/zinc. I hear Ted on the possible issue with the sacrificial material. Automotive is / was using tin/zinc on grounding lugs, but I was seeking direct experience. So, sounds like I should qualify tin over the steel, or redesign in solid copper.
Thanks for the inputs.

David Makinson
- Seneca, South Carolina
August 5, 2009

A. How about trying White Bronze plating.This is Cu/Tin/Zn having hardness as high as 500 HV

T.K. Mohan
plating process supplier - Mumbai, India
August 31, 2009

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