Optimization of Cu-Zn alloys-based electrical contacts for energy outlets

Euro-American socket outlets are consumer products marketed in millions annually to meet global energy demands. The modern-day devices require large quantities of conductive materials for their production and with the continuous rise in price of metals such as Copper and Silver, there is a need to identify cost effective alternate materials for contact terminals of socket outlet. In this research, the feasibility of CuZn37 and CuZn36 material combinations along with four conceptual designs for contact terminals are explored through numerical simulation methods. The current carrying capacity of post-fabricated conductors were considered for 16 Ampere ratings for low voltage devices up to 230 Volts. Significant amount of contact pressure is applied on contact terminals on the plug pin to minimize contact resistance which induce Mechanical stress. The study focusses on investigation of the mechanical stress imposed by plug withdrawal forces on these terminals. Further, the optimal terminal options were identified. The study shows that, CuZn37 R410 found to be the most suitable material meeting the IEC60884-1 standards for post-fabricated terminals with withdrawal forces ranging from 2 N to 54 N for 5000 endurance cycles. The study aids in identifying the optimal concept five and cost-effective material-design combination for basic and middle-segment electrical products with reduction of conductive materials and unnecessary consumption of 4.3 tons of material per year.