Beryllium copper rods (wires) for electronic components
Beryllium bronze rods and wires for electronic components are high-strength, elastic alloys based on copper with beryllium (1.6%-2.0%) and small amounts of nickel, titanium, and other elements. Due to its excellent conductivity, elasticity, wear resistance, and corrosion resistance, it is widely used in precision electronic components such as electronic connectors, switch contacts, and springs. Available in a variety of sizes, rod diameters typically range from 5-50mm and wire diameters from 0.1-10mm. After solution aging treatment, these rods retain copper’s high electrical conductivity (≥20% IACS) while also possessing exceptional strength (tensile strength ≥1100MPa) and elastic limit, meeting the precise transmission and signal transmission requirements of electronic components.
The production process for beryllium bronze rods (wires) used in electronic components requires a complex process involving alloy smelting, ingot casting, hot rolling, cold working, solution aging, and precision machining. First, electrolytic copper with a purity of 99.95% or higher, high-purity beryllium ( 99.5% or higher), and alloying elements are melted in a vacuum induction furnace at a vacuum of ≤ 5×10⁻⁴Pa and a melting temperature of 1050-1100 °C. Electromagnetic stirring ensures a uniform distribution of the beryllium, with a beryllium content tolerance within ±0.05% . Harmful elements such as lead and sulfur are also strictly controlled (≤ 0.001% ) to prevent them from affecting the material’s toughness. A semi-continuous casting process is used to produce round ingots with diameters of 80-120 mm . The cooling rate is controlled during the casting process to prevent beryllium segregation and the formation of pores. Hot rolling heats the ingot to 750-800°C and then rolls it through multiple passes into bars or wires with diameters of 10-60mm. The reduction and speed are controlled during rolling, with each pass achieving a reduction of ≤25% to ensure a dense microstructure and smooth surface. Cold working (cold rolling or cold drawing) is the core process for producing high-precision bars (wires). This process involves multiple passes, with deformation controlled at 10%-20% per pass. Specialized lubricants are used for cooling and lubrication, ensuring a diameter tolerance of ≤±0.01mm and a surface roughness Ra of ≤0.4μm. Solution aging treatment is a key step in improving performance. The material is first heated to 780-820°C for 30-60 minutes, then water quenched to achieve solid solution of beryllium. Subsequently, aging treatment is performed at 300-320°C for 2-3 hours, allowing the beryllium to precipitate as fine particles, forming a reinforcing phase that significantly improves the material’s strength and elasticity. Finally, precision cutting and surface polishing are performed to ensure the straightness and surface quality of the rod (wire).
The performance advantages of beryllium bronze rods (wires) for electronic components make them irreplaceable in the field of precision electronics. First, they have excellent mechanical properties. After solution aging treatment, beryllium bronze has a tensile strength of up to 1100-1300MPa , an elastic limit of ≥ 700MPa , and an elastic recovery rate of ≥ 95% . It can maintain stable elastic deformation under long-term stress and is suitable for precision springs and contact pieces. Second, they have excellent electrical and thermal conductivity, with an electrical conductivity of ≥ 20% IACS and a thermal conductivity of ≥ 180W/(m・K) . They can quickly conduct current and heat, ensuring low contact resistance (≤ 5mΩ ) and heat dissipation performance for electronic connectors and contacts . Third, they have good wear resistance and corrosion resistance. The material hardness can reach HV350-400 and the friction coefficient is small (≤ 0.3 ), maintains low wear even in the absence of lubrication, and has excellent corrosion resistance to air, fresh water, and various organic media, with a service life of over 100,000 operations. Fourthly, it has excellent processing performance and can be processed into components of complex shapes through turning, milling, stamping, etc., with a minimum processing accuracy of up to 0.001mm , meeting the requirements of microelectronic devices. Fifthly, it is non-magnetic, with a magnetic permeability of ≤ 1.002μ₀ , which avoids interference with the magnetic field environment of electronic components and is suitable for communication and sensor fields.
Beryllium copper rods (wires) for electronic components are a core material for precision electronic devices. In the communications sector, 5G base station RF connectors utilize beryllium copper rods with a diameter of 2-5mm, processed into pins and sockets. Their high elasticity and conductivity ensure stable signal transmission, with a plug-in/plug-out lifespan of 1,000 or more. In consumer electronics, smartphone and laptop connector springs utilize 0.1-0.5mm thick beryllium copper wire, achieved through stamping to achieve precise contact and low contact resistance. In automotive electronics, antenna springs and sensor contacts in on-board radars utilize beryllium copper rods, designed to withstand a wide temperature range of -40°C to 125°C. In industrial control, precision relay contacts and springs utilize beryllium copper wire, leveraging its high elasticity and wear resistance to ensure reliable switching (actuation lifespan of 1 million or more). In aerospace, satellite communication equipment connectors utilize high-strength beryllium copper rods to withstand vibration and shock. As electronic equipment develops towards miniaturization and high precision, the application scope of beryllium bronze rods (wires) continues to expand.
Industry trends indicate that beryllium bronze rods and wires for electronic components are moving toward high precision, low beryllium content, and functional composites. Breakthroughs in production technology for high-precision rods and wires have enabled diameter tolerances to be controlled within ±0.0005mm, meeting the demands of nanoscale electronic devices. Low-beryllium bronze (between 1.0% and 1.5% beryllium content) is reduced by adding other alloying elements (such as cobalt and nickel) to reduce beryllium content (reducing toxicity) while maintaining high performance, achieving tensile strength exceeding 1000 MPa. Functional composite materials (such as beryllium bronze-silver composite wire) combine high elasticity with high conductivity through cladding or welding techniques, reducing contact resistance by over 50%. Furthermore, the promotion of green production processes, including the use of closed melting and recovery systems, reduces beryllium volatilization pollution, increasing the beryllium bronze scrap recovery rate to over 95%. Intelligent manufacturing technologies (such as online flaw detection and performance testing) ensure consistent product quality. In the future, with the development of 5G communications, artificial intelligence and the Internet of Things, the demand for beryllium bronze rods (wires) for high-performance electronic components will continue to grow, driving the industry to make greater breakthroughs in material research and development, process optimization, and safety and environmental protection.
