Comparison of mechanical properties for several electrical spring contact alloys

Work was conducted to determine whether beryllium-nickel alloy 440 had mechanical properties which made it suitable as a substitute for the presently used precious metal contact alloys Paliney 7 and Neyoro G, in certain electrical contact applications. Possible areas of applicability for the alloy were where extremely low contact resistance was not necessary or in components encountering elevated temperatures above those presently seen in weapons applications. Evaluation of the alloy involved three major experimental areas: 1) measurement of the room temperature microplastic (epsilon approximately 10/sup -6/) and macroplastic (epsilon approximately 10/sup -3/) behavior of alloy 440 in various age hardening conditions, 2) determination of applied stress effects on stress relaxation or contact force loss and 3) measurement of elevated temperature mechanical properties and stress relaxation behavior. Similar measurements were also made on Neyoro G and Paliney 7 for comparison. The primary results of the study show that beryllium-nickel alloy 440 is from a mechanical properties standpoint, equal or superior to the presently used Paliney 7 and Neyoro G for normal Sandia requirements. For elevated temperature applications, alloy 440 has clearly superior mechanical properties.