ALLOY FOR ELECTRICAL CONTACTS

Abstract: An alloy for forming electrical contacts, comprises by weight Beryllium 1 - 2% Palladium 2 - 20%; and the balance being Nickel. The alloy may contain a trace amount (less than 0.01 per cent by weight) of titanium. An electrical contact may consist of a layer of gold deposited directly on a base of the beryllium/palladium/nickel alloy.

Description: This invention relates to an alloy useful for forming electrical contact areas on printed circuit boards. It is conventional to use beryllium-copper and phosphorus-copper alloys as base materials for electrical contacts. Such alloys make for reliable contacts and exhibit excellent ductility and strength. Satis­ factory use, however, comes at a price. Copper has poor corrosion resistance and tends to diffuse into other elements at a high rate. Accordingly these conventional alloys are sequentially plated with a thick barrier layer and a thick gold layer, with an inherent cost. Nickel is usually used as a barrier layer. Other base materials may be used. Spring steel and alloys such as nickel/silver have proved unsatis­ factory due to problems relating to corrosion, tensile strength, formability, and cost. It is also known to use palladium nickel alloys. They exhibit better properties than pure palladium, but such alloys contain more than 60% by weight of palladium and so are very costly. The present invention seeks to provide a base material for electri­ cal contacts which does not give rise to the problems noted above relating to corrosion resistance and diffusion. The invention provides an alloy comprising by weight between about 1 and about 2 per cent beryllium, between 2 and 20 per cent palladium, and the balance being nickel. No separate barrier layer is required over a base formed of an alloy embodying the invention to prevent its diffusion into a subsequently deposited gold layer. The alloy of the invention exhibits improved corrosion resistance even at elevated temperatures and possesses high tensile strength and formability. The alloy is heat treatable and has a wide range of desirable metallurgical properties. How the invention can be carried out will now be described by way of example. The alloy of the invention is preferably prepared by melting the following blend by weight of the metallic elements and mixing them in their molteon state: nickel 80 - 93% palladium 2 - 20% beryllium 1 - 2% The alloy can be cast in a block. The block is then cooled and worked in a series of rolling and annealing steps to strip. Of course other techniques such as powder metallurgy and sintering may be used to produce the alloy. The component metals must be thor­ oughly blended to obtain the best results. When the component metals are not so blended there is a tendency for the alloy to break along material borders during rolling. If the alloy is desired to be in rod or wire form it may be drawn from a block of the thoroughly blended component metals. It has been found that the addition of trace amounts (less than 0.01 per cent by weight) of titanium to the blend has an advantageous effect on the end product. Titanium assists in the nucleation of the alloy materials to so avoid micro segregration of the metals. The advantageous properties of the new alloy make it a cost effective alternative for a variety of applications. These properties are believed to be brought about because of the palladium in the blend. Known beryllium-nickel alloys have an undesirable tendency to oxidize. Tables I and II indicate the composition and properties of three alloys. It can be seen that Alloy C having 2% beryllium, 5% palladium and the balance nickel exhibits the best hardness and electrical conductivity for the preferred applications. It was found during preparation of the sample alloys that no heat scale formed on any of the three formulations. However, primarily because of cost considerations it was desirable to have a formulation with the least amount of palladium displaying the desired properties. Table III shows resistivity values for three samples of Alloy C as measured over 100 days at 85°C and 85% relative humidity. Table IV records the effects of temperature cycling on the resistivity of three samples of Alloy C over the same period of time. That there is so little change in conductivity level after a prolonged period of exposure indicates the excellent corrosion resistance of the preferred alloy composition. Table V records various mechanical and physical properties of the preferred alloy as measured for different physical conditions. Sample 1 values were measured after the alloy had been rolled to a thickness of 0.25 to 0.33 mm (0.010 - 0.013 mil), without cold or annealing treat­ ments. The second row of values were measured for Sample 2 after it was cold rolled to half hard temper. Sample 3 was annealed and aged at 482°C (900°F) for two hours. Sample 4 was cold rolled and aged to half hard temper at 510°C (950°F) for two hours. Controls 1 - 4 are Alloy 360 (BeNi) in similar conditions. Control 3 was aged at 510°C (950°F) for 2.5 hours; Control 4, at 496°C (925°F) for 1.5 hours. Alloy 360 was chosen as a control for comparison purposes because some of its properties are similar to those of alloys embodying the invention. Alloy 360 has the disadvantage of a tendency towards corrosion problems resulting from the formation of beryllium oxide, requiring cleaning to remove and plating to prevent. As measured for Sample 4, the alloy embodying the invention requires no plating because the forces shown in column 2 are sufficient to break both the oxide layer and adsorbed gases should these form at the surface. Alloys embodying the invention are particularly useful as a base material for electrical contacts. However, they may also be advanta­ geously used to make electrodes and lead frames for packaging electronic components. The advantages of the disclosed alloy include lower cost than conventional materials in part because the gold layer of the total contact structure need not be as thick. No barrier layer is required to prevent the base material from diffusing into a subsequent gold layer. As a consequence, no plating effluents or other environmental disadvantages are produced.

Claims: 1. An alloy comprising by weight between about 1 and about 2 per cent beryllium, between 2 and 20 per cent palladium, and the balance being nickel. 2. An alloy as claimed in claim 1, which comprises from 1.09 to 2.06 per cent by weight beryllium and from 4.7 to 5.4 per cent by weight palladium. 3. An alloy as claimed in claim 1 or claim 2, further comprising a trace amount, less than 0.01 per cent by weight, of titanium. 4. A method of forming a block of an alloy as claimed in any preceding claim, comprising sintering a blend of powdered elemental metals. 5. A method of forming a block of an alloy as claimed in any of claims 1 to 3, comprising mixing a blend of molten elemental metals and making a casting thereof. 6. A method as claimed in claim 5, further comprising alternately rolling and annealing the cast material. 7. A method of forming a rod of an alloy as claimed in any of claims 1 to 3, comprising drawing a rod from a block of the alloy formed by a method as claimed in any of claims 4 to 6. 8. An electrical contact comprising a base made of an alloy as claimed in any of claims 1 to 3. 9. An electrical contact as claimed in claim 8, further comprising a layer of gold deposited directly on the alloy base.

Inventors: MAHMOUD, ISSA SAID
Applicants: INTERNATIONAL BUSINESS MACHINES CORPORATION
Application year: 1987
Main classification: C22C19
IPC codes: C22C19, C22C1, H01H1