The core of the manufacturing process of miniature helical spring welding posts lies in the coordinated control of precision forming and low heat input welding. Key steps include cold rolling forming, material matching, microsecond-level pulse welding, and precise parameter control. A typical material combination is phosphor bronze/beryllium bronze + tin-plated copper wire. Welding parameters need to be dynamically adjusted according to the wire diameter (0.03–0.5mm), with current (5–50A) and time (0.1–2s) to ensure connection reliability.
Main Material: Commonly used phosphor bronze (QSn6.5-0.1) or beryllium bronze (QBe2), possessing high elasticity, fatigue resistance, and good conductivity.
Wire Bonding Material: Tin-plated copper wire or silver alloy wire is used to improve wettability and interfacial bonding strength.
The wire surface needs to undergo degreasing, pickling, and passivation treatment to ensure no oxide layer interference during welding.
Cold Coiling Forming Process
Using a CNC micro-coiling machine, wire is wound into a helical structure at room temperature, controlling the pitch diameter tolerance to ±0.02mm and ensuring uniform pitch.
After forming, stress-relief annealing (300–400℃, 1–2 hours) is performed to eliminate residual processing stress and stabilize the geometric dimensions.
