Metal Joining for Electrical Contacts and Integrated Bus Bar Systems

Cladding, brazing, and welding processes engineered to control electrical performance at the contact interface.

Checon applies advanced metal joining and cladding technologies to engineer electrical performance, dimensional control, and long-term reliability at the contact interface. Multi-layer base materials and clad systems are produced in-house and integrated with silver and silver alloy contact materials to support electrical contacts, contact assemblies, and bus bars with integrated electrical contacts.

Depending on application requirements, joining processes include cold cladding, hot bonding, and in-line brazing using Checon’s proprietary Toplay process. Silver and other contact materials are joined to copper, copper alloys, and other substrates through in-press, seam, and resistance welding, as well as furnace and induction brazing.

These processes are engineered to control bond integrity, electrical resistance, and thermal performance at the interface—ensuring consistent switching behavior and long-term reliability across industrial control and power distribution applications.

how we work

Cladding

Checon’s clad contact materials combine dissimilar metals—such as highly conductive copper and high-strength alloys—into engineered composite systems. This enables silver and silver alloy contact materials (AgSnO₂, AgCdO, AgNi) to be precisely applied only where electrical performance is required.

This approach improves cost efficiency while maintaining contact reliability, arc resistance, and durability in switching devices, circuit breakers, and industrial control systems.

Welded and Brazed Material Capabilities

Continuous Seam Welding

Checon produces continuously welded contact tape for electrical contact, switch, and sensor applications. These systems combine a precious metal contact layer with a non-precious base material, delivering consistent electrical performance in continuous coil or cut-to-length configurations.

Resistance Welding

High-speed automated stamping and resistance welding systems support the production of electrical contact components used in electromechanical switches, appliances, and automotive applications, ensuring consistent attachment and repeatable performance.

Toplay and Furnace Brazing

Checon performs brazing in controlled atmospheres using continuous mesh belt furnaces and its proprietary Toplay process, which ultrasonically verifies bond integrity. These high-throughput processes produce millions of electrical contacts annually, including bimetal buttons, studs, and rivet-style contacts.

Contact Us

‍Checon’s metal joining and cladding capabilities are integrated within a vertically integrated manufacturing platform, supporting electrical contacts, contact assemblies, and bus bars with integrated electrical contacts. By controlling joining methods, material interfaces, and process conditions in-house, Checon ensures consistent electrical performance, interface reliability, and long-term durability.

‍Consult with Checon to engineer metal joining solutions for electrical contact performance.

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