Electrical Metal Brass Stamping Parts: Solving Corrosion Challenges in EV Components

Electrical metal brass stamping parts are precision components. They are made by stamping brass alloys. They are key in EV electrical systems, like terminals and switches. Corrosion often causes these systems to fail. China's EV sales reached 3.2 million units in 2024. This is a 25% increase from the previous year (data from China Association of Automobile Manufacturers). But 30% of EV breakdowns are caused by component corrosion (data from China EV Technology Network). This article explores EV corrosion pain points, brass's anti-corrosion advantages, targeted technologies, processing guarantees, scenario validation, and related product solutions.

 

 

1. Key Corrosion-Prone Areas in EVs​

 

Battery pack terminals and switch contacts are most at risk. They touch moisture, electrolytes and high temperatures. Brass sheet metal parts terminal in battery packs often rust within 3 years without protection. This leads to over 15% power transmission loss.​

 

2. Why Brass Outperforms Other Materials​

 

Brass contains 60%-70% copper and 30%-40% zinc. It has natural anti-corrosion properties. Pure copper is easy to oxidize. Aluminum has poor conductivity. Brass keeps over 85% conductivity. It also resists electrolyte erosion. This fits EV's needs for efficiency and durability.

 

 

1. Industry often uses 68% zinc brass for brass stamping parts. This alloy forms a 5-8μm dense zinc oxide film on the surface. The film blocks electrolyte penetration. Its corrosion rate is 70% lower than standard brass (tested by China National Material Test Center).

 

2. Brass sheet metal stamping components are plated with 10μm nickel. Then they get a 2μm silicone sealing layer. This double protection passes 96-hour salt spray tests. It meets GB/T 2423.17-2021 standard. It also meets EV's 8-year service life requirement. BYD has adopted this for its 2025 EV models.​

 

3. For cold stamping brass for switch, we add a U-shaped rubber gasket around the contact area. The gasket stops electrolyte leakage into the brass core. This reduces switch corrosion failure rate to ≤0.1%. The industry average is 0.8%.

 

 

Brass has excellent cold stamping performance. This makes sheet metal brass stamping ideal for EV anti-corrosion needs. Domestic servo-stamping machines process cold stamping brass for switch. They achieve ±0.02mm accuracy. Tight fits eliminate gaps where moisture accumulates. Continuous stamping lines produce 250 brass sheet metal parts terminal per minute. They also do 100% online thickness testing. This ensures plating uniformity. This processing precision makes anti-corrosion technologies work. It avoids "technology failure due to poor processing".

 

 

1. EV Battery Packs​

High-zinc alloy and nickel-plated brass sheet metal parts terminal were tested in SAIC's EVs for 5 years. No rust occurred. Power transmission loss stayed below 5%. This meets SAIC's promise: "No battery terminal replacement in 8 years".

 

2. EV Motor Wire Connectors​

High-temperature resistant brass is used for motor wire connectors. It can withstand up to 180℃. These connectors were used in NIO's motors. Even when driving at 120km/h, the motor temperature reaches 160℃. No corrosion or conductivity drop was found.

 

3. EV Central Control Switches​

Cold stamping brass for switch with gasket design was installed in Geely's 2024 EVs. Tests were done in 90% humidity. The switch was operated 100,000 times. Contact resistance remained ≤10mΩ. No power failure happened.

 

 

Xiamen Apollo specializes in electrical metal brass stamping parts designed to address corrosion issues in electric vehicles (EVs). Our products incorporate advanced designs such as high-zinc brass, nickel plating, and structural sealing to withstand corrosion risks specific to EVs. We also offer customized sheet metal stamping services, tailoring the thickness of terminals and other components for optimized performance in EV battery packs.

 

Our company stands out for three key reasons:

 

1. We provide flexible transportation options, including sea, land, and air, ensuring quick deliveries to key EV hubs.

 

2. We hold IS09001-2015 and IATF16949 certifications, ensuring that every batch meets high-quality standards for corrosion resistance.

 

3. Our dedicated R&D team collaborates with EV manufacturers to design anti-corrosion solutions tailored to specific models, helping customers reduce long-term maintenance costs.