03-04-2025 | SV Microwave | Industrial
Gold plating has long been a standard in the connector industry, delivering a unique combination of durability, corrosion resistance, and electrical conductivity. Its application is crucial in aerospace, defence, and telecommunications, where reliable performance under harsh conditions is crucial. This blog examines the key benefits of gold plating on connectors, the diverse applications it serves, and some alternative materials. Understanding these factors will help you make informed decisions about which connectors are best suited for your needs. Some factors are:
The gold plating on connectors provides durability and corrosion resistance, ensuring consistent performance over time. Its ability to withstand corrosion greatly lowers maintenance needs and extends a connector's lifespan, particularly in harsh environments.
Gold is one of the least reactive metals. It does not react with oxygen or moisture, making it highly resistant to oxidation under environmental stressors. This ensures that it will not corrode in extreme environments.
Corrosion in connectors typically manifests as rust, base metal bleed-through, or tarnish, reducing electrical reliability. Rust, in particular, decreases reliability by forming an oxide layer that causes connection and conductivity issues. While tarnishing might not always affect performance, it can have cosmetic implications. A tarnished connector may be perceived as unreliable or damaged, leading to concerns about its performance.
Gold is the third most electrically conductive element, following copper and silver, due to its electron configuration. Although copper and silver surpass gold in conductivity, gold plating on connectors is frequently preferred because of its durability and corrosion-resistant properties, making it more suited for long-term use.
Gold-plated connectors are vital in high-stress environments, such as defence and aerospace applications. These areas demand connectors that endure extreme conditions while maintaining superior electrical and mechanical performance.
Also, gold-plated connectors are valuable in applications that need frequent mating cycles, such as testing and instrumentation. Gold's durability and longevity are excellent for connectors subjected to repeated use.
At SV Microwave, gold plating is applied to varied RF connectors, including blind-mate connectors and those with centre contacts. Any connector featuring a socket is also gold-plated, as its base, typically heat-treated Beryllium Copper, is prone to corrosion if unprotected.
While gold plating on connectors offers numerous advantages, several alternatives exist, including nickel, silver, and passivated stainless steel. These materials can offer cost-effective solutions while providing varying degrees of corrosion resistance.
Passivated stainless steel is commonly used for the company's threaded connectors and provides an excellent alternative to gold plating. The passivation process involves treating steel with nitric or citric acid to remove free iron from the surface. This treatment eradicates impurities that cause rust and forms a protective oxide layer, making the stainless steel more corrosion-resistant. This process applies to our threaded connectors because of their stainless steel bodies.
Silver is more conductive than gold and can serve as an alternative in some applications. However, gold's superior corrosion resistance often makes it the preferred choice.
Nickel plating offers a more cost-effective solution than gold. While it provides a degree of corrosion resistance, it does not match gold's long-term conductivity.
One way the company uses nickel is by underplating it beneath the gold plating. This prevents copper bleed-through, a process in which the copper base material seeps through the gold layer, leading to corrosion over time.
While these alternatives supply certain advantages, none can match the reliability, durability, and corrosion resistance of gold plating on connectors, making it the best option for critical applications.
The thickness and hardness of the gold layer on connectors can affect performance and durability. The company uses different gold thicknesses and hardness levels depending on the specific connector's needs.
Thick gold plating, typically measured at 1.27µm or above, provides superior corrosion resistance and is favoured in applications that face environmental stressors or high mating cycles.
Thin gold plating, around 0.25-0.76µm, is sufficient for connectors employed in low-stress environments. While it offers a cost-effective solution, thin plating can be porous, which may increase the chances of corrosion. As mentioned earlier, the company combats this with nickel underplating, adding an extra layer of protection.
Gold hardness, which varies based on purity levels, affects how well the gold performs under different conditions. With purity levels typically ranging from 99% to 99.9%, hard gold, gold containing more impurities, is particularly suited for connectors that must withstand sliding contact or high mating cycles, as its toughness helps prevent degradation over time.
Gold plating on connectors in any situation may cause gold embrittlement during the solder cycle, compromising performance. The company offers a line of Pre-Tinned Connectors designed to remove gold from solderable areas, preventing embrittlement. It also provides degolding services for cable ferrules, tailored to specific applications.
Gold plating remains the preferred choice for connectors requiring superior durability, corrosion resistance, and consistent performance, especially in demanding environments. While alternatives, like passivated stainless steel, silver, and nickel, offer certain advantages, none provide the same level of long-term reliability that gold does. Whether designing for high-stress applications or seeking a cost-effective solution, understanding the role of plating materials is critical. SV Microwave offers a range of gold-plated connectors and alternative solutions tailored to meet diverse industry requirements.
