What are the manufacturing processes of alloy resistors?

The key steps in the manufacturing process of alloy resistors mainly include the following aspects:


1、 Material selection and alloy preparation
Choose appropriate metal alloy materials: Based on the characteristics of the desired resistor (such as resistance value, temperature coefficient, stability, corrosion resistance, etc.), select suitable metal elements from common alloy materials such as nickel chromium (NiCr) and manganese copper (MnCu).
Alloy preparation and mixing: Accurately weigh selected metal elements in a certain proportion and mix them through methods such as melting or powder metallurgy to form alloy materials with the desired resistance characteristics.
2、 Wire blocking production and heat treatment
Wire blocking production: The prepared alloy material is made into fine wires through wire drawing technology, or an alloy thin film is formed on a conductive substrate through thin film deposition technology. The size and shape of the resistance wire will directly affect the resistance value and power bearing capacity of the resistor.
Heat treatment: Heat treatment is applied to the produced resistance wire to adjust its resistance characteristics and stability. This step usually includes processes such as heating, insulation, and cooling, aimed at eliminating internal stresses in the material, improving its microstructure, and enhancing the stability of its resistance value.
3、 Lead connection and packaging
Lead connection: Connect the made resistance wire to copper leads or other conductive materials through welding, crimping, and other methods to ensure good electrical connection and mechanical strength.
Encapsulation: Encapsulate the connected resistance wire and lead wire in an insulator or ceramic shell for fixation and protection. The packaging material should have good insulation and heat resistance properties to ensure the reliability and stability of the resistor in harsh environments.
4、 Laser adjustment and protective coating
Laser adjustment: Use laser technology to fine tune resistors to achieve the desired precise resistance value. This step usually adjusts the resistance value by selectively removing some thin films or filaments, which has the advantages of high precision and repeatability.
Protective coating: In order to improve the durability of resistors and prevent environmental factors such as moisture, pollutants, etc., a protective coating is usually applied to the surface of resistors. This coating can protect the resistor from mechanical stress, moisture, and pollutants, thereby extending its service life and reliability.
5、 Quality Control and Testing
Visual inspection: Conduct a visual inspection of the resistor to identify any physical defects or irregularities. This step helps ensure the appearance quality and integrity of the resistor.
Resistance measurement: Use precision measuring instruments to measure the resistance value of resistors to verify whether they are within the specified tolerance range. This step is crucial to ensure that the resistor performance meets the design requirements.
Temperature coefficient test: Measure the temperature coefficient of resistance (TCR) to ensure that the resistance value remains stable within the temperature variation range. This step helps evaluate the performance of resistors at different temperatures.
Reliability testing: Conduct rigorous reliability testing on resistors, including thermal cycling, humidity testing, etc., to simulate real-world operating conditions and evaluate their long-term performance. This step helps ensure the reliability and stability of the resistor in various harsh environments.
In summary, the key steps in the manufacturing process of alloy resistors include material selection and alloy formulation, resistance wire fabrication and heat treatment, lead connection and packaging, laser adjustment and protective coating, as well as quality control and testing. These steps together ensure that alloy resistors have stable resistance values, high precision, fast response, and long lifespan, making them widely used in various electronic devices.