Case Overview
A precision component manufacturer producing current-sensing resistors and magnetic sensor elements struggled with batch-to-batch resistance variation. Resistor elements stamped from different strip batches had different TCRs (temperature coefficients of resistance), pushing measurement circuits outside specifications at operating temperatures. The customer needed strip with controlled resistive properties and a documented supply chain for sensor-core alloys.
DZX qualified with 0.05 mm resistance-alloy strip (batch-verified TCR) and soft magnetic 1J79 strip for sensor cores, both under one quality system with complete chemistry and performance documentation.
This case summarizes the application requirements, materials supplied by DZX and delivery value. For case-specific technical data, please contact our engineering team.
| Item | Details |
|---|---|
| Client Profile | Precision electronic component manufacturer (sensing and resistive elements) |
| Project Scale | High-volume stamped resistor and sensor elements |
| Application | Current-sensing resistors, magnetic sensor cores and precision shunts |
| Materials Supplied | Precision resistance alloys, soft magnetic 1J79 and CuNi precision alloys |
| Supply Forms | Strip, wire and flat wire |
| Lead Time | Qualification batches: 2 weeks; production batches: 3-4 weeks |
| Project Country | Japan |
| Project Year | 2024 |
Our Solution
The customer’s production line revealed three material problems:
- TCR variation: resistor temperature coefficients differed between strip batches and exceeded the design window, causing measurement accuracy to drift across the operating range.
- Thickness-dependent resistance: strip thickness drift changed stamped-part resistance, requiring batch-specific compensation during assembly.
- Magnetic consistency: sensor cores required stable permeability and low core loss; uncontrolled annealing conditions caused inconsistent sensor outputs.
DZX made resistance and magnetic properties specified requirements:
Precision resistance-alloy strip was rolled to 0.05 mm, with resistance and TCR verified by batch so stamped parts remained within design limits without compensation. Soft magnetic 1J79 strip included documented heat-treatment condition and magnetic-property reports for stable sensor-core permeability. Every batch included chemistry, dimensional and performance documentation in the incoming-inspection format.
| Material | Representative Grades | Key Properties | Available Forms |
|---|---|---|---|
| Precision resistance alloys | 6J13, CuMnNi (Manganin type) | Low TCR and stable resistance | Strip and wire |
| Soft magnetic alloys | 1J79, FeNi50 | High permeability and low core loss | Strip, wire and plate |
| CuNi precision alloys | 6J40, CuNi10-30 | Shunts and terminals | Strip and wire |
View Soft Magnetic Alloys → | View CuNi Alloys → | View Copper and Copper Alloys →
Magnetic cores and shielding
TCR-controlled strip
Stampings and laminations
Technical Specifications
Key technical parameters agreed before production. Contact us for grade-specific datasheets and tolerance-verification reports.
| Parameter | Agreed Specification | Verification Method |
|---|---|---|
| Strip thickness | 0.05 mm ± 0.003 mm | Micrometer, sampling from each coil |
| Resistance per unit length | To drawing, ±2% | Batch resistance testing |
| TCR | Within customer window (e.g. ±10 ppm/°C) | Batch TCR measurement |
| Magnetic properties (1J79) | Permeability to specification | Magnetic-property report |
| Surface condition | Clean, oxide-free and ready for etching | Visual + cleanliness testing |
Each supplied batch includes a quality inspection certificate with chemical analysis, meeting the applicable standard for each grade.
| Material | Applicable Standards |
|---|---|
| Precision resistance alloys | GB/T 1234, IEC 60468 |
| Soft magnetic alloys | GB/T 32288 |
| CuNi precision alloys | ASTM B151 |
| Quality System | Quality inspection certificate including chemical analysis |
Delivery and Quality Support
- Fast delivery: Sample and production lead times follow the project schedule; standard grades and sizes can be dispatched promptly from stock.
- Quality traceability: Every batch includes material certificates and inspection reports, with full heat and batch traceability.
- Technical support: Responsive support covers pre-sale material selection, drawing review and post-sale processing advice.
- Ongoing service: Regular follow-up after delivery tracks performance and addresses feedback promptly.
Customer Feedback
- Batch-verified TCR: resistor elements stayed within design limits without batch compensation
- Dimensional stability: 0.05 mm ±0.003 mm strip eliminated thickness-driven resistance drift
- Consistent sensor output: documented heat treatment and magnetic properties stabilized core performance
- Auditable documentation: batch chemistry, resistance, TCR and magnetic-property reports
- Volume-production readiness: stable supply with 3-4-week lead times
- One quality system: resistance and magnetic alloys coordinated by one manufacturer
Our Capabilities
Jiangsu DZX Technology Co., Ltd. (Changzhou DLX Alloy) was founded in 2016. Its core team has worked in the field since 2002, with 24 years of precision-alloy R&D and production experience, operating a self-owned 12,000-square-meter modern factory with an ISO9001 system covering three inspection stages. Annual alloy output exceeds 1,200 tonnes, serving 1500+ business customers worldwide. The company operates integrated melting, drawing, annealing and precision-machining workshops, supporting volume customization of strip, wire, tube and bar. Every batch includes a chemical analysis report (MTC) for full delivery-quality traceability.
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