Durability studies on vibration-loaded electrical contact systems subjected to tribological stress
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Johannes Schautzgy
Abstract
Electrical connectors for signal applications in the automotive sector are subjected to stringent requirements. These systems must ensure dependable signal transmission throughout the service life of a vehicle, even under high stress conditions. To this end, redundantly structured contact systems with several lamellas are often used. Stress due to vibrations during vehicle operation can lead to relative displacements between the electrical contact partners, especially in the resonant frequency range of the connector. Fretting corrosion then leads to increased electrical resistance at the connection and to failure of the system when a certain resistance threshold is exceeded. For studying the durability of electrical contacts, a fretting test bench was developed that allows the emulation of stress due to vibrations on a contact system with test frequencies of up to 300 Hz. The Wöhler model was used for describing the durability as a function of the relative motion. The test procedure and evaluation for determining the model parameters were based on the pearl string method. The test unit was qualified as electrically failed if the resistance exceeded the 15 mΩ threshold. The studies showed that the lifetime of the redundantly structured contact system can be described via an analytic approach based on the methodology for determining Wöhler curves. The distribution function was based on a logarithmic normal distribution. With the aid of scanning electron microscopic analyses in combination with element distribution images from energy dispersive X-ray spectroscopy, it was possible to attribute electrical failure to the oxidation of the base material in the wear track.
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© 2019, Carl Hanser Verlag, München
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Artikel in diesem Heft
- Fachbeiträge/Technical Contributions
- Durability studies on vibration-loaded electrical contact systems subjected to tribological stress
- A new hybrid approach for reliability-based design optimization of structural components
- Investigation of the microstructure of dissimilar welds in duplex stainless steel and low alloyed steel
- Microstructure and fracture performance of 304 stainless steel laser repairs with Al2O3 nano-particles
- Wet corrosion behavior of copper exposed to recycled groundnut oil as biofuel
- Numerical and experimental performance evaluation of an innovatively manufactured centrifugal pump
- Effect of weld parameters on the microstructure and mechanical properties of dissimilar friction stir joints between pure copper and the aluminum alloy AA7075-T6
- Mechanical properties of waste mussel shell particles reinforced epoxy composites
- Effect of fiber length on the mechanical properties of banana fiber – vinyl ester composites
- Effect of rare earth elements on the microstructure and properties of a die-cast aluminum alloy
- Relationship between MnS precipitation and respective effects of Ti-Mg bearing inclusions on the induction of intergranular acicular ferrite
- Influence of graphene coating on altering the heat transfer behavior of microprocessors
- Microstructure and wear of FeCrC, SiC and B4C coated AISI 430 stainless steel
- Potentiometric studies on the influence of poly(N-vinylpyrrolidone) on the thermal degradation behavior of poly(vinyl chloride) blends