Abstract
The degradation of Al-Al and Al-Cu electrical connections under fretting conditions has been studied. In addition to contact resistance measurements, scanning electron microscopy (SEM) and X-ray fluorescence analysis were used to study the processes involved. The fretting tests were carried out with a simulated connector configuration at an oscillation frequency of 0.0033 Hz, slip amplitudes of 10 and 25 μm and contact loads of 2 and 10 N on lubricated and non-lubricated connections. The results showed that fretting adversely affects the contact resistance of Al-Al and Al-Cu connections, which show a rapid increase and substantial fluctuations with fretting time. The effects of fretting were reduced to some extent by applying higher contact loads, whereas lubrication practically eliminated the sharp fluctuations in contact resistance. SEM and X-ray fluorescence analysis revealed that considerable damage of the contact zones occurred as a result of the fretting action and substantial transfer of material was observed in Al-Cu connections.
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