Contact Failure Research Articles

Characterisation of surface morphology of high voltage DC relay contacts under arc erosion

Abstract High voltage DC relays are a crucial component in new energy vehicles. Due to the high failure rate caused by contact sticking (fusion welding), existing technologies can only analyze contact morphology after failure. There is an urgent need to determine the quantitative characterization value of contact surface morphology and the correlation between morphology, failure mechanisms, and working conditions. In this study, an Olympus DSX1000 microscope is used to extract surface topography data, and a quantitative topography characterization method based on a machine vision system is proposed to quantitatively analyze contact surface changes after arc erosion. Grey correlation analysis was applied to explore the relationship between electrical parameters such as voltage, current, and capacitance, and the contact morphology features. The results show that current and capacitance have the greatest influence on contact surface features after arc erosion, while voltage has a relatively smaller influence. This conclusion is consistent with the experimentally observed arc erosion features. Finally, an arc ion sputtering deposition model was developed to analyze the material transfer mode and its influence on the contact failure mechanism. The results provide a scientific basis for the analysis and design improvement of high voltage DC relays.

Role of Tail Dynamics on the Climbing Performance of Gecko-Inspired Robots: A Simulation and Experimental Study.

Geckos are renowned for their exceptional climbing abilities, enabled by their specialized feet with hairy toes that attach to surfaces using van der Waals forces. Inspired by these capabilities, various gecko-like robots have been developed for high-risk applications, such as search and rescue. While most research has focused on adhesion mechanisms, the gecko's tail also plays a critical role in maintaining balance and stability. In this study, we systematically explore the impact of tail dynamics on the climbing performance of gecko-inspired robots through both simulation and experimental analysis. We developed a dynamic climbing simulation system that models the robot's specialized attachment devices and predicts contact failures. Additionally, an adjustable-angle force measurement platform was constructed to validate the simulation results. Our findings reveal the significant influence of the tail on the robot's balance, stability, and maneuverability, providing insights for further optimizing climbing robot performance.

Unveiling the origin of metal contact failures in TOPCon solar cells through accelerated damp-heat testing

Tunnel oxide passivated contact (TOPCon) solar cells are expected to dominate the global photovoltaic market in the coming decade thanks to rapid advancements in power conversion efficiency (PCE). However, there are concerns about the reliability of TOPCon modules, particularly in hot and humid conditions. The current module-level fundamental analysis strategies for TOPCon solar cells provide too slow feedback for rapid process development. This study explores the degradation of metal contacts in TOPCon solar cells under accelerated testing conditions of 85 °C and 85 % relative humidity (DH85). The degradation was induced by two commonly used sodium-related salts, sodium bicarbonate (NaHCO3) and sodium chloride (NaCl), in the testing of the solar cells. When applied to the front side, NaHCO3 caused a ∼5%relPCE reduction after 100-h DH85 exposure, while NaCl leads to a more significant ∼92%relPCE reduction. The primary cause of degradation is a considerable increase in series resistance (Rs), likely due to electrochemical reactions within the Ag/Al paste. When the salts are applied to the rear of the TOPCon solar cell, the degradation becomes more complex. NaHCO3 increases recombination and results in a deterioration of the contact, resulting in a ∼16%relPCE reduction after 100-h DH85 testing. Conversely, NaCl primarily causes a decline in open-circuit voltage (Voc) and a ∼4%relPCE loss. This manuscript primarily investigates degradation mechanisms related on the rear side, with a focus on significant oxidation occurring at the interface between Ag and Si. These findings highlight the susceptibility of TOPCon solar cells to contact corrosion, emphasizing the electrochemical reactivity of metallisation as a potential risk for long-term TOPCon module operation. This study provides crucial insights into TOPCon cell degradation mechanisms, which are essential for optimising performance and enhancing the long-term reliability of TOPCon modules.

Electrical contact reliability investigation of high-speed electrical connectors under fretting wear behavior

Fretting is one of the common phenomena during the use of electrical connectors, which is usually affected by the working environment and has a significant impact on the electrical contact life. In this work, the influence of different fretting wear conditions on electrical contact failure is studied by combining theoretical analysis, finite element simulation and experimental verification. The mechanical and electrical properties are related through experiments in different environments. It can be concluded that the main causes of electrical contact failure are contact structure deterioration and surface coating loss. Increased fretting cycles aggravate the surface fretting wear of high-speed electrical connectors. The failure of electrical connectors can be delayed by a decrease in frequency and amplitude in addition to an increase in coating thickness. The insertion and withdrawal force gradually decreases due to continuous wear. The failure mechanism of electrical contact during wear is also explained. It provides theoretical guidance for predicting the life of electrical connectors.

An ensemble method for improving robustness against the electrode contact problems in automated sleep stage scoring

In-home automated scoring systems are in high demand; however, the current systems are not widely adopted in clinical settings. Problems with electrode contact and restriction on measurable signals often result in unstable and inaccurate scoring for clinical use. To address these issues, we propose a method based on ensemble of small sleep stage scoring models with different input signal sets. By excluding models that employ problematic signals from the voting process, our method can mitigate the effects of electrode contact failure. Comparative experiments demonstrated that our method could reduce the impact of contact problems and improve scoring accuracy for epochs with problematic signals by 8.3 points, while also decreasing the deterioration in scoring accuracy from 7.9 to 0.3 points compared to typical methods. Additionally, we confirmed that assigning different input sets to small models did not diminish the advantages of the ensemble but instead increased its efficacy. The proposed model can improve overall scoring accuracy and minimize the effect of problematic signals simultaneously, making in-home sleep stage scoring systems more suitable for clinical practice.

Finite element based homogenization of polypropylene/silica micro-composites: experimental work and numerical modeling

Polypropylene (PP) is one of the leading polymers in the polymer industry finding applications from automotive industry to medical equipment and adding silica can make it more desirable. A lot of experimental analysis has been done to study the effect of particle size among other parameters on PP/silica composites. However, very few literatures numerically analyze PP/silica composites. This study focuses on developing a 3D Finite Element based homogenization model that can accurately predict the elastic mechanical properties of PP/micro-silica composites. A Repeating Unit Cell is deployed during this study and periodic boundary conditions are imposed. The contribution of the model was demonstrated by comparing experimental results to the numerical analysis. The maximum error between the two for the Young’s modulus was less than 4% for 3% micro-silica composite. Similarly, to predict the compressive modulus, the maximum error was less than 7%. Parametric study was conducted to demonstrate how the proposed model behaves better than the analytical micro-mechanic models for soft materials like polymer composites and where contact failure occurs between the matrix and particle.

Stabilizing Zn2SiO4 Anode by a Lithium Polyacrylate Binder for Highly Reversible Lithium-Ion Storage.

Binders are crucial for maintaining the mechanical stability of the electrodes. However, traditional binders fail to adequately buffer the volume expansion of Zn2SiO4 anode, causing electrode contact failure and considerable capacity loss during cycling. In this study, we propose a simple and effective solution to address these challenges through a combined strategy of hollow structure design and the introduction of an aqueous lithium poly(acrylic acid) (LiPAA) binder. Hollow structures can shorten ion-transfer distance and accommodate volume change outside. The excellent adhesion of the LiPAA binder created a secure connection between the active Zn2SiO4 particles, conductive additives, and the current collector, which enhanced the mechanical stability and integrity of the electrode. As a result of these positive factors, a Zn2SiO4 electrode using LiPAA as a binder can deliver an excellent capacity of 499 mAh g-1 at a high current density of 5 A g-1 and a long life span of 1000 cycles at 1 A g-1 with a capacity retention of 98%, which significantly outperforms other binders. As demonstrated by ex situ X-ray diffraction and ex situ X-ray absorption spectroscopy, the storage of lithium ions in Zn2SiO4 follows a dual conversion-alloying mechanism, using Zn as the redox center. In this process, Zn is first reduced to metallic Zn and then forms a LiZn alloy upon lithium-ion insertion. This work shows that LiPAA offers a promising approach to improve the cycling longevity of conversion and alloying anodes in Li-ion batteries.

Surface-to-bulk synergistic modification enables stable interface of Ni-rich oxide cathode for all-solid-state lithium batteries

All-solid-state lithium batteries (ASSLBs) are supposed to a highly forward-looking battery technology by reason of their conspicuous energy density and excellent safety. Ni-rich layered oxide cathodes have been extensively studied in ASSLB systems with sulfide electrolytes owing to their high voltage and preeminent specific capacity. However, the electrochemical performance of ASSLBs is severely degraded due to the interfacial physical contact failure, space charge layer effect, and chemical/electrochemical side reactions between sulfide electrolytes and Ni-rich oxide cathodes. In this work, the surface of LiNi0.92Co0.04Mn0.04O2 (NCM92) is coated with a nano-level CeO2 buffer layer and is simultaneously doped with Ce element (NCM92–1%Ce) by one-step wet chemical method. Ce doping is beneficial for maintaining structural stability and suppressing irreversible phase transition. The CeO2 buffer layer can efficaciously avoid the oxidation and decomposition phenomenon at the interface between NCM92 and sulfide electrolyte. As expected, NCM92–1%Ce cathode shows the discharge specific capacity of 141.46 mAh g−1 after 80 cycles at 0.2C with 79.32% capacity retention rate, which is much higher than that of the unmodified NCM92 cathode. The results indicate that the surface-to-bulk synergistic modification strategy can successfully improve the structure toughness and interface stability of Ni-rich oxide cathode for ASSLBs with sulfide electrolytes.

Influence mechanism of grinding surface quality of 20CrMnTi steel on contact failure

To reveal the influence mechanism of the grinding surface quality of 20CrMnTi steel components on the tribological characteristics and contact fatigue performance, accelerated tests for sliding friction wear and fatigue damage were carried out. Tribological characteristics and contact fatigue performance get worse with increasing surface roughness while getting better with increasing surface microhardness. Residual compressive stress is conducive to inhibiting the initiation and propagation of cracks and promoting contact fatigue performance. Additionally, mechanical friction, abrasive wear, adhesive wear and fatigue damage coexist and form a competing failure mechanism under the synergistic effect of frictional wear and contact fatigue failure. The damage process mainly manifests as wear, stress concentration induced fatigue, microcracks, pitting, and spalling in the shallow layer. This study is more beneficial to promote the 20CrMnTi steel transmission parts manufacturing products for high precision, low damage, and long life.

An investigation of the electrical contact failure of JPT electric connectors used in automobiles under multiple stresses

The primary mode of failure in electric connectors is contact failure, one of the reasons is which occurs as a result of external vibrations in the environment. This failure arises due to the reduction in positive pressure on the electric connector terminal caused by the vibration, leading to fluctuations in the electrical contact resistance (ECR). When both vibrational stress and plug/pull stress is simultaneously present, the contact area of electric connectors experiences fretting wear and shear stress, resulting in a more intricate failure mechanism for the electrical connector. Thus, this study presents an accelerated degradation testing method designed to investigate the reliability of the junior power timer (JPT) electric connector employed in automobiles. A temperature resistance test, plug/pull test (sliding wear) and vibration test (fretting wear) were conducted for the JPT electric connector. The electrical contact failure mechanism of the JPT electrical connector was analyzed, with specific focus on its correlation with the concentration of oxides in the contact area.

Analysis of electrical contact characteristics of strap contacts used in high voltage bushings under eccentric conditions

AbstractThe contact finger electrical connection structure is a crucial component of high voltage bushings, and its safety and reliability directly impact the operational stability of the bushing. To investigate electrical contact performance of the contact finger under eccentric conditions, a three‐dimensional electrical, thermal, and force multi‐physics coupling calculation model was established. Additionally, a test platform was constructed to measure electrical contact characteristics of the contact finger. The contact characteristics of the contact finger when the male head was axially deflected and radially offset compared to the female head were obtained. The research findings indicate when the male head deflects axially, the contact force changes of the contact finger blades on both sides are opposite. Moreover, as the axial deflection angle of the male head increases, the resistance of the electrical connection structure shows a rising‐slow decreasing‐fluctuating trend. The resistance is highest at 3°, with a resistance increase rate of 7.35%. Furthermore, the resistance of the electrical connection structure varies with the radial offset of the male head, following a power function. Contact failure occurs when the radial offset is 1.31 mm, and the resistance increase rate reaches 24.9% at a radial offset of 1.58 mm.

Effect of microseparation and corner radius on contact mechanics and failure of dual mobility implants under regular and physically demanding gait loads

Effect of microseparation and corner radius on contact mechanics and failure of dual mobility implants under regular and physically demanding gait loads

FE-analytical slice model and verification test for load distribution analysis and optimization of planetary gear train in wind turbine

Load distribution behavior of planetary gear train (PGT) is crucial for the contact and bending fatigue failure of wind turbine transmission system. With the increasing power of wind turbines, the load and failure rate of wind turbine become larger, which leads to the demand of accurate and efficient modeling, analysis and optimization for load distribution of PGT. In this paper, a new efficient and accurate FE-analytical slice model for load distribution analysis and optimization of PGT in wind turbine is proposed, which is explicitly formulated by the geometry slice model of external/internal gear contact, original FE-analytical slice model for local contact deformation, and efficient finite element (FE) model for global structural deformation. In the FE-analytical slice model, geometry errors are effectively descripted by discretizing gears into a series of slices, while gear tooth contact elasticity and structural elasticity are addressed by the FE-analytical method accurately and efficiently. Upon the proposed model, the load distribution behaviors of PGT with coupling effects of elasticity and errors are revealed and optimized by tooth modification and in-phase eccentricity arrangement strategy. The load distribution tests of PGT in wind turbine are conducted, verifying the proposed FE-analytical slice model which is significant to improve the load-bearing capacity and avoid the fatigue failure of wind turbine transmission system.

Design and development of Rotational Magneto Abrasive Flow Finishing setup powered with machine learning tools for nanofinishing of cylindrical double camshaft followers

Surface finish and morphology play a vital role in the reliability and life of cam-roller or slider mechanisms, with improvement due to lesser contact pressure-based fatigue and failure as surface finish improves. An experimental setup using magnet-based abrasive finishing techniques is designed and developed to conduct studies on a double camshaft follower arrangement that resulted in less than 300 nm finish at an enhanced finishing rate. Finishing rate improves greatly as speed of rotation of the workpiece increases with relatively bigger abrasive particles while the best finish is obtained at lower speeds and particle sizes with progression of the finishing cycles. Subsequently, using the results as the training dataset, a machine learning system is developed to overcome the limitations of surface measurement techniques and human interventions, to predict outcomes like number of cycles, speed of rotation of workpiece, time to reach the desired finish and particle size to be used for the given material of workpiece, initial surface roughness and final desired surface finish. The predictions from the completely trained system are compared with the physics-based model and the real data and the error is found to be within 20 nm which has led to development of a highly reliable system.

Effect of surface rolling process on rolling contact fatigue behavior and failure mechanism of powder metallurgy steel

The effect of surface rolling process on the surface microstructure and rolling contact fatigue of the Fe-2Cu-0.6 C powder metallurgy steel was investigated in the present investigation. Results indicated that a densified and hardened layer with a densification depth of 330 μm and a surface hardness of 330 HV0.1 was generated in the surface layer after rolling process. Ferrite grain and pearlite lamellae became typical fibrous structures on the top surface. The microstructure of pearlite was presented by two typical features. One was that the discrete cementite plates were severely curled and wavy. The other one was that the cementite plates remained parallel to each other, but were a reticular structure at a macroscopic level. The rolling contact fatigue (RCF) test showed that the RCF life of the rolled sample was superior. The L10, L50, L63.2 life increased by 182%, 105%, 92%, respectively. Surface initiated spalling was the main fatigue failure mode. Subsurface equivalent contact stress and local equivalent stress were calculated. The results showed that surface cracks were due to the repetitive tensile stress, which caused pits. Subsurface cracks nucleated and propagated in the region where the local equivalent stress was higher than the matrix yield strength, which caused spalling as connecting with surface cracks. The surface densified layer plays an important role in improving the rolling fatigue resistance of the material.

Nano‐Scale Interface Engineering of Sulfur Cathode to Enable High‐Performance All‐Solid‐State Li–S Batteries

AbstractAll‐solid‐state lithium–sulfur batteries (ASSLSBs) are expected to be the next generation of high‐energy battery systems due to their long lifespan and high safety. However, unstable interfaces between elemental sulfur, conductive carbon, and solid electrolytes lead to slow charge transport and mechanical failures, thereby limiting battery performance. Herein, atomic layer deposition‐derived lithium phosphorus oxide is applied to the surface of carbon/sulfur particles to enhance the interfacial stability of the sulfur cathode and improve the electrochemical performance of ASSLSBs. The coating layer can inhibit electrolyte decomposition and improve interfacial stability by blocking electron conduction between carbon and electrolyte. Moreover, it not only serves as an ion‐conducting layer to facilitate Li+ transport but also acts as a stress buffer layer to alleviate contact failure. The assembled ASSLSBs with sulfide electrolyte exhibit an initial specific capacity of 1322 mAh g−1 at 0.2 C and capacity retention of 86.4% after 300 cycles. Furthermore, ASSLSBs maintain a reversible capacity of 645 mAh g−1 at 0.5 A g−1 after 1000 cycles, confirming the long cycling stability of the coated sulfur cathode. Even under high sulfur loading, ASSLSBs achieve high areal capacities of 4.6 mAh cm−2 at 30 °C and 11.7 mAh cm−2 at 60 °C.

A general phase-field model for simulating impact-sliding contact failure

Multiple failure modes of cyclic impact-sliding contacts, including brittle fracture, shear failure, and low-cycle fatigue, are investigated within the work. For this regard, a general thermo-elasto-plastic phase-field model is developed and validated that considers brittle-ductile failure mode transitions and fatigue degradation effects. And a temperature-dependent cyclic constitutive relation, combined with thermal softening, damage degradation, strain hardening, and fatigue degradation, is introduced to explain the cyclic thermo-elasto-plastic behavior of bearing steels. Combining the dynamic point/line contact model and the general phase-field model, the damage evolution and failure mode transitions of typical bearing parts under impact-sliding contacts are studied. The results indicate that cage-pockets and balls undergo low-cycle fatigue at low impact-sliding velocities, while guiding surfaces of the cage and ring are subjected to shear failure during cyclic high-speed sliding. Moreover, it is revealed that the abnormal phenomenon of more severe damage for the harder material than the softer material is due to multiple effects of strong thermal softening, damage degradation, and fatigue degradation.

Improved interfacial contact and electrochemical performance of highly Ni-rich LiNixCoyMn1-x-yO2 (x>90%) cathode in all-solid-state lithium battery

Single-crystal LiNixCoyMn1-x-yO2 (SC-NCM) cathodes design is an effective solution for enhancing electrochemical performance of all-solid-state lithium battery (ASSLBs). For highly Ni-rich SC cathode (Ni>90 %), the accumulation of local stress caused by anisotropic lattice shrinkage at deeply charging state is more destructive, and even SC-NCM design can not prevent the structure damage and interfacial contact failure between cathode and solid electrolyte (SE). In this work, small-size single-crystal design and Al-doping strategy are firstly combined to synthesize LiNi0.91Co0.04Mn0.04Al0.01O2 (S-SC-NCMA) cathode. Electrochemistry test, CP-SEM, GITT and in-situ EIS techniques are combined to reveal the interfacial evolution of cathode/SE. The kinetic limitation caused by local contact failure of cathode/SE and the formation of intergranular crack under high voltage are the main reason for capacity loss of ASSLBs. Small-size single-crystal design can reduce the volumetric strain effect and Al-doping strategy can further inhibit lattice shrinkage to improve contact. This work provides an effective cathode modification strategy for highly Ni-rich NCM (Ni>90 %) cathode to improve high-voltage performance of sulfide-based ASSLBs.

A comparative study on the electrical contact behavior of CuZn40 and AgCu10 alloys under fretting wear: Effect of current load

The current load is one of the most significant factors in the reliability of electrical contact under fretting conditions. In this paper, the fretting wear experiments are conducted for CuZn40 and AgCu10 alloys with varied current loads. The variations of electrical contact resistance (ECR), ECR endurance, temperature, and wear volume with the increasing current load of two alloy materials under fretting conditions are investigated, and the differences between their electrical contact behaviors are compared. The microstructures of the surface wear morphology are examined to reveal the mechanisms of fretting wear and electrical contact failure. In addition, the fretting wear volume evolution of both alloys under different fretting cycles is studied. The results show the current load impacts the wear morphology. The wear particles become smaller and the oxide layer becomes stable with the increase of current load. The effect of current load on ECR and temperature is more significant for CuZn40 alloy. The ECR endurance for both materials first increases and then decreases. This is attributed to two competitive mechanisms controlling the evolution of ECR endurance under varied current loads.

Low‐velocity impact response of 3D carbon fiber reinforced polymer auxetic lattice structures

AbstractIn this paper, low‐velocity impact properties and impact damage responses of a novel type of 3D hybrid auxetic structures made from carbon fiber‐reinforced polymer (CFRP) laminates were investigated experimentally and numerically. The structures were first fabricated with three different rib's width ratios t1/t0, and then impacted with three different impact energies of 30, 40, and 50 J using a drop tower impact system equipped with a cylindrical impactor. The finite element (FE) models were built in ABAQUS/Explicit, and the Hashin criteria were applied to predict the failure of the structures. The contact force histories, energy histories, displacements, and failure modes were compared between the experiment and FE simulation at all three impact energy levels. The failure morphologies and mechanisms were obtained and studied. The impact testing results suggest that the 3D auxetic structure with a higher t1/t0 ratio can lead to higher peak contact force and sustain higher impact energy. The failure of the structure starts from the middle area and propagates to the upper and lower areas. This research provides a better understanding of the impact responses and failure modes of the 3D auxetic lattice structure, which can promote the potential applications of the auxetic materials.Highlights Drop weight low‐velocity impact responses of 3D novel hybrid auxetic lattice structures are investigated through both experiment and finite element simulation. The effects of structural parameters on the impact performance of the 3D auxetic structures at different impact energy levels are analyzed. The failure morphologies and mechanisms of the 3D auxetic structures are studied.