A Degradation Model of Electrical Contact Performance for Copper Alloy Contacts with Tin Coatings Under Power Current-Carrying Fretting Conditions
Source abstract
Abstract
The fretting degradation of coating materials is complicated when the Joule heating effect of the load current is non-negligible. In this work, the fretting degradation behavior of tin-coated copper alloy contacts was examined across the current range from 5 A to 30 A and the fretting amplitude range from 200 μm to 400 μm. The uniform degradation process and associated mechanisms, including the wear-dominated stage, softening-dominated stage, and oxidation-dominated stage were recognized and interpreted explicitly. An innovative fusion model for the degradation of electrical contact performance, data-driven and based on physics mechanism, was proposed. The contact voltage was selected as the characterization variable and pre-processed by the threshold-crossing filter method and the Levenberg–Marquardt algorithm. The optimal degradation model, considering the coupled effects of current and fretting amplitude, was presented with the use of the support vector regression method. Finally, the prediction accuracy of the model was validated by experiment results.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Electrical Contact Performance and Analysis · Mechanical stress and fatigue analysis · Electronic Packaging and Soldering Technologies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
School of Instrumentation Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
Funding
National Natural Science Foundation of China · Key Research and Development program project of Ningbo City · Postdoctoral Science Foundation of China · Postdoctoral Science Foundation of Heilongjiang
References (40)
Show source-provided references
1. Effect of temperature on the fretting corrosion of tin plated copper alloy contacts10.1016/j.wear.2006.05.020 ↗
2. Vibration-Induced changes in the contact resistance of high power electrical connectors for hybrid vehicles10.1109/TCPMT.2011.2170168 ↗
3. Mechanical behavior and fatigue life estimation on fretting wear for micro-rectangular electrical connector10.1016/j.microrel.2016.09.013 ↗
4. A review and perspectives on predicting the performance and durability of electrical contacts in automotive applications10.1016/j.engfailanal.2020.105143 ↗
5. A Study of the physical characteristics of vibration-induced fretting corrosion10.1109/TCAPT.2006.875901 ↗
6. Fretting fatigue experiment and simulation of WC-12Co coating taking into account the wear effects10.1016/j.surfcoat.2022.128555 ↗
7. Numerical simulation on the effect of current intensity on electrical contact performance of electrical connectors subject to micro-slip wear10.1016/j.wear.2024.205270 ↗
8. The fretting sliding transition as a criterion for electrical contact performance10.1016/S0043-1648(01)00685-8 ↗
9. Effect of fretting amplitude and frequency on the fretting corrosion behaviour of tin plated contacts10.1016/j.surfcoat.2006.03.031 ↗
10. Studies of tin coated brass contacts in fretting conditions under different normal loads and frequencies10.1016/j.surfcoat.2007.03.039 ↗
11. A prognostics and health management roadmap for information and electronics-rich systems10.1016/j.microrel.2010.01.006 ↗
12. Contact and rubbing of flat surfaces10.1063/1.1721448 ↗
13. Fretting wear reliability assessment methodology of gold-plated electrical connectors considering manufacture parameters distribution10.1016/j.microrel.2020.113787 ↗
14. An energy description of wear mechanisms and its applications to oscillating sliding contacts10.1016/S0043-1648(03)00117-0 ↗
15. Fretting corrosion degradation of non-noble metal coated contact surfaces: A theoretical model10.1016/j.triboint.2016.01.006 ↗
16. Degradation data-driven time-to-failure prognostics approach for rolling element bearings in electrical machines10.1109/TIE.2018.2811366 ↗
17. Approach for fault prognosis using recurrent neural network10.1007/s10845-018-1428-5 ↗
18. A novel multi-information fusion grey model and its application in wear trend prediction of wind turbines10.1016/j.apm.2019.02.043 ↗
19. Equivalence analysis of accelerated degradation mechanism based on stochastic degradation models10.1002/qre.2190 ↗
20. Estimation of bearing remaining useful life based on multiscale convolutional neural network10.1109/TIE.2018.2844856 ↗
21. Li, W., Shao, D., and Liu, S. (2014, January 16). Study on PCA-RBF Neural Network Prediction Method of Storage Life for Hermetically Sealed Relay. Proceedings of the 5th International Conference on Reliability of Electrical Products and Electrical Contacts, Wenzhou, China.
22. A sequential bayesian updated wiener process model for remaining useful life prediction10.1109/ACCESS.2019.2962502 ↗
23. Degradation data analysis and remaining useful life estimation: A review on wiener-process-based methods10.1016/j.ejor.2018.02.033 ↗
24. Fouvry, S., Jedrzejczyk, P., Perrinet, O., Alquier, O., and Chalandon, P. (2012, January 23–26). Introduction of a “Modified Archard Wear Law” to Predict the Electrical Contact Endurance of Thin Plated Silver Coatings Subjected to Fretting Wear. Proceedings of the 58th Holm Conference on Electrical Contacts, Portland, OR, USA.10.1109/HOLM.2012.6336604 ↗
25. A tribo-oxidation abrasive wear model to quantify the wear rate of a cobalt-based alloy subjected to fretting in low-to-medium temperature conditions10.1016/j.triboint.2018.04.032 ↗
26. Prediction of the electrical contact resistance endurance of silver-plated coatings subject to fretting wear, using a friction energy density approach10.1016/j.wear.2014.12.006 ↗
27. Influence of the relative humidity and H2S-SO2 polluted air on the fretting wear behavior of silver-plated electrical contacts10.1016/j.wear.2022.204455 ↗
28. Remaining useful life prediction of aviation circular electrical connectors using vibration-induced physical model and particle filtering method10.1016/j.microrel.2018.11.015 ↗
29. Switching Kalman filter for failure prognostic10.1016/j.ymssp.2014.08.006 ↗
30. Feng, Q., Zhao, K., Sun, B., and Zhu, C. (2013, January 8–11). Electrical Connector Ultimate Vibration Load Quantization and Application Technology. Proceedings of the 4th IEEE International Conference on Prognostics and System Health Management (PHM), Milan, Italy.
31. The influence of current load on fretting of electrical contacts10.1016/j.triboint.2008.09.004 ↗
32. Statistical study of voltage fluctuations in power connectors during fretting vibration10.1109/TCAPT.2009.2019633 ↗
33. Effect of electric currents on tribological behaviors of Ti/MoS2 composite film sliding against aluminum10.1088/2051-672X/ab1d9e ↗
34. Thermo-mechanical study of a power connector10.1016/j.measurement.2012.02.007 ↗
35. Meng, Y., Fang, H., Zhang, C., He, Y., and Ren, W. (2023, January 4–11). Investigation on Melt Erosion Phenomenon of Heavy-Duty Connectors under Fretting Conditions. Proceedings of the 68th Holm Conference on Electrical Contacts, Seattle, WA, USA.10.1109/HOLM56075.2023.10352262 ↗
36. Effects of current load on wear and melt erosion of electrical contacts under fretting condition10.1016/j.triboint.2024.109511 ↗
37. Effects of current load on wear and fretting corrosion of gold-plated electrical contacts10.1016/j.triboint.2013.09.024 ↗
38. Slade, P.G. (2014). Electrical Contacts: Principles and Applications, CRC Press. [2nd ed.].
39. Braunovic, M., Konchits, V.V., and Myshkin, N.K. (2006). Electrical Contacts: Fundamentals, Applications and Technology, CRC Press.10.1201/9780849391088.ax3 ↗
40. Stability analysis of the modified Levenberg-Marquardt algorithm for the artificial neural network training10.1109/TNNLS.2020.3015200 ↗