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Possibilities of fretting corrosion model testing for contact surfaces of automotive connectors
(2001)
The number of electrical contacts in automotive applications increases steadily. The trends of miniaturisation in all fields of technique and the increasing demands concerning functionality, mechanical and thermal load require the permanent development of connectors. An improvement of electrical connectors can be achieved by coating of the connector elements. Additionally, the price of improved connectors has to remain as low as possible. One of the most important degradation processes that limits electrical functionality is fretting corrosion, caused by vibrations. The development of better coatings requires a check of functionality at a very early state of development. For this purpose different test facilities are available, that be used in order to qualify the improvement. In model tests with simple specimens made of original connector materials the electrical degradation mechanisms caused by friction and wear processes can be studied. It is shown for tin- and gold-coatings that in tribometer tests under certain parameters wear appearances and mechanisms can be similar to that in product testing. Thus, model testing methods can help to reduce time-to-market.