Evolution of electrical contact status and wear pattern under various loading conditions for copper-beryllium alloy

Abstract

Electrical contact behavior under fretting conditions is influenced by several factors, among them the most significant ones are current and fretting displacement. In this study, current-carrying fretting wear experiments are conducted on a copper-beryllium alloy to investigate the effects of both factors on the electrical contact status and wear pattern. The evolution of electrical contact resistance (ECR), temperature around the contact zone, and wear morphology with current load and fretting displacement are analyzed to distinguish three different patterns of ECR and two different types of wear morphology. Based on the experimental data, a phase diagram to distinguish electrical contact statuses is drawn based on the equivalent current densities under different conditions. The mechanism for different wear patterns and the tribological transfer structure layer are also revealed. The results can provide theoretical support for the design and application of related electrical connectors.