Mitigating electrode erosion through molten metal confinement in ceramic nanowire networks

Metal electrodes in high-current switches endure intense thermal shocks (e.g., arc discharge), eroding through mechanisms such as metal evaporation, molten droplet splashing, and subsurface pore/crack formation. These degrade electrical contact quality, aggravating erosion and accelerating premature failure. Here, we demonstrate that incorporating ceramic nanowire networks (e.g., ZnO) effectively confines molten metal (e.g., Ag), mitigates electrode erosion, and enhances contact durability. Unlike extensively studied ceramic nanoparticle-metal composites, high-aspect-ratio nanowires readily entangle to form a cohesive 3D network, holding the metal together in both solid and molten states, maintaining the composite’s electrical and mechanical properties and structural integrity. The network significantly increases molten metal viscosity, suppressing flow, splashing, and subsurface pore/crack formation. Consequently, the improved microstructural stability results in sustained contact performance after repeated arc-discharge testing.