In situ observation and understanding of the arc erosion behavior of electrical contact materials

Abstract Arc erosion studies are carried out on electrical contact materials in the switching current experiment. A test rig is developed to capture the 2-D image and the 3-D profile of eroded silver tin oxide electrical contact material in situ. Image processing algorithms are specially presented to accurately recognize the features of erosion region. The initial small patch of erosion traces gradually evolves into the deep crater with the increment of switching cycle enabling a study of the arc erosion behavior. 2-D image, 3-D profile, and micro surface morphologies of the eroded contacts are analyzed and then related to the extent of erosion. The results show that the evolution process of central erosion region could be divided into the enlargement in breadth of contact surface and the extension in depth of contact profile. The end result of arc erosion is the net loss of contact material, which would lead to the substantial reduction of contact force and potential electrical contact instability.