Falex Tribology Case Study 5

Quality
Knowledge
Partner Solutions


Falex Tribology nv
Wingepark 23b | 3110 Rotselaar Belgium
T +32 (0)16 40 79 65 | F +32 (0)16 40 51 28 | office@falex.eu | www.falex.eu


Electrical Connectors
Reliability in Fretting Conditions

Electrical connections in moving
equipment may fail from fretting
damage

Compare different solutions to the
problem by a Falex Fretting Wear
test

Today, electrical connectors are present in many products from cars to mobile phones and
other portable electronics. Because the product moves, the connectors slide over very small
displacements and generate damage that blocks the electrical connection. Such small
displacements are hard to lubricate and damage must be avoided in another way. The
geometry of the connector can be changed, to reduce mechanical pressure, or wear
resistant coatings can be applied, or a suitable grease can be used to avoid the fatal fretting
damage. The different approaches can be tested by a Falex fretting wear test Falex fretting wear test Falex fretting wear test Falex fretting wear test.

Simulate the fretting wear motion on
the real components (or models)
Less than 100 m displacement
Compare useful lifetime of the
electrical contact or low electrical
contact resistance
Compare designs or materials, or the
effect of lubrication or coatings



0 20000 40000 60000 80000 100000
0,0
0,5
1,0
1,5
2,0
Test Geometry A
Fretting at 1 Hz, 50 m displacement, 100000 cycles


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0 20000 40000 60000 80000 100000
0,0
0,4
0,8
1,2
1,6
2,0
Test Geometry B
Fretting at 1 Hz, 50 m displacement, 100000 cycles


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Falex Tribology Case Study 5
Quality
Knowledge
Partner Solutions


Falex Tribology nv
Wingepark 23b | 3110 Rotselaar Belgium
T +32 (0)16 40 79 65 | F +32 (0)16 40 51 28 | office@falex.eu | www.falex.eu


Introduction Introduction Introduction Introduction
The reliability of electrical contacts is essential
in many
applications
but the
mechanical
parts are
often
subjected to vibrations and small
displacements during their use.

This may cause fretting damage and this
damage in turn may create wear particles that
isolate the electrical contact, or damage an
electrically conductive coating, like gold.

To ensure correlation between the lab
simulation and the application, we use the real
components (small electrical
connectors) in our test equipment.




Objective Objective Objective Objective
In an unlubricated contact, fretting in
ambient conditions leads to severe fretting
corrosion which ultimately results in connector
electrical failure.

By applying the right grease, this can be
avoided or delayed. To test the durability of the
electrical contact, we combine a Falex high
frequency fretting wear test with an electrical
conductivity measurement of the contact.

We also evaluate the effect on the friction
force, by performing insertion tests and friction
tests with the Falex MUST microtribometer.
Results Results Results Results
Without lubrication, electrical resistance
increases due to the fretting damage.

Greases A, B and C prevent this increase.
Further distinction is visible in the wear
tracks : grease C is more effective in
reducing the total wear than grease A.

CONTACT CONTACT CONTACT CONTACT PROJECTED AREA (m) PROJECTED AREA (m) PROJECTED AREA (m) PROJECTED AREA (m)
Unlubricated 296.753
With Grease A 159.326
With Grease C 46.783

This way, a relative comparison can
easily be made of the anti-wear
properties of the greases.
The insertion force and sliding friction
force of the electrical connectors can be
measured with a MUST Micro
Tribometer.






Conclusion Conclusion Conclusion Conclusion
The anti-wear and friction reducing
properties of special greases for
electrical contacts can be quantitatively
evaluated by laboratory simulations.

0,0 5,0x10
5
1,0x10
6
1,5x10
6
2,0x10
6
2,5x10
6
0,08
0,09
0,10
0,11
0,12
0,13
0,14
0,15
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Number of fretting cycles
GreaseA GreaseB GreaseC
0,0 5,0x10
5
1,0x10
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1,5x10
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2,0x10
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2,5x10
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Number of fretting cycles
Unlubricated Unlubricated Unlubricated Unlubricated A A A A C CC C