---
_id: '12763'
abstract:
- lang: eng
text: "In a previous paper, the correlation between the wear resistance of coatings
and the lifetime of electrical connectors under fretting load was discovered.
Based on this knowledge, various modifications of silver-based coatings with markedly
increased wear resistance have been developed, and a calculation model for predicting
connector lifetime has been formulated. Investigations on silver-coated electrical
contacts with increased wear resistance show extended lifetimes in fretting wear
and fretting corrosion tests, and the calculation model with various modified
coating materials can be validated. However, contacts with very high wear-resistant
coatings fail earlier than the specific wear coefficient and the calculation model
prediction suggest.\r\nThe in-depth investigation of the coating material and
the wear scar revealed the reasons for this unexpectedly shorter lifetime. The
high wear resistance of modified silver coatings is achieved by increased micro-hardness.
Both coatings with coating materials of high hardness and high thickness can lead
to longer lifetimes under fretting load. However, increased fretting cycles can
also cause fatigue and electrical contacts can fail due to delamination of the
surface coating caused by fretting fatigue, and this delamination can lead to
a sudden exposure of the base material, thus enabling its corrosion.\r\nTherefore,
both wear resistance and fatigue resistance should be increased in order to achieve
a long lifetime of electrical contacts under fretting load."
article_number: '205971'
article_type: original
author:
- first_name: Jian
full_name: Song, Jian
id: '5297'
last_name: Song
- first_name: 'Soeren '
full_name: 'Tuelling, Soeren '
last_name: Tuelling
- first_name: Jonas
full_name: Hengstler, Jonas
last_name: Hengstler
citation:
ama: 'Song J, Tuelling S, Hengstler J. Correlation between wear and fatigue properties
and the lifetime of silver coated electrical connectors. Wear : an international
journal on the science and technology of friction, lubrication and wear .
Published online 2025. doi:10.1016/j.wear.2025.205971'
apa: 'Song, J., Tuelling, S., & Hengstler, J. (2025). Correlation between wear
and fatigue properties and the lifetime of silver coated electrical connectors.
Wear : An International Journal on the Science and Technology of Friction,
Lubrication and Wear , Article 205971. https://doi.org/10.1016/j.wear.2025.205971'
bjps: 'Song J, Tuelling S and Hengstler J (2025) Correlation between Wear
and Fatigue Properties and the Lifetime of Silver Coated Electrical Connectors.
Wear : an international journal on the science and technology of friction,
lubrication and wear .'
chicago: 'Song, Jian, Soeren Tuelling, and Jonas Hengstler. “Correlation between
Wear and Fatigue Properties and the Lifetime of Silver Coated Electrical Connectors.”
Wear : An International Journal on the Science and Technology of Friction,
Lubrication and Wear , 2025. https://doi.org/10.1016/j.wear.2025.205971.'
chicago-de: 'Song, Jian, Soeren Tuelling und Jonas Hengstler. 2025. Correlation
between wear and fatigue properties and the lifetime of silver coated electrical
connectors. Wear : an international journal on the science and technology of
friction, lubrication and wear . doi:10.1016/j.wear.2025.205971,
.'
din1505-2-1: 'Song, Jian ; Tuelling,
Soeren ; Hengstler, Jonas:
Correlation between wear and fatigue properties and the lifetime of silver coated
electrical connectors. In: Wear : an international journal on the science and
technology of friction, lubrication and wear . Amsterdam [u.a.], Elsevier
(2025)'
havard: 'J. Song, S. Tuelling, J. Hengstler, Correlation between wear and fatigue
properties and the lifetime of silver coated electrical connectors, Wear : An
International Journal on the Science and Technology of Friction, Lubrication and
Wear . (2025).'
ieee: 'J. Song, S. Tuelling, and J. Hengstler, “Correlation between wear and fatigue
properties and the lifetime of silver coated electrical connectors,” Wear :
an international journal on the science and technology of friction, lubrication
and wear , Art. no. 205971, 2025, doi: 10.1016/j.wear.2025.205971.'
mla: 'Song, Jian, et al. “Correlation between Wear and Fatigue Properties and the
Lifetime of Silver Coated Electrical Connectors.” Wear : An International Journal
on the Science and Technology of Friction, Lubrication and Wear , 205971,
2025, https://doi.org/10.1016/j.wear.2025.205971.'
short: 'J. Song, S. Tuelling, J. Hengstler, Wear : An International Journal on the
Science and Technology of Friction, Lubrication and Wear (2025).'
ufg: 'Song, Jian/Tuelling, Soeren/Hengstler, Jonas: Correlation between wear
and fatigue properties and the lifetime of silver coated electrical connectors,
in: Wear : an international journal on the science and technology of friction,
lubrication and wear (2025).'
van: 'Song J, Tuelling S, Hengstler J. Correlation between wear and fatigue properties
and the lifetime of silver coated electrical connectors. Wear : an international
journal on the science and technology of friction, lubrication and wear . 2025;'
date_created: 2025-04-04T11:00:08Z
date_updated: 2025-04-07T12:53:17Z
department:
- _id: DEP6012
doi: 10.1016/j.wear.2025.205971
keyword:
- Fretting
- Wear
- Fatigue
- Lifetime
- Electrical contacts
language:
- iso: eng
place: Amsterdam [u.a.]
publication: 'Wear : an international journal on the science and technology of friction,
lubrication and wear '
publication_identifier:
issn:
- 0043-1648
publication_status: published
publisher: Elsevier
quality_controlled: '1'
status: public
title: Correlation between wear and fatigue properties and the lifetime of silver
coated electrical connectors
type: scientific_journal_article
user_id: '83781'
year: '2025'
...
---
_id: '11359'
abstract:
- lang: eng
text: The reliability and lifetime of electrical contacts is an important aspect
in system reliability and is influenced by numerous factors. Micro motions as
well as vibrations lead to fretting wear, which can result in wear through of
the protective coating. If this layer is worn through, the non-noble layer underneath
is exposed, resulting in the occurrence of fretting corrosion with further relative
motion. This leads to an increased electrical contact resistance (ECR) and can
cause the contact to fail. Increasing the hardness of the coating material can
reduce the wear and in turn increase contacts’ lifetime. The micro hardness, wear
and lifetime of contacts with modified hard silver coatings are investigated in
fretting wear and corrosion tests and the results compared to a conventional silver
coating. Since one of the modifications shows a significant reduction in wear
and hence improvement in lifetime, further analysis with SEM and FIB is conducted
in order to identify the key mechanisms leading to this improvement. With a further
increase in lifetime however, fatigue as well as delamination of the coating are
revealed to be of high relevance. Both can be main causes of electrical contact
failure under fretting load. In general, at lower number of cycles, increased
micro hardness has the greatest effect on lifetime and wear while at the higher
number of cycles, fatigue is observed to be the dominant failure mechanism.
author:
- first_name: Roman
full_name: Probst, Roman
id: '69156'
last_name: Probst
- first_name: Jian
full_name: Song, Jian
id: '5297'
last_name: Song
citation:
ama: Probst R, Song J. Influence of Hardness and Fatigue on the Lifetime of a
Modified Silver Coating in Fretting Wear and Corrosion Tests. IEEE; 2023:88-94.
doi:10.1109/holm56075.2023.10352299
apa: Probst, R., & Song, J. (2023). Influence of Hardness and Fatigue on the
Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests. In
2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM) (pp. 88–94).
IEEE. https://doi.org/10.1109/holm56075.2023.10352299
bjps: 'Probst R and Song J (2023) Influence of Hardness and Fatigue on
the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests.
[Piscataway, NJ]: IEEE.'
chicago: 'Probst, Roman, and Jian Song. Influence of Hardness and Fatigue on
the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests.
2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM). Electrical
Contacts-IEEE Holm Conference on Electrical Contacts. [Piscataway, NJ]: IEEE,
2023. https://doi.org/10.1109/holm56075.2023.10352299.'
chicago-de: 'Probst, Roman und Jian Song. 2023. Influence of Hardness and Fatigue
on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests.
2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM). Electrical
Contacts-IEEE Holm Conference on Electrical Contacts. [Piscataway, NJ]: IEEE.
doi:10.1109/holm56075.2023.10352299,
.'
din1505-2-1: 'Probst, Roman ; Song, Jian: Influence of Hardness and
Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion
Tests, Electrical Contacts-IEEE Holm Conference on Electrical Contacts.
[Piscataway, NJ] : IEEE, 2023'
havard: R. Probst, J. Song, Influence of Hardness and Fatigue on the Lifetime of
a Modified Silver Coating in Fretting Wear and Corrosion Tests, IEEE, [Piscataway,
NJ], 2023.
ieee: 'R. Probst and J. Song, Influence of Hardness and Fatigue on the Lifetime
of a Modified Silver Coating in Fretting Wear and Corrosion Tests. [Piscataway,
NJ]: IEEE, 2023, pp. 88–94. doi: 10.1109/holm56075.2023.10352299.'
mla: Probst, Roman, and Jian Song. “Influence of Hardness and Fatigue on the Lifetime
of a Modified Silver Coating in Fretting Wear and Corrosion Tests.” 2023 IEEE
68th Holm Conference on Electrical Contacts (HOLM), IEEE, 2023, pp. 88–94,
https://doi.org/10.1109/holm56075.2023.10352299.
short: R. Probst, J. Song, Influence of Hardness and Fatigue on the Lifetime of
a Modified Silver Coating in Fretting Wear and Corrosion Tests, IEEE, [Piscataway,
NJ], 2023.
ufg: 'Probst, Roman/Song, Jian: Influence of Hardness and Fatigue on the
Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests, [Piscataway,
NJ] 2023 (Electrical Contacts-IEEE Holm Conference on Electrical Contacts).'
van: 'Probst R, Song J. Influence of Hardness and Fatigue on the Lifetime of a Modified
Silver Coating in Fretting Wear and Corrosion Tests. 2023 IEEE 68th Holm Conference
on Electrical Contacts (HOLM). [Piscataway, NJ]: IEEE; 2023. (Electrical Contacts-IEEE
Holm Conference on Electrical Contacts).'
conference:
end_date: 2023-10-11
location: 'Seattle '
name: 68th Holm Conference on Electrical Contacts (HOLM)
start_date: 2023-10-04
date_created: 2024-04-18T10:05:51Z
date_updated: 2025-06-26T07:54:13Z
department:
- _id: DEP6012
doi: 10.1109/holm56075.2023.10352299
keyword:
- electrical contacts
- lifetime
- silver coating
- fretting corrosion
- fatigue
- wear through
language:
- iso: eng
page: 88 - 94
place: '[Piscataway, NJ]'
publication: 2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM)
publication_identifier:
eisbn:
- '979‐8‐3503‐4246‐8 '
- 979‐8‐3503‐4245‐1
isbn:
- 979‐8‐3503‐4244‐4
issn:
- 2158‐9992
publication_status: published
publisher: IEEE
series_title: Electrical Contacts-IEEE Holm Conference on Electrical Contacts
status: public
title: Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating
in Fretting Wear and Corrosion Tests
type: conference_editor_article
user_id: '83781'
year: '2023'
...
---
_id: '9204'
abstract:
- lang: eng
text: The development of autonomous vehicles and the integration of new information
and communication technologies are making the reliability of electrical systems
and components in modern vehicles increasingly important. Electrical connectors
are a crucial component in an electrical on-board system. They are exposed to
a wide variety of influences by the environment and operating conditions. Thus,
the degradation of electrical connectors can occur. Material and surface analysis
methods are the tools used to analyze the degradation mechanisms in connectors
after lifetime tests, as well as in field operations. Within the framework of
this study, a wide variety of methods from the analytical scope are presented
and discussed. The connector surfaces degraded by different failure mechanisms
are analyzed using various material and surface analysis methods. The quality
and the nature of the analyses results obtained from various analysis methods
are compared. Also, this study deals with the benefits and limitations, as well
as the effort and the specific challenges of different material and surface analytical
methods for the evaluation of failure mechanisms from the point of view of a material
and surface analyst.
author:
- first_name: Philipp
full_name: Kolmer, Philipp
last_name: Kolmer
- first_name: Abhay Rammurti
full_name: Shukla, Abhay Rammurti
id: '72757'
last_name: Shukla
- first_name: Jian
full_name: Song, Jian
id: '5297'
last_name: Song
citation:
ama: 'Kolmer P, Shukla AR, Song J. Methods of Material and Surface Analysis for
the Evaluation of Failure Modes for Electrical Connectors. Technologies : open
access journal. 2022;10(6):124. doi:https://doi.org/10.3390/technologies10060124'
apa: 'Kolmer, P., Shukla, A. R., & Song, J. (2022). Methods of Material and
Surface Analysis for the Evaluation of Failure Modes for Electrical Connectors.
Technologies : Open Access Journal, 10(6), 124. https://doi.org/10.3390/technologies10060124'
bjps: 'Kolmer P, Shukla AR and Song J (2022) Methods of Material and Surface
Analysis for the Evaluation of Failure Modes for Electrical Connectors. Technologies :
open access journal 10, 124.'
chicago: 'Kolmer, Philipp, Abhay Rammurti Shukla, and Jian Song. “Methods of Material
and Surface Analysis for the Evaluation of Failure Modes for Electrical Connectors.”
Technologies : Open Access Journal 10, no. 6 (2022): 124. https://doi.org/10.3390/technologies10060124.'
chicago-de: 'Kolmer, Philipp, Abhay Rammurti Shukla und Jian Song. 2022. Methods
of Material and Surface Analysis for the Evaluation of Failure Modes for Electrical
Connectors. Technologies : open access journal 10, Nr. 6: 124. doi:https://doi.org/10.3390/technologies10060124,
.'
din1505-2-1: 'Kolmer, Philipp ; Shukla, Abhay Rammurti ; Song,
Jian: Methods of Material and Surface Analysis for the Evaluation of Failure
Modes for Electrical Connectors. In: Technologies : open access journal
Bd. 10. Basel, MDPI (2022), Nr. 6, S. 124'
havard: 'P. Kolmer, A.R. Shukla, J. Song, Methods of Material and Surface Analysis
for the Evaluation of Failure Modes for Electrical Connectors, Technologies :
Open Access Journal. 10 (2022) 124.'
ieee: 'P. Kolmer, A. R. Shukla, and J. Song, “Methods of Material and Surface Analysis
for the Evaluation of Failure Modes for Electrical Connectors,” Technologies :
open access journal, vol. 10, no. 6, p. 124, 2022, doi: https://doi.org/10.3390/technologies10060124.'
mla: 'Kolmer, Philipp, et al. “Methods of Material and Surface Analysis for the
Evaluation of Failure Modes for Electrical Connectors.” Technologies : Open
Access Journal, vol. 10, no. 6, 2022, p. 124, https://doi.org/10.3390/technologies10060124.'
short: 'P. Kolmer, A.R. Shukla, J. Song, Technologies : Open Access Journal 10 (2022)
124.'
ufg: 'Kolmer, Philipp/Shukla, Abhay Rammurti/Song, Jian: Methods of Material
and Surface Analysis for the Evaluation of Failure Modes for Electrical Connectors,
in: Technologies : open access journal 10 (2022), H. 6, S. 124.'
van: 'Kolmer P, Shukla AR, Song J. Methods of Material and Surface Analysis for
the Evaluation of Failure Modes for Electrical Connectors. Technologies : open
access journal. 2022;10(6):124.'
date_created: 2022-12-11T12:35:54Z
date_updated: 2024-08-05T07:19:56Z
ddc:
- '600'
department:
- _id: DEP6012
doi: https://doi.org/10.3390/technologies10060124
intvolume: ' 10'
issue: '6'
keyword:
- electrical connector
- failure modes
- wear
- fretting corrosion
- analysis
- material
- method
language:
- iso: eng
page: '124'
place: Basel
publication: 'Technologies : open access journal'
publication_identifier:
eissn:
- '2227-7080 '
publication_status: published
publisher: MDPI
status: public
title: Methods of Material and Surface Analysis for the Evaluation of Failure Modes
for Electrical Connectors
type: scientific_journal_article
user_id: '83781'
volume: 10
year: '2022'
...
---
_id: '2183'
abstract:
- lang: eng
text: To connect terminals in a cyber–physical system, large quantities of electrical
contacts are used. In order to guarantee a high reliability of the system, the
lifetime of the electrical contacts should be very long. Thus, it is of great
importance to understand the failure mechanism and then to predict the lifetime
of the electrical contacts. For the applications under high thermal and/or mechanical
loads, noble plating is a good choice, considering its inertness to oxidation.
For noble plating, one of the most critical failure mechanisms is the fretting
wear. Wear debris generated in the contact area, acting as the third bodies, will
greatly influence the further wear behavior and electrical performance. In this
study, the state of the art regarding third bodies is firstly reviewed, and then
the influence of the third bodies on the wear and electrical performance is investigated,
from the aspects of lifetime and the element distributions in contact area. Finally,
an example of prediction of the wear of noble plating is shown with the consideration
of the third bodies. Based on this study, by involving the third bodies, the wear
of noble plating can be predicted with a higher accuracy.
article_number: '77'
author:
- first_name: Haomiao
full_name: Yuan, Haomiao
id: '61860'
last_name: Yuan
- first_name: Jian
full_name: Song, Jian
id: '5297'
last_name: Song
citation:
ama: Yuan H, Song J. An Improved Calculation Model for the Prediction of the Wear
of Coated Electrical Contacts. Technologies. 2019;7(4). doi:10.3390/technologies7040077
apa: Yuan, H., & Song, J. (2019). An Improved Calculation Model for the Prediction
of the Wear of Coated Electrical Contacts. Technologies, 7(4). https://doi.org/10.3390/technologies7040077
bjps: Yuan H and Song J (2019) An Improved Calculation Model for the Prediction
of the Wear of Coated Electrical Contacts. Technologies 7.
chicago: Yuan, Haomiao, and Jian Song. “An Improved Calculation Model for the Prediction
of the Wear of Coated Electrical Contacts.” Technologies 7, no. 4 (2019).
https://doi.org/10.3390/technologies7040077.
chicago-de: Yuan, Haomiao und Jian Song. 2019. An Improved Calculation Model for
the Prediction of the Wear of Coated Electrical Contacts. Technologies
7, Nr. 4. doi:10.3390/technologies7040077,
.
din1505-2-1: 'Yuan, Haomiao ; Song, Jian: An Improved Calculation Model
for the Prediction of the Wear of Coated Electrical Contacts. In: Technologies
Bd. 7 (2019), Nr. 4'
havard: H. Yuan, J. Song, An Improved Calculation Model for the Prediction of the
Wear of Coated Electrical Contacts, Technologies. 7 (2019).
ieee: H. Yuan and J. Song, “An Improved Calculation Model for the Prediction of
the Wear of Coated Electrical Contacts,” Technologies, vol. 7, no. 4, 2019.
mla: Yuan, Haomiao, and Jian Song. “An Improved Calculation Model for the Prediction
of the Wear of Coated Electrical Contacts.” Technologies, vol. 7, no. 4,
77, 2019, doi:10.3390/technologies7040077.
short: H. Yuan, J. Song, Technologies 7 (2019).
ufg: 'Yuan, Haomiao/Song, Jian (2019): An Improved Calculation Model for
the Prediction of the Wear of Coated Electrical Contacts, in: Technologies
7 (4).'
van: Yuan H, Song J. An Improved Calculation Model for the Prediction of the Wear
of Coated Electrical Contacts. Technologies. 2019;7(4).
date_created: 2020-01-08T12:46:14Z
date_updated: 2023-03-15T13:49:39Z
department:
- _id: DEP6012
doi: 10.3390/technologies7040077
intvolume: ' 7'
issue: '4'
keyword:
- electrical contacts
- noble plating
- third bodies
- wear prediction
language:
- iso: eng
main_file_link:
- open_access: '1'
url: https://www.mdpi.com/2227-7080/7/4/77
oa: '1'
publication: Technologies
publication_identifier:
issn:
- 2227-7080
publication_status: published
status: public
title: An Improved Calculation Model for the Prediction of the Wear of Coated Electrical
Contacts
type: journal_article
user_id: '45673'
volume: 7
year: 2019
...