[{"title":"Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors","author":[{"first_name":"Jian","id":"5297","last_name":"Song","full_name":"Song, Jian"},{"first_name":"Soeren ","full_name":"Tuelling, Soeren ","last_name":"Tuelling"},{"full_name":"Hengstler, Jonas","last_name":"Hengstler","first_name":"Jonas"}],"publication_identifier":{"issn":["0043-1648"]},"citation":{"ieee":"J. Song, S. Tuelling, and J. Hengstler, “Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors,” <i>Wear : an international journal on the science and technology of friction, lubrication and wear </i>, Art. no. 205971, 2025, doi: <a href=\"https://doi.org/10.1016/j.wear.2025.205971\">10.1016/j.wear.2025.205971</a>.","ama":"Song J, Tuelling S, Hengstler J. Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors. <i>Wear : an international journal on the science and technology of friction, lubrication and wear </i>. Published online 2025. doi:<a href=\"https://doi.org/10.1016/j.wear.2025.205971\">10.1016/j.wear.2025.205971</a>","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;","din1505-2-1":"<span style=\"font-variant:small-caps;\">Song, Jian</span> ; <span style=\"font-variant:small-caps;\">Tuelling, Soeren </span> ; <span style=\"font-variant:small-caps;\">Hengstler, Jonas</span>: Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors. In: <i>Wear : an international journal on the science and technology of friction, lubrication and wear </i>. Amsterdam [u.a.], Elsevier (2025)","bjps":"<b>Song J, Tuelling S and Hengstler J</b> (2025) Correlation between Wear and Fatigue Properties and the Lifetime of Silver Coated Electrical Connectors. <i>Wear : an international journal on the science and technology of friction, lubrication and wear </i>.","chicago":"Song, Jian, Soeren  Tuelling, and Jonas Hengstler. “Correlation between Wear and Fatigue Properties and the Lifetime of Silver Coated Electrical Connectors.” <i>Wear : An International Journal on the Science and Technology of Friction, Lubrication and Wear </i>, 2025. <a href=\"https://doi.org/10.1016/j.wear.2025.205971\">https://doi.org/10.1016/j.wear.2025.205971</a>.","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).","mla":"Song, Jian, et al. “Correlation between Wear and Fatigue Properties and the Lifetime of Silver Coated Electrical Connectors.” <i>Wear : An International Journal on the Science and Technology of Friction, Lubrication and Wear </i>, 205971, 2025, <a href=\"https://doi.org/10.1016/j.wear.2025.205971\">https://doi.org/10.1016/j.wear.2025.205971</a>.","apa":"Song, J., Tuelling, S., &#38; Hengstler, J. (2025). Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors. <i>Wear : An International Journal on the Science and Technology of Friction, Lubrication and Wear </i>, Article 205971. <a href=\"https://doi.org/10.1016/j.wear.2025.205971\">https://doi.org/10.1016/j.wear.2025.205971</a>","short":"J. Song, S. Tuelling, J. Hengstler, Wear : An International Journal on the Science and Technology of Friction, Lubrication and Wear  (2025).","chicago-de":"Song, Jian, Soeren  Tuelling und Jonas Hengstler. 2025. Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors. <i>Wear : an international journal on the science and technology of friction, lubrication and wear </i>. doi:<a href=\"https://doi.org/10.1016/j.wear.2025.205971\">10.1016/j.wear.2025.205971</a>, .","ufg":"<b>Song, Jian/Tuelling, Soeren/Hengstler, Jonas</b>: Correlation between wear and fatigue properties and the lifetime of silver coated electrical connectors, in: <i>Wear : an international journal on the science and technology of friction, lubrication and wear </i> (2025)."},"place":"Amsterdam [u.a.]","publication_status":"published","language":[{"iso":"eng"}],"date_created":"2025-04-04T11:00:08Z","_id":"12763","article_number":"205971","publication":"Wear : an international journal on the science and technology of friction, lubrication and wear ","article_type":"original","date_updated":"2025-04-07T12:53:17Z","doi":"10.1016/j.wear.2025.205971","quality_controlled":"1","type":"scientific_journal_article","publisher":"Elsevier","keyword":["Fretting","Wear","Fatigue","Lifetime","Electrical contacts"],"abstract":[{"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.","lang":"eng"}],"user_id":"83781","year":"2025","department":[{"_id":"DEP6012"}],"status":"public"},{"user_id":"83781","year":"2023","department":[{"_id":"DEP6012"}],"status":"public","keyword":["electrical contacts","lifetime","silver coating","fretting corrosion","fatigue","wear through"],"abstract":[{"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.","lang":"eng"}],"page":"88 - 94","conference":{"location":"Seattle ","end_date":"2023-10-11","start_date":"2023-10-04","name":"68th Holm Conference on Electrical Contacts (HOLM)"},"type":"conference_editor_article","publisher":"IEEE","doi":"10.1109/holm56075.2023.10352299","date_updated":"2025-06-26T07:54:13Z","series_title":"Electrical Contacts-IEEE Holm Conference on Electrical Contacts","publication":"2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM)","_id":"11359","author":[{"first_name":"Roman","full_name":"Probst, Roman","last_name":"Probst","id":"69156"},{"last_name":"Song","id":"5297","full_name":"Song, Jian","first_name":"Jian"}],"publication_identifier":{"eisbn":["979‐8‐3503‐4246‐8 ","979‐8‐3503‐4245‐1"],"issn":["2158‐9992"],"isbn":["979‐8‐3503‐4244‐4"]},"citation":{"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.","ufg":"<b>Probst, Roman/Song, Jian</b>: 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).","chicago-de":"Probst, Roman und Jian Song. 2023. <i>Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests</i>. <i>2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM)</i>. Electrical Contacts-IEEE Holm Conference on Electrical Contacts. [Piscataway, NJ]: IEEE. doi:<a href=\"https://doi.org/10.1109/holm56075.2023.10352299\">10.1109/holm56075.2023.10352299</a>, .","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.","apa":"Probst, R., &#38; Song, J. (2023). Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests. In <i>2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM)</i> (pp. 88–94). IEEE. <a href=\"https://doi.org/10.1109/holm56075.2023.10352299\">https://doi.org/10.1109/holm56075.2023.10352299</a>","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.” <i>2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM)</i>, IEEE, 2023, pp. 88–94, <a href=\"https://doi.org/10.1109/holm56075.2023.10352299\">https://doi.org/10.1109/holm56075.2023.10352299</a>.","ama":"Probst R, Song J. <i>Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests</i>. IEEE; 2023:88-94. doi:<a href=\"https://doi.org/10.1109/holm56075.2023.10352299\">10.1109/holm56075.2023.10352299</a>","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).","ieee":"R. Probst and J. Song, <i>Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests</i>. [Piscataway, NJ]: IEEE, 2023, pp. 88–94. doi: <a href=\"https://doi.org/10.1109/holm56075.2023.10352299\">10.1109/holm56075.2023.10352299</a>.","chicago":"Probst, Roman, and Jian Song. <i>Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests</i>. <i>2023 IEEE 68th Holm Conference on Electrical Contacts (HOLM)</i>. Electrical Contacts-IEEE Holm Conference on Electrical Contacts. [Piscataway, NJ]: IEEE, 2023. <a href=\"https://doi.org/10.1109/holm56075.2023.10352299\">https://doi.org/10.1109/holm56075.2023.10352299</a>.","bjps":"<b>Probst R and Song J</b> (2023) <i>Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests</i>. [Piscataway, NJ]: IEEE.","din1505-2-1":"<span style=\"font-variant:small-caps;\">Probst, Roman</span> ; <span style=\"font-variant:small-caps;\">Song, Jian</span>: <i>Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests</i>, <i>Electrical Contacts-IEEE Holm Conference on Electrical Contacts</i>. [Piscataway, NJ] : IEEE, 2023"},"place":"[Piscataway, NJ]","publication_status":"published","date_created":"2024-04-18T10:05:51Z","language":[{"iso":"eng"}],"title":"Influence of Hardness and Fatigue on the Lifetime of a Modified Silver Coating in Fretting Wear and Corrosion Tests"},{"type":"journal_article","issue":"4","date_updated":"2023-03-15T13:49:39Z","doi":"10.3390/technologies7040077","year":2019,"user_id":"45673","department":[{"_id":"DEP6012"}],"status":"public","keyword":["electrical contacts","noble plating","third bodies","wear prediction"],"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."}],"author":[{"last_name":"Yuan","id":"61860","full_name":"Yuan, Haomiao","first_name":"Haomiao"},{"full_name":"Song, Jian","id":"5297","last_name":"Song","first_name":"Jian"}],"intvolume":"         7","publication_identifier":{"issn":["2227-7080"]},"citation":{"havard":"H. Yuan, J. Song, An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts, Technologies. 7 (2019).","short":"H. Yuan, J. Song, Technologies 7 (2019).","apa":"Yuan, H., &#38; Song, J. (2019). An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts. <i>Technologies</i>, <i>7</i>(4). <a href=\"https://doi.org/10.3390/technologies7040077\">https://doi.org/10.3390/technologies7040077</a>","mla":"Yuan, Haomiao, and Jian Song. “An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts.” <i>Technologies</i>, vol. 7, no. 4, 77, 2019, doi:<a href=\"https://doi.org/10.3390/technologies7040077\">10.3390/technologies7040077</a>.","ufg":"<b>Yuan, Haomiao/Song, Jian (2019)</b>: An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts, in: <i>Technologies</i> <i>7</i> (<i>4</i>).","chicago-de":"Yuan, Haomiao und Jian Song. 2019. An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts. <i>Technologies</i> 7, Nr. 4. doi:<a href=\"https://doi.org/10.3390/technologies7040077,\">10.3390/technologies7040077,</a> .","ieee":"H. Yuan and J. Song, “An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts,” <i>Technologies</i>, vol. 7, no. 4, 2019.","ama":"Yuan H, Song J. An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts. <i>Technologies</i>. 2019;7(4). doi:<a href=\"https://doi.org/10.3390/technologies7040077\">10.3390/technologies7040077</a>","van":"Yuan H, Song J. An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts. Technologies. 2019;7(4).","bjps":"<b>Yuan H and Song J</b> (2019) An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts. <i>Technologies</i> <b>7</b>.","din1505-2-1":"<span style=\"font-variant:small-caps;\">Yuan, Haomiao</span> ; <span style=\"font-variant:small-caps;\">Song, Jian</span>: An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts. In: <i>Technologies</i> Bd. 7 (2019), Nr. 4","chicago":"Yuan, Haomiao, and Jian Song. “An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts.” <i>Technologies</i> 7, no. 4 (2019). <a href=\"https://doi.org/10.3390/technologies7040077\">https://doi.org/10.3390/technologies7040077</a>."},"volume":7,"publication_status":"published","language":[{"iso":"eng"}],"date_created":"2020-01-08T12:46:14Z","main_file_link":[{"open_access":"1","url":"https://www.mdpi.com/2227-7080/7/4/77"}],"title":"An Improved Calculation Model for the Prediction of the Wear of Coated Electrical Contacts","publication":"Technologies","_id":"2183","oa":"1","article_number":"77"},{"publisher":"Sciencedomain International","type":"journal_article","doi":"10.9734/BJAST/2014/5536 ","date_updated":"2026-03-04T14:37:50Z","issue":"1","status":"public","department":[{"_id":"DEP6012"}],"year":"2014","user_id":"83781","page":"18 - 39","abstract":[{"text":" The current carrying capacity, which is determined by the electrical-thermal behaviour, is one of the main features of an electrical contact system. The purpose of this study is to develop an analytical model which describes the electricalthermal behaviour of electrical contact systems. Established mechanical, electrical, thermal and contact physical relations are combined to design the analytical model. Differential equations with appropriate boundary conditions are used to solve the heating problem. The various parts of an electrical connector represent separate subsystems. The geometry, the material properties and the heat transfer coefficients for the contact system, the terminal clamp and the wire have been taken into account. These different subsystems have been connected to obtain the overall temperature distribution. In order to verify the analytical model, contact systems made of three copper alloys with different electrical and thermal properties are investigated experimentally at various current loads. It was shown that the analytical model can predict the temperature rise for simple geometry well. Using the analytical model several parameters can be easily changed. Moreover, the main influencing factors and their relationships can be identified directly on the equations. Therefore, the physical mathematical point of view of an analytical calculation can help Research Article British Journal of Applied Science & Technology, 4(1): 18-39, 2014 19 to understand the model structure of a contact system.","lang":"eng"}],"keyword":["Analytical calculation","electrical contacts","contact physics","electric conductivity","heating","thermal behaviour"],"volume":4,"publication_status":"published","date_created":"2021-09-15T07:59:41Z","language":[{"iso":"eng"}],"citation":{"ama":"Blauth M, Berger F, Song J. Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems. <i>British Journal of Applied Science &#38; Technology</i>. 2014;4(1):18-39. doi:<a href=\"https://doi.org/10.9734/BJAST/2014/5536 \">10.9734/BJAST/2014/5536 </a>","van":"Blauth M, Berger F, Song J. Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems. British Journal of Applied Science &#38; Technology. 2014;4(1):18–39.","havard":"M. Blauth, F. Berger, J. Song, Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems, British Journal of Applied Science &#38; Technology. 4 (2014) 18–39.","ieee":"M. Blauth, F. Berger, and J. Song, “Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems,” <i>British Journal of Applied Science &#38; Technology</i>, vol. 4, no. 1, pp. 18–39, 2014, doi: <a href=\"https://doi.org/10.9734/BJAST/2014/5536 \">10.9734/BJAST/2014/5536 </a>.","chicago":"Blauth, Michael, Frank Berger, and Jian Song. “Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems.” <i>British Journal of Applied Science &#38; Technology</i> 4, no. 1 (2014): 18–39. <a href=\"https://doi.org/10.9734/BJAST/2014/5536 \">https://doi.org/10.9734/BJAST/2014/5536 </a>.","chicago-de":"Blauth, Michael, Frank Berger und Jian Song. 2014. Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems. <i>British Journal of Applied Science &#38; Technology</i> 4, Nr. 1: 18–39. doi:<a href=\"https://doi.org/10.9734/BJAST/2014/5536 \">10.9734/BJAST/2014/5536 </a>, .","ufg":"<b>Blauth, Michael/Berger, Frank/Song, Jian</b>: Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems, in: <i>British Journal of Applied Science &#38; Technology</i> 4 (2014), H. 1,  S. 18–39.","mla":"Blauth, Michael, et al. “Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems.” <i>British Journal of Applied Science &#38; Technology</i>, vol. 4, no. 1, 2014, pp. 18–39, <a href=\"https://doi.org/10.9734/BJAST/2014/5536 \">https://doi.org/10.9734/BJAST/2014/5536 </a>.","apa":"Blauth, M., Berger, F., &#38; Song, J. (2014). Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems. <i>British Journal of Applied Science &#38; Technology</i>, <i>4</i>(1), 18–39. <a href=\"https://doi.org/10.9734/BJAST/2014/5536 \">https://doi.org/10.9734/BJAST/2014/5536 </a>","din1505-2-1":"<span style=\"font-variant:small-caps;\">Blauth, Michael</span> ; <span style=\"font-variant:small-caps;\">Berger, Frank</span> ; <span style=\"font-variant:small-caps;\">Song, Jian</span>: Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems. In: <i>British Journal of Applied Science &#38; Technology</i> Bd. 4, Sciencedomain International (2014), Nr. 1, S. 18–39","short":"M. Blauth, F. Berger, J. Song, British Journal of Applied Science &#38; Technology 4 (2014) 18–39.","bjps":"<b>Blauth M, Berger F and Song J</b> (2014) Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems. <i>British Journal of Applied Science &#38; Technology</i> <b>4</b>, 18–39."},"publication_identifier":{"issn":["2231-0843"]},"intvolume":"         4","author":[{"last_name":"Blauth","id":"49095","full_name":"Blauth, Michael","first_name":"Michael"},{"last_name":"Berger","full_name":"Berger, Frank","first_name":"Frank"},{"first_name":"Jian","last_name":"Song","id":"5297","full_name":"Song, Jian"}],"title":"Analytical and Experimental Investigation of the Electrical-Thermal Behaviour of Electrical Contact Systems","publication":"British Journal of Applied Science & Technology","_id":"6248"}]