Surface Analysis of Fretting Damage in Electrical Contacts of Aluminum with different Contact Materials

The surface analysis of the fretting damage produced in the contact zones between aluminum wires and different contact materials is presented. For this purpose scanning electron microscopy (SEM), secondary ion mass spectroscopy (SIMS), scanning Auger microprobe (SAM), and energy dispersive analysis of X-rays (EDAX) were used as the main surface characterization techniques. From the results it is shown that the contact zones were severely damaged and that a substantial transfer of material occurred as a result of the fretting action. Although the precise nature of the transfer mechanism is not known at the present time, some evidence was found indicating that the transfer of material is a result of the combined action of several mechanisms such as adhesion, abrasion, arcing/melting, delamination wear.