Investigation and analysis of arc ablation on WCu electrical contact materials

In this paper, arc ablation behavior of tungsten-copper (WCu) alloy contacts was investigated by the measurement of weight-loss, or erosion rate, and microstructures of tungsten-copper alloy contacts were examined by using scanning electron microscopy after electrical breakdown process. Experimental results showed that the arc erosion process started at the tiny sharp edges, then the arc spreaded on the second phases, or copper phase on the surface. Because of electrons/ions bombardment, the rapid evaporation and sputtering of liquid copper droplets were serious. As a result, an even contact surface became rugged, and tungsten skeleton remained because of being less eroded. With the increase of applied breakdown voltage, the ablation of tungsten-copper alloy became more significant. The WCu alloys with a higher content of copper showed more severe erosion rate as compared with that with a higher tungsten content under the same erosion conditions. Furthermore, when the number of breakdown is less, WCu alloys with a high copper content are easier for erosion for the conditions of fewer numbers of breakdowns. Whereas, WCu alloys with a high content of tungsten are easier for ablation for the conditions with many times of arc breakdown.