The effect of the temperature on the wear and resistance of automotive connectors subjected to vibration tests

A connector is designed to allow the passage of a current across different electrical systems. A connector subjected to car vibrations and a high temperature can suffer damage. This damage leads to a rapid degradation in the electrical performance, which results in a considerable increase in the electrical contact resistance. This work aims to address the influences of a variety of factors such as the fretting amplitude, the frequency, the temperature and the current on the performance of tin-plated automotive connectors. The changes due to the degradation in the electric conduction of the connectors under mechanical vibrations and temperature cycles are analysed. A detailed analysis of the contact surface is made using a profilometer, an optical microscope and a scanning electron microscope.