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Effect of Operating Conditions on Tribological Response of Al–Al Sliding Electrical Interface

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Abstract

Aluminum is widely used in electrical contacts due to its electrical properties and inexpensiveness when compared to copper. In this study, we investigate the influence of operating conditions like contact load (pressure), sliding speed, current, and surface roughness on the electrical and tribological behavior of the interface. The tests are conducted on a linear, pin-on-flat tribo-simulator specially designed to investigate electrical contacts under high contact pressures and high current densities. Control parameters include sliding speed, load, current, and surface roughness. The response of the interface is evaluated in the light of coefficient of friction, contact resistance, contact voltage, mass loss of pins, and interfacial temperature rise. As compared to sliding speed, load, and roughness, current is found to have the greatest influence on the various measured parameters. Under certain test conditions, the interface operates in a “voltage saturation” regime, wherein increase in current do not result in any increase in contact voltage. Within the voltage saturation regime the coefficient of friction tends to be lower, a result that is attributed to the higher temperatures associated with the higher voltage (and resulting material softening). Higher interfacial temperatures also appear to be responsible for the higher wear rates observed at higher current levels as well as lower coefficients of friction for smoother surfaces in the presence of current.

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Acknowledgments

This research was conducted at Georgia Institute of Technology, and supported in part through the Department of Defense Multidisciplinary Research Program of the University Research Initiative as Office of Naval Research Grant N00014-04-1-0601, entitled “Friction & Wear under Very High Electromagnetic Stress.” Information conveyed in this manuscript does not necessarily reflect the position or policy of the Government, and no official endorsement should be inferred.

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Authors and Affiliations

  1. Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37831-6063, USA

    Dinesh G. Bansal

  2. G. W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332-0405, USA

    Jeffrey L. Streator

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  1. Dinesh G. Bansal
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  2. Jeffrey L. Streator
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Correspondence to Dinesh G. Bansal.

Additional information

The research was conducted at Georgia Institute of Technology when the author Dinesh G. Bansal was a graduate student.

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Bansal, D.G., Streator, J.L. Effect of Operating Conditions on Tribological Response of Al–Al Sliding Electrical Interface. Tribol Lett 43, 43–54 (2011). https://doi.org/10.1007/s11249-011-9784-8

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  • DOI: https://doi.org/10.1007/s11249-011-9784-8

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